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Technical solutions SPC «KRUG» Power engineering automation
Technical solutions
SPC «KRUG»
Power engineeringautomation
Company profile
SPC «KRUG» is a large multi-disciplinary engineering company involved in the industrial automation of the fuel and energy sector facilities.
The company’s staff accounts for more than 250 skilled specialists. Branches and representative offices of the Company operate in a number of cities of the country. The quality management system complies with the ISO 9001 standard, which has been recorded in the GOST R certification system since 2002. More than 30 certificates, licenses, permits and testimonials, issued by recognized authorities such as the Russian Federal Agency on Technical Regulation and Metrology (RF Rostekhregulirovaniye), Russian Federal Environmental, Engineering & Nuclear Supervision Agency (RF Rostekhnadzor), Russian Federal Agency for Construction, Housing Maintenance and Utilities (RF Rosstroy), ensure a high reliability and quality of products and services to be provided to our clients.
Products and services
• DCS for the fuel & energy sector facilities • Certified software & hardware systems for developing industrial automation
systems for critical manufacturing processes • Software for industrial automation systems • Integrated utilities metering systems • Control boards for developing automated workstations for operators and supervisors• Operating and process personnel training • Cost estimating• Engineering• Startup & commissioning • Project management.
Implementations
Since 1992, SPC KRUG, in close cooperation with a number of its partners, has commissioned more than 300 DCS systems at the fuel and energy sector facilities, in particular, more than 100 systems for the power industry. Automation systems, which are based on KRUG’s software & hardware, are in commercial operation at many power facilities of such power systems as OGK-4, OGK-6, TGK-2, TGK-3, TGK-4, TGK-6, TGK-7, TGK-8, Bashkirenergo and Tatenergo as well as in Belarus, Ukraine and Kazakhstan.
DCS for thermal engineering equipment have been implemented at CHPs belonging to FSUE Siberian Chemical Combine, Tuapse Refinery, Krasnodar Refinery, Mittal Steel Temirtau Metallurgical Plant (Temirtau, Kazakhstan), etc.
DCS have been developed for various-capacity boiler and turbine units, gas turbines, gas pressure reducing station, water treatment plants, auxiliary equipment, heating systems, etc. Some companies have implemented consolidated supervisory control and data acquisition and processing systems as well as integrated utility metering and remote control systems.
Experience, accumulated by the Company in the field of implementation of automation systems, allowed us to develop a range of standard engineering solutions for power facility automation. Our solutions are integrated projects for improving effective management of sophisticated power generating equipment as well as integrated utility metering and supervisory control systems.
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Certificates and licenses
Controlled objects
Steam boilers of various steam generating capacity, including E-160-100, E-230/100 and E-420/140, BKZ-210-140, BKZ-420/140 NGM, NZL-110, E-20/14 GM, TGM 84 B, KVGM-50, TGMP-204, etc.
Objectives and tasks
• Ensure efficient and reliable control of boilers in routine and transient modes to allow production of the required amount and quality of steam, taking into account safety requirements
• Bring steam generation process in accordance with applicable standards and regulations
• Provide operating staff with timely, accurate and sufficient information about the process status and major equipment condition
• Protect boiler by its shutdown in case of possible accidents
• Implement the logic for automatic gas equipment leak and burner ignition tests
• Improve reliability of the equipment by reducing the likelihood of erroneous actions of the personnel and by using advanced control and monitoring technologies
• Increased efficiency of the equipment through optimization of non-steady modes of operation and reduced time interval for start-up operations.
Functions
• Meter and monitor process parameters • Detect, generate alarms and record parameter
deviations from established boundaries • Generate and print deliverables • Archive parameter change history • Resolve calculation problems • Provide remote control of process equipment
• Provide remote control of actuators • Execute process protection logic• Ensure logic control• Implement automatic control• Control the process of control command transfer to
the controller • Support system time uniformity • Delimit access to system functions • Provide software and hardware self-testing of
controllers and output information to board indicators and to upper levels
• Verify reliability of information signals • Provide online system resetting and software
reconfiguration, etc.
Architecture
Boiler DCS has four hierarchical levels.
Level 1 (lower level) includes sensors of measured analog and digital signals, actuators, including isolating and control valves, and overcurrent relay protection cubicles.
Level 2 (middle level) includes the boiler burner control cabinets.
Level 3 (middle level) includes: microprocessor controllers of process protection, remote control, automatic control and information subsystems.
Level 4 (upper level) includes:• Operator’s automated workstations with a 100%
interchangeability in terms of capabilities (the operator’s station functions may be combined with server functions)
• System Engineer’s automated workstation, allowing DCS support
• Printer for printing out event logs, behavior records, shift records, etc..
Boiler DCS
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Features
Process protections. An automatic protection activation/ deactivation system provides routine operation of the process equipment in all modes of operation, including start-up modes, without personnel intervention in the protection system operation. The logic of the process protection and interlock subsystem interface is easy to understand and allows a quick and prompt understanding of the causes of activation of the protection and interlock subsystem.
Process protections envisage:
• Automatic and authorized manual start-up/ trip• Authorized adjustment of the protection settings • Action control and recording of root causes of the
activation• Generation of emergency protocols, which record
changes of analog and digital parameters before and after the accident.
Automated boiler burner control subsystem (ABCS).
Deep integration with upper-level DCS system is a design feature of the subsystem. ABCS automatically checks gas valve leaks and burner ignition status as well as implements regulatory requirements for safe operation of boiler gas equipment.
Automatic control.
