• 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 feeding and burning fuel, APCS of pneumatic caving in raw coal bunkers. Customer: Kostolac-B TPP (Serbia)

The APCS is implemented on the basis of DCS1 “Tornado-V” and designed for operational remote monitoring and control of electrifiable actuators as part of the solid fuel feeding and burning system as well as for the pneumatic caving system in raw coal bunkers of grinding fans.

About the project

kostolaz1.jpgThe project was implemented as part of collaboration between CJSC “Tornado Modular Systems”, CJSC “SibCOTES”, OJSC “Ziomar engineering company” and JSC "Technopromexport" companies.

Development of the APCS was started in February 2000. In July, the assembled and tested DCS was shipped to the station together with the documentation.

The integration of the system was delayed for a long time because of the change of the station management. Setup work was started in autumn 2002. In October, after adjustment, the APCS commissioning was carried out.

The functions and structure of the system

As part of the system along with the conventional tasks of the equipment remote control and monitoring of measured technological parameters, the problems of registration and archiving all incoming information in the system, data preparation for calculation of technical and economic operation indexes of the equipment and analysis of emergency situations are being solved.

APCS includes the following main subsystems:

  • Data processing (performs the function of collection, primary processing and display of data and acts as a technological alarm system);
  • Remote control of equipment;
  • Automatic control system.

The central part of the APCS is the DCS. The DCS has the following control algorithms of the automatic controllers:

  • Heat load regulators. The DCS produces analog assignment signals for eight subordinate regulators of the mill load.
  • Shared air regulator. The DCS produces analog assignment signals for eight subordinate regulators of secondary air to the mill.
  • Mill load regulator. The DCS controls the actuators of two variators (batcher and conveyer) and also manages three variators (batcher and two conveyers) for the coal-pulverization systems.
  • Temperature control of air-and-fuel mixture by addition of the cold gas. The DCS operates the gate of cold gas.
  • Temperature control of air-and-fuel mixture by addition of the hot air. The DCS operates the gate of primary (hot) gas.
  • Regulator of the ventilating performance of the mill. The DCS operates the control & shut-off gate.
  • Regulator of secondary air to the mill. DCS operates two gates of the secondary air.

In addition, automatic control of the pneumovibrators of coal arch caving in the bunkers is implemented in the DCS. The DCS operates the 15 solenoid shutoff valves.

The DCS consists of the following components:

  • AWS2 of operator No. 1 and AWS of operator No. 2 (also performs the service engineer’s AWS and database server functions );
  • Controller of the automatic combustion system;
  • Controller of pneumatic caving system – the fuel supply to the grinding fans;
  • Uninterruptible power supplies;
  • LAN of operational circuit.

Operator’s AWS

kastolaz3.jpgThe operator’s AWS is designed to perform the following functions:

  • Registration and archiving of all current data which comes from the controllers;
  • Creating the data flow to the archive database located on the database server;
  • Visualization of parameters;
  • Presentation of information in the form of symbolic circuits, histograms, graphs and tables;
  • Solving the data-processing tasks (emergency events registration, parameters deviations registration, archiving, calculation of parameters for the technical & economic index);
  • Providing the information for remote “client” work places using WEB server resources.

Service engineer’s AWS

The Service engineer’s AWS is a computer with configuration similar to the operator’s AWS which serves as a “hot” reserve in case of operator’s AWS failure. In addition, this AWS operates as a database server and is designed for storing data in the archive as well as for providing data on demand.

The upper level of the system is implemented using standard computer engineering equipment which is compatible with IBM PC. The “InTouch” SCADA-package manufactured by “Wonderware” company is used for visualization of technological processes.

Technological controller

kastolaz5.jpgThe controller provides connection of cable communications from the sensors and conversion of analog signals from the sensors into a digital form required for further processing by the system.

The controllers are placed in the double-sided service cabinets. Cabinet includes a controller with remote terminal units, field interface units and necessary switching and electrical equipment.

The cable communications connect directly to the sensors and actuators, including 220 V signals, bypassing the special converters and industrial terminal block cabinets.

The controller is designed as a VME crate of 3U format. The controller has a modular architecture. All the controller modules are installed in the crate, where they are combined using the VME local line. The main control element of the controller is VM42-Base CPU module manufactured by “Kontron” (“PEP Modular Computers”) company.

The VMOD-2 carrier modules with functional submodules of the MODPASK standard are used as the remote terminal unit. Up to two functional sub-modules are installed on each carrier module. On the front panel of the VMOD-2 module there is a 50-pin connector for connection of two field interface units.

Up to 14 carrier-modules with 28 functional submodules can be installed in the crate of the controller. These submodules provide input from various information channels via corresponding number of the field interface units.

kastolaz2.jpgThe carrier-modules provide the processing unit with an interface of access to the functional submodules. Processing in the controller is centralized on the VM42-Base processing unit.

Field interface units

The field interface units allow to connect the field cables from sensors to the controllers directly without intermediate converters, alighners, etc. The crosss-section of the field cable connected to the field interface units is from 0,8 to 2,5 mm2. The “Wago” spring-loaded terminals are used for connection of the cables to the field interface units. This modern technology facilitates the connection of cable to the system and provides a very reliable and non-sensitive to vibration contact equivalent to “cold welding”.

Ethernet network

An Ethernet hub connects controllers and computers of the system into a common local computer network.

1 Distributed control system.

2 Automated workstation.



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