• 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 fire-chamber water blasting devices and ducts of the Ep-670-140 boiler (Pljevlja TPP (Montenegro))

The APCS is implemented on the basis of DCS “Tornado-I” and designed for monitoring and control of water cleaning devices for the boiler heating surfaces of TPP power-generating unit.


plevla1.jpgAs part of Russia's economic cooperation with Montenegro, JSC “Technopromexport” did boiler equipment upgrading of the Pljevlja TPP. The supplier of the main equipment, Podolsk Boiler Plant (OJSC “Ziomar engineering company”), had selected two Novosibirsk’s companies (CJSC “SibCOTES” and CJSC “Tornado Modular Systems”) as designers and suppliers of automation equipment.

Designing and assembly of the system began in late September 2000. In December, the completed DCS was shipped to the facility for setup and adjustment.

The short terms of the system creation were a result of a well-organized interaction between contractors, as well as of the fact that a similar system has already been developed and implemented by specialists of CJSC “Tornado Modular Systems” and CJSC “SibCOTES” at Yimin CHPP in China.


The system is designed for monitoring and control of devices of E-80 and E-400 types of water cleaning of the boiler heating surfaces and steam “cannon” blasting. The system is also designed to automatically detect emergency situations that arise in the process of the boiler cleaning and to take measures to prevent failures of the system hardware and the main equipment of the boiler connected with the cleaning process.

The system is designed for the periodical operation mode. The system actuation is performed by the operator when appropriate (according to the degree of sediment contamination of the heating surface). The system performs all monitoring and control functions of the devices automatically. The role of the operator is reduced to the system configuration, start-up and acknowledgment of the emergency situations via special sound and light signals.

The system has built-in tools for diagnostic of its own hardware and the current state of the cleaning devices.


The system structure and the functions of its parts.

The system provides control of cleaning devices in the automatic and manual modes as well as in the system configuration mode.

In the manual control mode the selection of a device, direction and movement time of the device is performed manually by the operator from the control desk.

In the automatic mode the cleaning cycles are performed step by step. At the end of the cycle of one device the cycle of the second device begins.


The system consists of the following main components:

  • process controller with a set of the remote terminal units and field interface units;
  • control panel;
  • switching units;
  • power assemblies of drives.

Structurally, the hardware of the system is placed in one controller cabinet, two cabinets-assemblies and five peripheral boxes – the switching units.

Process controller

plevla2.jpgThe main element of the system is the process controller of IUC series manufactured by “Kontron” company (“PEP Modular Computers”), Germany.

The controller provides:

  • processing signals from the sensors placed on the devices;
  • processing command issued by the operator using the control panel;
  • alternating control of each of the devices of the group using of the corresponding commands;
  • displaying the information about the current state of the cleaning process at the indication display on the control desk for the operator;
  • identification of emergency situations and issuing commands to prevent breakages of the cleaning devices and the main equipment of the boiler connected with the cleaning process.

Control panel

Control panel provides a human-machine interface of the control system. The control panel is located directly on the door of the controller cabinet. The control panel allows to set operational modes of the system, change configuration and display the current state of devices, diagnostic results, alarm messages, etc.

The panel has the input mechanisms (buttons and a digital patch board) and indicators (two-line text indicator board and LEDs).

Switching units

The switching units are an intermediate, switching elements between the process controller and devices for cleaning processes. Five switching units are connected to the controller. The water cleaning devices are connected to four units and the armature on the steam supply to the “canon” blasting device is connected to the fifth unit.

On commands from the controllers switching units provide:

  • alternating switching of three-phase supply 380 V voltage to the electric motor of cleaning devices or switching of “open” / “close” commands to the armature on the steam supply to the “canon” blasting devices;
  • alternate switching of the signals from the sensors located on the devices and the armature to the controller.

The switching units are made using setup boxes manufactured by the “Rittal” company. The box provides a equipment protection of the IP 55 level.

Power assembly cabinets.

In the power assembly cabinets there are the power switching equipment and protecting cutout devices. In the system there are two power assembly cabinets: In the first cabinet there are the power assemblies from eight units of the armature of the technological unit of the steam “cannon” blasting of the boiler. In the second cabinet there are the power assemblies from two units of the armature and two pumps of the technological unit of the boiler water cleaning.


The cabinet of the controller

plevla3.jpgThe controller is placed in a two-door cabinet unilateral service manufactured by “Rittal” company. It provides the IP 55 level of the equipment protection.

The process controller with remote terminal units and field interface units, secondary power supply sources as well as the necessary switching and electrical equipment are placed inside the cabinet. Connection of the cables is carried out directly, bypassing industrial terminal blocks. The control panel of the controllers , alarm signal lights and a key of the pump operational mode selection are placed on the cabinet doors.

Process controller

The process controller is designed in the form of CXC crate of 3U format and has a modular architecture. All the controller modules are installed in the crate and combined using CXC-bus line. The main control element of the controller is an IUC-32 CPU module. The IMOD-2 module-carriers with functional submodules of MODPASK series are used as remote terminal units. The module-carriers with PB-DIN3 and PB-DOUT2 functional submodules are installed in the crate of each controller. These modules provide input of discrete 24V signals and output of discrete 24V commands, accordingly.

Field interface units

The field interface units provide connection of the field cables to the controllers without intermediate converters, alighners, etc. The “Wago” spring-loaded terminals that provide reliable and insensitive to vibrations contact are used to connect the cables to the field interface units.



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