Automatic regulators integrate advanced circuit solutions, ensuring stable operation of these regulators in the permissible load range, such as:
• Implementation of multi-loop control circuits and control circuits with corrective signals
• Logic for switch-over from one fuel to another• Possibility of changing controlled parameters and
actuators• Adjustment of a task for the regulator, controlling air
supply to combustion dependent on oxygen content, flow and type of fuel burned
• Logic control and process interlock diagrams, ensuring safety of regulators in routine and transient modes
• Different balancing types • Fault alarm • False parameter processing • Tracking modes, etc.
Actuator control.
Actuators are controlled, taking into account priorities of incoming signals. Process protection signals have the top priority. Next, in terms of priority, are logic problem commands (routine operation interlocking). Then operator’s control commands follow. Remote control of actuators is provided from video frames, on which corresponding equipment is displayed, using virtual control panels, a mouse manipulator or a functional keyboard. Actuator group control functions are envisaged.
Results
Implementation of DCS, designed on the KRUG hardware & software system, allows out clients to fulfill all requirements of existing regulations in the field of thermal engineering, a significantly expand functional capabilities of the system, increase reliability level of process equipment and automation hardware, and reduce labor costs for maintenance and repair.
These solutions are implemented at the following facilities: Samara TPP, Tuapse Refinery CHP, Penza CHP-1, CHP-17 (JSC MOSGORENERGO), SCC CHP (Seversk), Gubkinsky GPP and others.
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Controlled objects
Burners of boilers of various modifications and steam generating capacities.
Objectives and tasks
• Provide operating staff with timely, accurate and sufficient information about the process status and major equipment condition
• Bring the boiler burner control process in accordance with applicable standards and regulations
• Implement the logic for automatic gas equipment leak and burner ignition tests
• Coordinate operational logic of burners.
Functions
• Remote control of electrified burner valves and spar-discharging device in compliance with all interlocks and local protections, in accordance with applicable standards and regulations
• Automatic burner valve leak tests • Automatic execution of the burner ignition operations • Semi-automatic ignition with step-by-step execution
of operations, using intermediate commands from remote controls (from control board, from controls in the burner control cabinet (BCC), or from operator workstation)
• Gas pressure control upstream of the burner • Burner gas-air ratio control• Diagnostics and indication of the cause of gas supply
cut-off to the burner • Control of motorized valves in the burner fuel oil path
(for gas & fuel oil burners)• Coordination of the BCC operation during automatic
ignition of burners • Integration into the boiler DCS• Information acquisition, recording, visualization and
archiving (if the subsystem is implemented without boiler DCS).
Features
Technical implementation.
Burner control cabinets are placed next to the boiler on the maintenance platform. This hardware includes a full range of protection and interlock logic required to control the burner. Dependent on the requirements to the subsystem, information capacity, type of gas equipment used and process features, the following subsystem implementation options are available:
1) BCC are designed with a microprocessor controller with increased requirements for operating conditions (backup function capability), which implements burner valve automatic and remote control logic, using the SCADA KRUG-2000 software. All logic in the BCC is coordinated by a separate device called central burner control cabinet (CBCC). Information from BCC and CBCC is transferred to database servers. ABCS may be implemented in the boiler DCS (see block diagram).
2) Burner valve automatic and remote control logic is implemented using intelligent input/ output (I/O) modules, placed in the BCC. Operation of all burners is coordinated by a microprocessor controller located in the boiler control cabinet (boiler automatic control, protection and interlock subsystems may be implemented in this control cabinet). The controller is connected with the BCC via a redundant RS485 bus. Data from the controller is transmitted to database servers.
3) ABCS is placed directly into the boiler control cabinet (BOCC). At the same time, BOCC (controller as a whole or its I/O modules) is located in the immediate vicinity of the boiler.
Boiler burner ignition control subsystem (ABCS)
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Automatic leak testing of gas equipment and burner ignition.
These tasks, launched by the operator, allow bringing pressure test and burner ignition processes in accordance with existing regulations, prevention of erroneous actions of personnel, and reduction of the time required for these process operations. The burner gas valve leak test is initiated either from the operator workstation, or in-situ, automatically, from BOCC. Ignition of gas and fuel oil burners is performed from the operator workstation, or in-situ, automatically or manually.
Automatic regulation.
Automatic regulators embody advanced circuitry solutions, allowing stable burner operation in various modes of
operation. This includes various types of balancing, fault alarms, unreliable parameter processing, tracking modes, gas-to-air ratio control in the burner, etc. In some cases, ABCS may also be used for boiler load control.
Process protections.
Automatic input and output protection system allows normal operation of process equipment at all modes of operation, including start-up modes, without the personnel’s intervention in the protection operation. Process protections provide for automatic and authorized manual activation/ trip, authorized adjustment of protection settings, action monitoring, and recording of the root causes of tripping. The interface logic of the process protection and interlock subsystem is easy to understand and allows quick and efficient understanding of the causes of activation of the protection or interlocking hardware.
These solutions are implemented in DCS of various-capacity boilers at Samara TPP, Penza CHP, CHP-17, CHP-12 (JSC MOSGORENERGO), Tuapse Refinery CHP, SCC CHP (Seversk), Arkhangelsk CHP-2, Surgut TPP, etc.
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Controlled objects
Turbosets T-115-8,8, PT-65/75-90/3, PT-60/75-90/13, PT-30-8,8, T-12-243, P-6-3,4/1,0-1 and auxiliary equipment.
