Gas generator station (GGS) № 5 (16 gas generators)
The management system has been under the ongoing development within the last 50 years. The management tasks have been put into effect in consecutive stages: on the control computer: power amplifier 1 (produced by the Sievierodonetsk plant). Later on, the system was upgraded for the СМ 1800 controlling machine (the computer line of the Comecon countries), which afterwards was replaced with a more powerful СМ 4.
In 2004, the GGS-5 controlling system was upgraded completely in all aspects. We started using the distributed technical structure: 12 programmable controllers W 8734 (one gas generator – one controller). The controllers were programmed by means of the GoodHelp programme supplied by IPC2U. For visual representation, the TraceMode Scada system was used. Computers and controllers were exchanging information through Ethernet. The control algorithms were modified considerably. The quality of the process management was improved. The system generated a lot of profit.
At present, the automatic process control system GGS-5 consists of 19 programmable controllers, 4 industrial computers, the database computer (Sybase), the network printer which generates reports about the technological mode every hour, every shift, every day.
1,000-ton gas generator (large-capacity gas generator)
The initial automatic process control system was developed on the basis of ECM СМ 1800 in 1993. In 2001, the new management system was modified completely. It was implemented through the three programmable controllers I 7188 (supplied by IPC2U) and the industrial computer. The visual representation was implemented through Scada TraceMode system, using the RS-485 interface. The new management algorithms were developed. In the result, the runlife between repairs has increased twice. The system paid off within 8 months.
At present, the automatic process control system of the 1,000-ton gas generator includes 3 programmable WINCON controllers (supplied by IPC2U), 2 I 7188 controllers, 2 industrial computers, the database computer (Sybase), and the network printer that generates reports about the technological mode.
Gas generator station № 3 (16 gas generators)
The very first management system based on Siemens controllers. Its development started in 1991. The object management task was accomplished by using the Simatic S5-95 controller. For visual representation, we developed a user programme, which was debugged on Delphi 3, a programming tool of the higher level. The controller and the computer with visual representation were interconnected by means of the RS-232 interface.
For the first time, the predicted value control algorithm was implemented. This system was further developed in 1999. Simatic S5-95 was replaced by S7-200, and 18 Logo (Siemens) microcontrollers, which control the generator loading processes and transmit information to S7-200, were programmed and installed. The user programme was expanded. Now it also records information in the local database and generates the process history at customers´ requests.
At present, in addition to the devices listed above, the system also includes the programmable controller WINCON (supplied by IPC2U), 2 industrial computers, and the system of data transmission from GGS-3 to VKG Energia through Intranet.
Gas generator station № 4 (20 gas generators)
The GGS-4 management system has been built on the basis of the four Unitronics controllers (produced by Klinkmann) and three industrial computers. The uppermost management level and visual representation are implemented through two Scada systems: Intouch and TraceMode. The MS SQL database, which archives technological information and generates the history of the processes at the request of the users through Intranet, works in conjunction with Intouch.
The unit for the preparation of heavy and medium light resin (including 6 Amafiltr filters)
The Amafiltr company sells its technology together with the management system for S7-300. This is why this unit has a hybrid system. The Amafiltr section of the programme is displayed on Siemens graphic panels.