• 04 july 2017
    At the Technoprom Forum, an agreement was signed between "Tornado Modular Systems" with "Siblitmash" and "Komintern"

    The tripartite agreement provides for import substitution for components of the injection molding complex from SibLitMach in the field of industrial robots ("Comintern") and the control system ("Modular Tornado Systems") that will cover the entire production cycle of the LAP, including the management of industrial robots

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APCS of the BKZ-240 boiler unit

The system is based on DCS1 “Tornado-M” and designed for automation of technological process control of the boiler unit in all operational modes. The automation covers all functions. There are about 1000 monitoring and control channels in the system.

“...The work performed under the contract by CJSC “Tornado Modular Systems” was executed on schedule and at a high professional level. I would like to mention the high level of management, openness and commitment of the company. “Tornado Modular Systems” company can be rightfully called the best of many other organizations involved in the boiler shipment and setup”.

Igor Viktorovich Popov
Chief Engineer of Chita CHPP-1
February 7, 2002

Technological object

Technological control object is BKZ-240 boiler, which is equipped with the following devices:

  • raw coal feeders: 4 pcs;
  • tangential hammer mill: 4 pcs,
  • exhausters: 2 pcs;
  • blower fans: 2 pcs;

Stages of work

Reconstruction of boiler unit No. 1 began in 2000 year as part the technical re-equipment and reconstruction program of OJSC “Chita Energo”. A complete dismantling of all old equipment was executed and BKZ-240 boiler plant was installed.

In April 2001 “Tornado Modular Systems” entered into a contract of supply and implementation of ACPS of boiler unit No. 1. The contract covered a whole range of works on development and integration of the system at the object: development of technical working design in accordance with the normative documents; packaging, manufacture and shipment of the system to the station; setup, assembling & commissioning of the system.

Specialists of “Sibtechenergo” technological organization (which is the leader in the Siberian region) and “Teploelektroproekt” Novosibirsk Institute have participated in this project as subcontractors. Part of the adjustment works was executed by “Chitatechenergo” company.

All DCS creation work was completed at the site of CJSC “Tornado Modular Systems” in mid-August. The integration test of the DCS was executed in the presence of the Customer, after which the system was shipped to the site. All setup and adjustment works of the ACPS and technological equipment of the boiler were completed by January 2002.

The new boiler unit additionally provided heat to a microdistrict of Chita.


APCS creation purposes

The modern APCS implementation has resulted in the achievement of the following purposes:

  • Improvement of reliability and technical, economical & ecological operation indices due to performance of more complex laws of automatic control.
  • Creation of better work conditions for the operational staff to facilitate the decision-making for the boiler unit control and to reduce the operator's workload.
  • Increase of responsibility of the staff due to the functions of monitoring and logging of the staff actions in the system for the boiler unit control.
  • Increase of fail-safety of the control system functioning, facilitation of its operating service and reduction of time required for search and elimination of violations in its work.
  • Providing objective information received in the process of monitoring the technological regimes at the boiler unit in an operational and user-friendly form for the future usage, to non-operational engineering, technical and administrative staff of the department and the station to perform production and business tasks.

The system has enabled the control of technological processes of the boiler unit in all operational modes: normal, transitional, pre-emergency and emergency, including start-up and shutdown. Safety of the staff, integrity of the control system and technological equipment, as well as the environmental protection has been provided in all operational modes.

Description of the system

The system performs the full-scale monitoring and control functions of the boiler unit as follows:

  • control functions, including technological protections, interlocks, and all kinds of automatic, automatized and remote control;
  • information functions, including receiving, preprocessing, storage, accumulation and display of information, performance of data-processing tasks;
  • service functions, which provide the system efficiency, in particular, diagnostics of state of the APCS tools and the technological equipment.

Structure scheme of the boiler unit APCS.


Central part of the APCS is a distributed control system (DCS). The system also consists of sensors, actuators, traditional control tools, non-programmable automation tools, which are supplied together with technological equipment and power assembling of gates of RTZO type and devices for preparation of the automatic chemical control samples.

The control system of the boiler unit is a distributed control system with two-level multifunctional structure. The lower information & control level is based on programmable controllers and performs the functions as follows: collection of analog, discrete and impulse-number parameters from the control object, control of reliability and primary processing of the parameters, formation of an instant database, transmission of information to the upper level, automatic control.

The upper level provides communication of a process control operator and engineering staff with the technological equipment, reception of information from the lower level, processing of the information and putting it into the upper level database. It includes the automated workstations (AWSs) for an operator of the boiler unit and an engineer of the APCS, as well as database and application servers.

The cabinets of the controllers

The DCS controller equipment is located in the two-sided cabinets installed in the non-operational part of the group control desk. Two dual-crated controllers are located in the four controller cabinets, where there are also FIUs2 and terminal blocks which are used to connect a field cable to the controller. The level of protection from external effects is IR55.

The FIUs used in this system allowed avoiding use of bulky and highly-priced cabinets (intermediate terminal blocks) and improving the reliability of the cable connections.

Controllers of the functional units

The technological controllers are designed as a crate of 6U format with installed electronic modules and submodules of the remote terminal unit (RTU), which provide conversion of electrical signals from / to the technological equipment to the digital code. The main element of the controller is modules of intellectual functions (MIF) manufactured by “Tornado Modular Systems”, which are designed for use in automation tasks of the major heat-power engineering objects. The functional sub-modules of ModPack architecture are used as the RTU sub-modules. Each MIF-module can contain up to three functional sub-modules.

A "hot swapping" of the MIF-modules and automatic initialization after their replacement are implemented in the controllers. The cables for modules connection are brought from backside of the controller crate. All of this allows quick replacement of the MIF-modules without any impact on the system efficiency.

Operator’s automated workstation (AWS)

Duplicated AWS of the boiler’s operator is made in the form of two IBM-PC compatible computers, installed in the operational part of the group control desk. The application server program and InTouch visualization program (manufactured by “Wonderware”) are installed on each of the operator's AWS. The information is provided for the operator as symbolic circuits, graphs, tables and histograms of various detail level in the most user-friendly form for the operator to control a current state and manage the technological equipment. The symbolic circuits are fully configurable and contain graphic elements and characters, which give an accurate and easily readable picture of the controlled object operation.

APCS engineer’s AWS and metrologist’s AWS

APCS engineer’s AWS is designed for servicing and modification of the system and is installed in the administrative & amenity building. The AWS is equipped with the necessary specialized software engineering packages, which allow to perform the system service and modification tasks using the package for software development of the controllers, package for modification of the operator’s AWS mimic diagrams and software for installing / uninstalling programs on the technological controllers.

DCS also includes metrologist’s AWS which allows to perform calibration (testing) of modules and channels and creation of required metrological documents in the automated mode.

1 Distributed control system.

2 Field Interface Units



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