Objectives and tasks
• Improve process control efficiency and reliability in normal and transient modes
• Implement process protection, interlock, control and software-and-logic control logics, computational tasks, which meet up-to-the-date requirements
• Improve working conditions of the operating personnel.
Functions
• Meter and monitor process parameters • Provide data to operating and maintenance personnel • Produce emergency, warning and diagnostic alarms
in case of parameter outreach of established boundaries, process protection actuation, equipment failure, etc.
• Provide remote control of actuators • Control process parameters, using programmed
controllers• Keep logs of pre-emergency and post-emergency
situations
• Provide protection and interlock actuations in accordance with regulatory documents
• Provide software logic control • Backup data• Calculate turboset cost-performance indices • Calculate steam and hot water flows with the
correction for temperature and pressure • Transfer data to ERP and MES• Correct system time of the DCS subscribers • Protect against unauthorized access to system
functions • Diagnose the condition of the software and hardware
system.
Components
• Microprocessor controllers (100% hot redundancy of controllers for the protection and interlock subsystem, 100% hot redundancy of the processor part of the regulation subsystem, non-redundant diagrams for information sub-systems, redundancy of individual boards and I/O modules)
• Installation cabinets• 100% redundant database servers• Operator workstations, including dual-monitor
stations, placed in the KonsErgo® control board stations
• Network equipment (100% hot redundancy) • Printers• SCADA KRUG-2000®
• Controller software with in-situ heat check metering, inter-controller exchange and accident recording capabilities
• Web-server.
This solution was implemented at the following facilities: JSC Mittal Steel Temirtau (Temirtau, Kazakhstan), Penza CHP, Saransk CHP-2, Samara TPP, SCC (Seversk), Sormovo CHP (Nizhny Novgorod), etc.
Turboset DCS
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Controlled objects
Steam turbogenerator package (STP) is the controlled facility. Steam turbine control valve is a governing body of the steam turbine. The control valve has an electro-hydraulic actuator (oil servomotors controlled by shut-off spools, with an electric torque motor).
Objectives and tasks
Ensure operability and reliability of “fast” turbogenerator speed and turbine outlet pressure control loops.
Subsystem functions
• Compute turbine rotor speed and its reliability based on triplex speed sensor readings
• Compute turbine outlet steam pressure and its reliability based on triplex pressure sensor readings
• Maintain specified speed during STGP start-up, synchronization and loading by control valve actuation
• Limiting turbine outlet steam pressure in case if it exceeded permissible limits, by control valve actuation, using a PI control law.
Components• Frequency signal amplifiers • Intelligent I/O modules • 100% “hot” redundancy of controllers.
ConclusionThe use of this subsystem as part of the turbogenerator DCS allowed the fulfillment of the turbine manufacturer’s requirements imposed on the fast speed and turbine outlet steam pressure control loops.
This subsystem is in operation as part of the Turbo-generator No. 3 DCS at the Samara TPP, etc.
Turbine speed governing subsystem
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DCS for gas pressure reducing stations Controlled objects
Gas pressure reducing stations (GPRS) intended for gas pressure reduction and maintenance at the given consumption levels.
Objectives and tasks
• Increase process equipment reliability and reduce risks of severe accidents so that equipment failures would not develop in situations, dangerous to life and human health, and would not damage the equipment
• Ensure effective automated process control in routine, transient and emergency gas distribution modes
• Timely provide operating personnel with sufficient and reliable information on the status of the process and the condition of the equipment and controls
• Cut automation hardware maintenance and repair costs
• Provide custody transfer metering of natural gas consumption.
Functions
• Acquire and process data, obtained from temperature and pressure transmitters, connected to the orifice, and compute mass and volume natural gas flow in the pipeline
• Automatically switch over differential pressure measurement ranges to increase flow measurement range
• Recover measurement parameters following an outage of the system, with the addition of the production of the downtime period by an agreed constant or flow rate value before tripping to these values at the time of shutdown
• Compare parameter values with corresponding settings, with the recording of violations and generation of a corresponding entry in the message protocol
• Monitor the reliability of the received information by limit values, the rate of change and other criteria
• Receive digital information on the valve status from the local control cabinet keys
• Provide actuation of the emergency shutdown and interlocking equipment in accordance with the regulations: gas pressure increase downstream of the GPRS to Level 1 and Level 2; gas pressure decrease downstream of the GPRS; gas reduction line switch over to OPERATION, ATOMATIC TRANSFER and OFF; prohibition to control valves from two locations
• Provide remote control of actuators • Compute mass and volume of natural gas that passed
metering station • Display information for the operating staff on color
monitors in the form of mimic diagrams, with the indication of parameters in digital, tabular or chart forms
• Generate light and sound alarms in case of parameter deviation from specified warning and pre-accident borders as well as in other emergencies
• Display mnemonic images of motorized valves, with a dynamic indication of the status and the possibility of remote control of these valves
• Manually enter input data online• Automatically generate and submit data to the
operating personnel, and print out deliverables automatically or on request
• Execute the Winter-Summer and Summer-Winter transitions
• Provide a system time correction • Provide a multi-user mode of operation, using
password-based system access rights; person access & action logging
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• Automatically generate and print system event logs • Back up data to the PC hard drive • Browse process parameter history in the form of
graphs and tables • Browse on the display and print-out paper
documentation archives • Display information about the status and operability
of the DCS components, conduct diagnostics of its elements.
