Generator resin distillation unit at VKG Oil 

The distillation technology was updated in 2005-2006. A new furnace for resin distillation and the first rectification column were built on the basis of the technology developed by KG Process Innovations. KG Process Innovations developed the system of management of these pieces of equipment. In cooperation with the automation department at Viru RMT, the system was debugged and updated on site. Later on, the management system, including software, was handed over to the automation department, and all subsequent system modifications were made by us. The second distillation column, the reservoir fleet, and dispatch representation have been managed by our company right from the start.

The management system is based on three Simatic S7-300 controllers. The technological process is managed through two standard S7-300 controllers, while locking, alarm system, and technological protection are based on the controller with the execution of the enhanced security (“yellow” modules). Visual representation and interface with an operator are implemented on the basis of two industrial computers using the SCADA WINCC system and two computers with the SCADA Trace Mode system. Both computer pairs are interchangeable, and processes can be managed from any of them. For technologists, an all-purpose workstation is provided, which can be used to manage any processing facility of the unit.

For the first time, the motor operated valve management system based on the ProfiBUS network  has been used in the tank fleet management system, in which tens of actuating units are managed through one network cable. The information about self-sustaining parameters and important technological parameters is transmitted to the common database of the byproduct-recovery department. 

Dephenolation unit at VKG Oil

Phenol water, which is generated by generator stations, is purified by the unit to the level that is appropriate for the pharmaceutical industry. The unit includes three sections: dephenolation section, phenol distillation section, and pure phenol separation section. The structure of the system and the hardware of different sections of the automatic process control system differ from each other.

System of the management of dephenolation section is based on the modules of the I7000 series, a programmable NE-1600 controller, electronic BTC-9300 regulators. There are 32 electronic regulators in the system.

The information from these devices is displayed on the industrial computer through the SCADA TRACE Mode5 system. The entire set of the equipment, including the computer and the 24” monitor, is installed within the case of the console. The same computer is used for calculating the rate of steam consumption by the unit by means of processing the information transmitted from Flow to the RS485 interface.

The system of managing the phenol distillation section is based on Dicon programmable controller, the modules of the 7000 series, and 12 electronic regulators BTC-9300. The entire set of equipment is concentrated on the control panel module. The information is displayed on the 24” monitor. The SCADA TRACE Mode5 system is used. The separation of pure phenols through the automatic process control system is implemented on the basis of the WinCon controllers and two computers. One computer is installed on the panel of the third control panel module, while the monitor of the second computer is used by a technologist and is outside of the control panel. Visual representation and graphic interface of the system are implemented through the SCADA TRACE Mode5 system. The computers are interchangeable, which increases the reliability of the system.

Coking unit at VKG Oil

The unit is used for making electrode coke from still bottoms in the columns of generator oil distillation for the purposes of the electrical engineering industry. The management system covers 34 cubes, in which shale oil is evaporated. The solid residue is electrode coke of high quality. The steam condensates and moves on to other units for further processing.

The management system has been implemented through four Unitronics controllers, one WinCo controller, and three administrative computers. The evaporation process progresses in the preset sequence,  consiting of 11 stages.

The crucial moment is determining the point of transition to the next stage. An error in determining the end of the stage can lead to an emergency situation, and at worst, to coking up the condensation system.  This is why the algorithms of additional check-ups that are run at the point of transition to another stage of the process have been implemented.

The coking management system was under development for two decades and is patented by several inventor’s certificates. On the two computers, the system of visual representation has been implemented by the specialists from the automation department with the help of Delfi, a programme of the higher level.  The system of visual representation of the process of separation of condensated water uses the SCADA TRACE Mode system. The information about the process is transmitted to the SQL Server 2005 database and further on to outside users through the network using information technology.

Oil shale unit at VKG Oil

The unit is used for the final processing of the products before dispatching them to the consumer. The acceptance of raw materials from tank cisterns and vehicles as well as dispatching the products. The automatic system of control over loading and unloading of shale oil and other liquid components into railway tank cars has been implemented. The operator initiates the process of loading/unloading remotely from the central control board.

The automatic system controls the process of filling and stops loading/unloading when the technological process is completed. The system of dosing and mixing of the products has also been implemented in the tank farm of the installation, which is the largest aggregation at VKG AS. The automatic process control system controls the levels in the tanks with due account of temperature and density of the product. Special level control sensors are used, which were developed by the specialists from the automatic equipment department. In order to perform the operations of control and management of production processing as well as of loading/unloading raw materials, the Profibus network is used for controlling the actuating devices, including 137 electric drives. The management system is built on the basis of 14 Unitronics controllers, the Simatic S7-300 controller and 5 administrative computers. The system of visual representation of interaction with the operator is implemented on the basis of SCADA TRACE Mode systems.