Architecture and equipment
GPRS DCS is a distributed two-level system with a multi-stage failure protection, which ensures high reliability.The lower level DCS consists of advanced, highly reliable microprocessor controllers. Controllers are made with a 100% “hot” redundancy. Controllers are located in the control and monitoring cabinets.The upper level DCS consists of operator workstations (operator stations/ backup server, with a full scope of graphic design, with a 100% “hot” redundancy and backup functions).Communication with the lower-level controllers is made through a local area network using fiber-optic communication lines, with a 100% “hot” redundancy.
Software
• The upper level software is implemented based on SCADA KRUG-2000®, including: development environment (database generator, graphical editor, programming language, etc.) and implementation environment (operator station’s executables modules).
• Controller real-time system (CRTS), allowing “hot” redundancy schemes to be developed: 100% controller redundancy, redundancy of processor parts, I/O modules.
Conclusion
Implementation of the GPRS DCS allows the following to be provided:
• Optimize calculations through the implementation of a custody natural gas transfer metering module in accordance with all requirements issued by Gosenergonadzor and the Federal Agency for Technical Regulation and Metrology
• Improve the reliability of the process protection subsystem through structural redundancy and permanent hardware and software diagnostics
• Provide the staff with a comprehensive operating and archival information about operation of the system, provide broad opportunities for the operator to control the process
• Provide steady operation of process equipment control systems
• Ensure “survivability” of the system due to controller independence from each other
• Implement sophisticated control and monitoring logic.
This solution is implemented at the following facilities: • Kirishi TPP (GPRS-2)• Penza CHP-1 GPRS• Saransk CHP-2 GPRS• Ulyanovsk CHP-1 GPRS• Severodvinsk CHP-2 GPRS• Arhangelsk CHP GPRS
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Controlled objects
Major and auxiliary equipment of turbine halls of power plants: turbines of various capacity, deaerators, feed pumps, steam bypass stations, steam evaporators, etc.
Objectives and tasks
• Monitor, control and diagnose thermal power equipment of power plants in the routine, transient and pre-accident modes
• Protect equipment by shutdown in case of possible accident
• Implement computational tasks related to the calculation of cost-performance indicators.
Functions
• Monitor and meter process parameters • Generate alarms in case of parameter deviations
from the established boundaries • Generate alarms in case of equipment condition
failures • Provide manual data entry• Compile and submit data to the operating personnel
in the form of message protocols, mode sheets and accident logs
• Keep archives• Provide remote control of process equipment• Provide remote control of actuators in the manual
control mode • Execute protection and interlock logics• Perform automatic regulation• Monitor control command transfer to the controller• Monitor protection and interlock actuation• Provide software and hardware self-test of controllers,
with data output to board indicators and to the upper level
• Monitor failures of the I/O module communication lines
• Display diagnostic information to the operator workstation and engineering workstation
• Automatically restart a PC if the WatchDog has been launched
• Promptly reset the system and reconfigure the software
• Maintain system time uniformity • Register the person, controlling the facility, and log
all his actions.
Architecture
The system is designed based the KRUG hardware & software system as a four-level distributed control system (DCS), using a client-server architecture.
Level 1 (lower level) of the system includes: remote I/O modules for automatic data acquisition, receipt of control pulses from microprocessor controller (MPC) processing units and generation of control pulses to actuators; redundant interface lines for connecting I/O modules to the MPC processing units.
Level 2 (lower level) of the system includes MPCs of process protection and interlock, automatic governance, remote control and information subsystems, which include processing units for processing measured values, using preset process logics, and for generating control pulses in the form of digital codes. Some of them also include I/O modules.
Level 3 (medium level) of the system includes hardware for computer-aided data processing, recording and backup, implemented in servers with a 100% “hot” redundancy.
Level 4 (upper level) of the system includes operator workstations, engineering workstation, printers.
Communications between the system levels is provided through a redundant Ethernet LAN.Power cabinets with I/O modules and transmitters are powered from two independent inputs, ~220 VAC and =220 VDC. The upper level consumers are powered through individual uninterruptible power supply units (UPS), which increases the stability of the system to power failures.
Large-scale thermal power equipment group control system
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Components
• Microprocessor-based controllers, including: controllers of the turboset protection subsystem with a 100% “hot” redundancy, controllers of the governance, local protection & interlock and remote control subsystems with a 100% “hot” redundancy of processor modules, controllers of the information subsystem
• Database servers with backup and “hot” redundancy features
• Automated operator workstations, including 2-monitor workstations
• Engineering workstation • Web-server• Network printers• SCADA KRUG-2000® • Web-Control™ software.
Features
Possibility of placing I/O modules in the immediate vicinity of the controlled objects is a specific feature of this architecture. These modules allow the receipt and issue of control signals to the object. Processor modules of the controllers are mounted in control cabinets, located in the central control room. Processor modules are connected with the I/O modules through a redundant controller bus via protocol (maximum distance without the use of repeaters is 1,200 m).
This architecture allows significant savings in cable products, reduction of installation costs and a shortened DCS installation period. In addition, it significantly reduce the area used by DCS equipment, placed directly in the central control room.
This solution is implemented, e.g., for a CHP–steam/ air blowing station DCS at Mittal Steel Temirtau Metallurgical Plant (Temirtau, Kazakhstan).
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Controlled objects
Thermal power plants, comprising turbosets, boilers and auxiliary equipment.
Objectives and tasks
• Ensure efficient and reliable control of heat & power generating equipment of power plants in routine and transient modes, taking into account safety requirements
• Provide operating staff with timely, accurate and sufficient information on the process status and major equipment conditions
• Provide supervisory control and remote monitoring of the process.
Functions
• Meter and control process parameters • Detect, produce alarms and record parameter
deviations from established boundaries• Provide manual data entry• Generate and submit online data to personnel • Generate and print deliverables • Backup parameter change history• Resolve calculation problems• Monitor and record protection actions• Provide remote control of processing equipment and
actuators• Execute process protection logic• Provide logic control • Ensure automatic regulation • Implement diagnostic functions • Support the system time unity• Differentiate access to the system functions,
dependent on the rights of the currently logged user• Conduct remote monitoring of the process and
process equipment condition.
Components
• Control cabinets with industrial controllers (100% “hot” redundancy of process protection and interlock systems; for especially critical parameters - redundancy of modules and separate I/O channels, a 100% “hot” redundancy of processor units for remote control and regulation systems as well as information subsystem)
• Database servers with backup functions (own pair of servers for each local DCS)
• Operator’s workstation (combination with database server functions is possible)
• Shift Engineer’s automated workstation (one for all local DCS)
• Engineering workstation (one for all local DCS) • TimeVisorТМ universal time server designed based
on a single-board computer, complete with a GPS receiver
• Web-server (for data transfer from all DCS systems to external subscribers of the system)
• Web-server clients (local network of the station and remote clients)
• Printers• Integrated modular SCADA KRUG-2000® • Controller real-time system • TimeVisorТМ universal time server • Web-ControlТМ software • Engineering workstation software.
This solution is implemented at the Samara TPP, Sormovo CHP, etc.
DCS for heat & power equipment of power plants
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Objectives
• Ensure effective online monitoring over a rational use of all utilities
• Minimize production and non-production costs of utilities, and reduce the imbalance between output and consumption of energy by key use areas
• Streamline mutual financial settlements for energy output/ consumption
• Cut costs of maintenance of a number of separate metering systems.
Functions
Basic:• Visualize information data • Backup data• Maintain an accurate system time
Heating medium and heat energy metering:• Directly meter instantaneous values and calculate
interval-averaged heating medium temperatures, pressures and flows
• Calculate a flow and heat energy of the heating medium for the reported time intervals
• Calculate heating medium & heat energy production and consumption balances, and determine regulatory and actual heat loss of each heating line
• Automatically generate heating medium & heat energy metering sheets for reported time intervals for each kind of use
Natural gas and natural gas components metering:• Directly meter instantaneous values and calculate
averaged gas temperatures, pressures and flows• Meter and monitor of quality indicators of consumed
natural gas (calorific value, moisture content, etc.) by integrating a subsystem with high-precision gas analyzers and chromatographs
• Compute accumulated natural gas parameters (weight, volume at operating and normal conditions) for reported time intervals
• Compute natural gas release/ consumption by types of use, and determine regulatory and actual gas loss of each line
• Automatically generate natural gas metering sheets for reported time intervals for each kind of use
Power metering:• Periodic and/or (on request) automatic acquisition
of measured data, associated with a common
astronomical time, on power augmentation at a preset metering increments
• Automatic calculation of generated power by each connection, group of connections, actual and permissible imbalance for the station (substation), imbalance for bus systems, transformer losses, and electricity supplied to the grid, with the established averaging interval
• Automatic generation of daily power metering sheets and balance statements for the month, quarter and year for station as a whole and for individual station groups (connections).
Architecture
Automated Data Measuring System for Fiscal Power Metering (ADMS FPM) is a multilevel system, whose hierarchy typically has several functionally and geographically distributed data acquisition and processing levels. Integrated utilities metering systems are available in several options.
Option 1. Integrated utilities metering systems designed based on a microprocessor controller for accounting a decentralized (distributed) structure. Automation objects are distributed throughout the plant area. The I/O measuring modules of the controller are located in the immediate vicinity of automation objects.
Option 2. Integrated utilities metering systems designed based on heat computers and gas flow correctors and power meters of the decentralized structure. Intelligent data acquisition and processing modules are located in the immediate vicinity of automation objects and are integrated by a data bus of a arbitrary topology.
Option 3. ADMS FPM of a large plant industrial enterprise. This option is a hybrid of separate local independent automated systems of different topology and functional purpose, which is typically applicable for rather large industrial enterprises. Features
• Integrity. All levels of the system, from the metering station to the energy metering workstations, are integrated into a single information space. This provides a horizontal integration among individual local sub-systems (integration of heat, gas, electricity metering sub-systems) and also vertical integration with higher-level data acquisition and processing systems, e.g., with the ERP- and MES systems of the enterprise.
Integrated automated system for comprehensive utility metering at regional and territorial power generating companies
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• Modularity. The system is built as a set of interrelated, but relatively independent, components installed stage by stage. Design is carried out in such a way so that the system could be implemented in parts (stage by stage), without shutdown of the already existing parts of the system.
• Scalability (replicability). The system anticipates scaling (extension) of the already implemented parts and replication of its individual segments (subsystems), which allows a gradual tie-in of the facilities of Stage 1, Stage 2, Stage 3, etc., to the system.
• Openness. The use of open technologies enables the integration and controlled coordinated operation in the system with a wide nomenclature of instrumentation made by leading domestic and foreign manufacturers.
These solutions are implemented at the following facilities:• Automated supervisory process control system at the
Ulyanovsk CHP-1, CHP-2 • Automated natural gas custody transfer metering
system at the Saransk CHP-2 gas pressure reducing station
• Automated natural gas & heating medium custody transfer metering system at the Cheboksary CHP-2, etc.
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Objectives
• Provide prompt monitoring and control over heat and water supply modes
• Improve reliability and fail-safety of technological processes
• Optimize heat and water supply processes in order to achieve maximum energy-saving
• Archive acquired data for further processing and analysis.
Functions
• Acquire and record process parameters, condition of the equipment and automation hardware
• Generate process alarms to warn of violations occurred
• Log events• Provide remote control of process equipment • Display information on the operator’s technological
panels, workstation monitors and a group display • Generate and print out documented forms in the
form of deliverables, mode sheets, pre- and post-emergency protocols, communication protocols, etc.
• Compile long-term archives of measured process parameters, system events and its documented forms
• Synchronize system timers of computing components of the automated supervisory and process control system (ASPCS)
• Integrate ASPCS with a corporate computer network of the heat distribution company and differentiate user’s access to information data of the system
• Provide service functions. Architecture ASPCS of a heat distribution company is a multi-level hierarchically distributed system with a two-stage centralized process facility supervisory control structure (the level of regional supervisory control offices and central supervisory control office). Several solutions for implementing information exchange between system components are available.
Solution 1. Building a system with only one supervisory control point in various hardware and software configurations.
Solution 2. To provide data exchange through a radio channel, an existing municipal data transfer network, for example, a network supporting the RadioEthernet technology in the 802.11a standard with working transmission frequencies of 5.15-5.35 GHz and a modulation rate of up to 54 Mbit/s, may be used. In this case, leased equipment, consisting of a radio bridge connected to an antenna-feeder system, provided by a communication provider, is used as terminal channel-adapting equipment for the ASPCS radio channels.
Solution 3. To provide data exchange through a cellular communication channel, an existing municipal cellular network, for example, a network supporting the GSM/GPRS technology, is used. In this case, GSM/GPRS modems are used as terminal channel-adapting equipment for the ASPCS cellular communication.
Solution 4. Models, supporting a distributed structure of I/O terminal modules and processor modules redundancy modes or a 100% reserve, may be used as controllers mounted at process facilities.
Features
• Data exchange between adjacent components of the system envisages data array reading from lower levels and transfer of control commands from higher levels.
• Only standardized interfaces, e.g., RS-232, RS-485, Ethernet, etc., are used as hardwired inter-level interfaces. Open protocols such as TSP/IP, OPC, ModBus, ProfiBus, etc., are used as inter-level data communication protocols.
• The system allows for a phased automation of new-commissioned facilities without shutdown of already existing parts of the system.
• Maximum use of existing automation hardware at heat distribution company’s facilities through integration of the existing automation hardware in the system under development.
This solution is implemented in the following projects: ASPCS for Saratov Heating Networks, Ulyanovsk Heating Networks, Kursk Heating Networks, Togliatti (JSC Tavis), DCS for SaranskTeploTrans’ heat transfer & metering station.
Automated supervisory and process control systemfor heat distribution companies
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Objectives and tasks
• Ensure required power quality parameters and required level of service for the market participants
• Improve the efficiency of supervisory and process control process
• Reduce power loss and increase reliability while solving power generation, transmission, transformation and distribution tasks.
Functions
• Provide acquisition and primary processing of measured data (filtering, linearization, scaling, etc.)
• Receive digital information (with time marks) on the condition of communication equipment, relay protection hardware, etc.
• Verify reliability of information received (by limits, by rate of rise, etc.)
• Ensure remote control of distributed objects • Transfer data (with time marks) to higher levels of
the supervisory control hierarchy • Visualize general mimic diagrams with a dynamic
indication of displayed measured and calculated parameters in digital, table or change vs. time chart formats (trends), on the operator workstation monitors
• Monitor compliance with a preset operations schedule and record deviations
• Generate visual and audible alarms if current process parameters outreach specified limits, or in case of other upset situations
• Maintain the system event log
• Enter input data (contract values, coefficients, etc.) online
• Document and print out reporting information • Backup data (in the form of trends, reports, event
logs)• Monitor the condition of communication channels,
with a diagnostic information submission • Provide time synchronization for all subscribers
included in the system • Automatically adjust system clock using the primary
time source (GPS receiver).
Architecture
ASCS is structured as an automated integrated hierarchical system with a centralized control and distributed measurement function.The ASCS structure has three geographically and functionally distributed data acquisition and processing levels (lower level, middle level - information acquisition & transmission system, and upper level - operational and information software subsystem).
The lower level transmitters provide a full range of remote measurements for one connection and ensure the implementation of remote signaling and remote control functions, recording of pre-accident, emergency, post-emergency readings, and electricity and power metering functions.
Automated power grid supervisory control system
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The middle level includes communication servers, which acquire and process data received via a digital interface from telecommunication data points as well as via local area network, from the upper level equipment.
The upper level equipment (operational and information system) is designed, using a client-server architecture, and includes database servers, operator workstations (with control capabilities), monitoring workstations (without control capabilities), and engineering workstation.
Features
Flexibility – possibility of a staged upgrade of the system, with a gradual build-up of functionality and reconfiguration without dismantling and replacement of the equipment installed.
Versatility – designed based on a common software & hardware execution environment of specialized energy metering systems (any energy sources) and supervisory control & monitoring systems.
Reliability – the use of effective redundancy diagrams, such as control network redundancy, database server redundancy, controller equipment redundancy, etc.
Openness – the use of public and universally recognized communication standards and protocols (Fast Ethernet, CAN, Modbus, IEC 60870-5-101/104, TCP/IP, etc.). Availability of mechanisms for data sharing with adjacent and superior systems, including OPC and ODBC. Access to the system information is provided to third-party users through a browser of the Internet network.
Scalability – the possibility of cost-effective creation of small-sized control and monitoring systems as well as full-scale DCS of large power plants.
The system is in operation at the Ulyanovsk CHP-1, CHP-2 and others.
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Objectives and tasks
• Improved process control efficiency at territorial generating companies (TGC)
• Provide online control over utilities production and consumption at TGC (hot and cold water, steam, electricity, natural gas, fuel oil)
• Optimize modes of operation and increase service life of equipment
• Enhance reliability and trouble-free operation of major and auxiliary equipment
• Reduce operating costs. Functions
• Provide long-term storage, statistical processing and prompt submission of operational information on planned and actual cost-performance indices and actual energy consumption, generation and supply rates to the TGC Management and supervisors
• Ensure monitoring and statistical processing of the status of electric mode parameters and electric energy quality indicators for all regional power generating facilities
• Calculate planned consumption of active, reactive, apparent power and electricity in accordance with the approved TGC operations for a month
• Monitor planned active power consumption indicators, and generate messages if actual consumption exceeds target levels
• Perform statistical analysis of data on deviations, and generate reports required for handling claim issues with power supply companies
• Analyze the impact of power quality deviations on the efficiency of electrical equipment operation for TGC as a whole
• Analyze consumption of active, reactive & apparent power and electricity by areas of use as well as the causes of deviations from planned electricity consumption values at TGC as a whole
• Display generalized information on the electrical equipment condition at the TGC-owned power generating facilities as a whole
• Generate consolidated spreadsheets for power facilities and for the region as a whole.
Architecture
The system is implemented as an integrated geographically distributed hierarchical 4-level system.
At Level 1, existing automated data acquisition systems at power facilities (CHP, substations of the main power networks, power distribution zones, etc.) are used.
Level 2 includes process servers for data acquisition, which receive, process and store data for one region (power generating facility) as well as retransmit these data through a TGC corporate network to the system upper level.
Level 3 is a consolidated Center for data acquisition, processing and storage. At this level, data from process servers are received, processed, stored and provided to users.
Level 4 is the level of automated workstations of the supervisory control staff. This level also includes jobs of the TGC corporate network users, who, dependent on the
Process data acquisition and processing system for powergenerating companies
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established access level, may view required information online, using any web browser of the Internet network.
There are several options of standard solutions for data exchange.
Option 1. Data exchange between relational databases (using ODBC mechanisms (the Open DataBase Connectivity) and ADO.NET - Microsoft ADO (ActiveX Data Objects)
Option 2. Development of software, which provides access to data sources or transforms source data into a SQL-compatible format
Option 3. Software development, using TCP/IP pipe, IPC, DCOM protocols, etc.
Process data acquisition and processing system is in operation at Volzhskaya TGC OJSC.
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Controlled objects
Major and auxiliary equipment, switch units of the plant substations. Objectives and tasks
• Improve efficiency of supervisory and process control of electrical equipment
• Optimize modes of operation and increase service life of the equipment
• Improve reliability and trouble-free operation of major and auxiliary equipment
• Enhance functional capabilities of the remote control system (RC) as compared with the existing one, through the use of the most promising equipment and management methods
• Reduce operating costs • Establish an information & technical basis for further
RC system development • Ensure a long-term storage of measured data• Furnish personnel with retrospective process
information (event logging, equipment diagnostics, etc.) for analysis, organization and planning of major electrical equipment operation and repair.
Functions• Provide acquisition and primary processing of
process data received from analog and digital signal transmitters (telemetry and remote signaling)
• Provide process alarms to warn of violation occurred• Log events• Enter data manually • Display information to operating staff • Provide information to the corporate network users
(Web-Control™) • Backup parameter history • Display information to the operator’s control board• Implement the individual acknowledgment function
from the operator’s control board• Provide remote supervisory control.
Architecture
The RC system, being an automated hierarchical integrated system with a centralized control and distributed measurement function, is implemented based on the KRUG software & hardware system and is represented by three geographically and functionally distributed data acquisition and processing levels.Level 1 (lower level) includes analog measuring transmitters and switching device status sensors.Level 2 (middle level) consists of programmable logic controllers and I/O modules. Level 3 (upper level) includes a backup server for data acquisition, supervisor’s automated workstation (AWP) and Web-server.
Hardware for data receipt/ transmission (remote measurements, remote signaling, remote control) is often installed in unheated rooms of substations and, therefore, they operate in severe climatic conditions (ambient temperature -40...+60°C). In case of 220V power supply interruption, the remote control system often fails at substations, and, sometimes, there is no information on the feeder status. In these cases, heated remote control cabinets with individual uninterruptible power supply to controller equipment of the system are used to ensure an uninterrupted 24-hr data transmission in a wide range of ambient conditions.
Programmable controllers are characterized by a modular structure. I/O modules are designed for primary processing of hardwired signals and for converting these signals into a digital format. If the replacement of existing remote control devices at controlled points is not planned, it is possible to organize connection with them, using the Modbus protocol, etc.
The range of companies, for which remote control systems are developed, predefines the variety of communication channels for transmitting data from substations to the control room. Our technical solution assumes the use of equipment working with: RS-485 communication channel, dedicated non-switched communication lines, dial-up communication lines, radio channel, Ethernet network, communication channel based on RadioEthernet, etc. Information transfer between controlled and controlling stations is crucial for the entire remote control system, therefore, this ensures high reliability and accuracy of transmitted data and a rather short RC transfer time for providing a real time mode while monitoring and controlling technological processes.
Remote control system for plants
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Information, coming from controlled points, is typically transmitted not only to the data acquisition server and to the operator’s workstation, but also to the control panel (group display). It is possible to exchange information with third-party systems via IEC 60870-5-101, IEC 60870-5-104 protocols.
Components
• Remote monitoring & control cabinets with programmable controllers and I/O modules
• Data acquisition & backup server (with the possibility of a 100% “hot” backup)
• Operator’s workstation (it’s possible to combine with the data acquisition & backup server functions)
• Group display• Printer• SCADA KRUG-2000®
• Controller software • Web-Control™ software (Web-server, Web-clients).
Conclusion
Equipment of the companies, where RC systems are in operation for a long time (decades), usually does not meet up-to-the-date functional requirements and is obsolete; rework of this equipment requires significant investments. In this regard, upgrading of existing RC systems is critical, in particular, this refers to data receiving/ transmission equipment.
The KRUG-manufactured RC systems have a number of advantages and allow the following:– Timely provide personnel with sufficient, accurate and reliable operational information on the process status and on the condition of equipment and controls– Provide personnel with retrospective process information (event logging, equipment diagnostics, etc.) for analysis, organization and planning of operation and repair of major electrical equipment – Ensure long-term storage of archival information – Reduce the probability of erroneous actions of the operating personnel through a timely presentation of information in visual formats – Improve technological discipline through an accurate and timely recording of personnel’s actions – Improve working conditions of the operating personnel.
This solution is implemented at Uralchimplast JSC (Nizhny Tagil).
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Power utilities of industrial enterprises
• FSUE Siberian Chemical Combine» (Seversk) • OJSC NK Rosneft-TNPZ’s Tuapse Refinery (Tuapse)• Krasnodar Refinery - Krasnodarekoneft (Krasnodar)• Mittal Steel Temirtau Metallurgical Plant (Temirtau, Kazakhstan)• Saratov Refinery (Saratov)• OJSC Uralchimplast (Nizhny Tagil) • OJSC Gubkinsky GPP (Gubkinsky).
Consumers
Large-scale power generation
TGK-2: • Arkhangelsk CHP-2 • Mini-CHP “Bely Ruchey” (Vologda)
TGK-3 (MOSENERGO): • CHP-8 • CHP-9 • CHP-11 • CHP-12 • CHP-17 • CHP-23 • CHP-25 • TPP GRES-3 (Elektrogorsk)
TGK-4: • Belgorod CHP-1
TGK-5: • Cheboksary CHP-2
TGK-6: • Saransk CHP-2, • Penza CHP-1, CHP-2 • Sormovo CHP
TGK-8: • Astrakhan CHP
TGK-7: • Samara GRES (TPP), • Togliatti CHP • Ulyanovsk CHP-1, CHP-2 • Saratov heating systems
OGK-4: • Surgut GRES-2 (TPP)
OGK-6: • Kirishi GRES (TPP)
BASHKIRENERGO: • Salavat CHP • Ufa CHP-1,2,3,4 • Priufimskaya CHP • Novo-Salavatskaya CHP • Zauralskaya CHP • Shaksha CHP
TATENERGO: • Kazan CHP-1, CHP-2 • Nizhnekamsk CHP-2 • Naberezhnye Chelny CHP-1 etc.
Municipal housing sector
• OJSC TEVIS (Togliatti, Samara region) • JSC Volzhskaya TGK subsidiary - Saratov Heating Systems (Saratov)• Kurskenergo (Kursk)• Orenburgenergo’s Orenburg Heating Systems (Mednogorsk) • OJSC SaranskTeploTrans.
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Basic specifications of the distributed control system (DCS)
Total number of analog and digital measuring/ control channels max 60,000
Data update period at DCS upper level 1 second and above
Signal scanning interval to meet accuracy requirements for event
logging and recording of analog signal values with respect to the DCS
system time (dependent on dynamic properties of the parameter)
passive discrete signals: 0.03-0.5 s
discrete action signals: 10 ms
analog signals: 0.02-0.2 с
analog signals for temperature
parameters: 0.25 - 2 s
Time for issuing control action via process protection channels (PP)
after identification of emergency (for PP without time delay)
max 0.1-0.2 s
Command transmission time from the time when operator pushed the
button on a virtual control unit to the time of signal origination in DCS
output circuits
max 1 s
Delay from the time of issue of a remote control command by the
operator to the time when the results of command execution display
on the monitor, without the time required for the controlled object to
respond
max 1.5 s
Generated trend parameters:
• number of trends
• interval of entries into trends
• number of discrete points in trends (trend depth):
a. operational
b. archival
max 50,000
1 second and above
max 100,000
limited only by the capacity of the disk
Number of messages (events) recorded in the DCS:
• operational
• archival
minimum 21,000 per day
limited only by the capacity of the disk
Discreteness of messages (events) recorded 10 ms and above
Redundancy: • 100% hot redundancy of network • 100% hot redundancy of databases
servers• N-fold redundancy of operator
workstations• 100% hot redundancy (duplication) of
controllers • 100% hot redundancy of processor
modules in controllers with a redundant computing part
• Redundancy of individual boards and I/O modules in the controller.
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Address: SPC «KRUG»1, German Titov st., Penza, 440028, Russia
Tel.: +7 (8412) 49-97-75, 49-94-14, 49-72-24, 49-75-34
Fax: +7 (8412) 55-64-96
www.krug2000.comwww.krug2000.ru [email protected]
КР1.80301.БМ.И1.0316
