Structure of automated control system of the :

Principle of automated control system construction is traditional. The basic functions of data control and collection are performed by controller installed in process automation cabinet. The controller is equipped with the necessary means for galvanic isolation and conversion of sensor signals into digital form as well as assigning control actions. Control cabinet is connected by information channels with a graphical operator terminal(installed directly on the cabinet door), digital indicators (installed in autoclaves), as well as top level computer located in a separate room.

Automated control system of fish processing unit includes:

• personal computer;
• cabinet of automated process control;
• operator terminal (our own development). Has a graphic display and keypad;
• digital indicators;
• sensors installed on process equipment.

All signals from sensors connected to the cabinet of automated process control, which is located in the unit and is hinged. Signals of the automated process control cabinet are sent to normalization motherboard and galvanic isolation (our own production). Further analogue-to-digital conversion (PCL-818, Advantech) and discrete input boards(UNIO-95-5, Fastwel) are used, they are digitise. Obtained values are programmatically converted into real variables (PCA-6753, Advantech) and transmitted through information communication channels to PC, local operator terminal and digital indicators for displaying and archiving.

The mnemonic displays following process parameters:

• steam pressure in the steam generator and temperature in the autoclave cameras;
• the temperature in solting baths;
• level of the sauce in the pot;
• number of cans coming down the conveyor;
• flow of cold water;
• oil temperature in the roasting furnace;
• pressure of cold water in the line;
• air pressure in the line;
• steam pressure in steam generators.

Technology of production

One of the most simple and effective technological schemes of animal feed production is serial (in-line) scheme. The source components are pre-cleaned and each one is placed into separate bunker. After that the components are weighed metered depending on the form of manufactured feed. Prepared mixture goes into crusher, which simultaneously does component shredding and mixing. Then mixture is sieved goes into extruder. While extrusion milled mixture is treated by high mechanical pressure (30-50 atm), it heats up due to friction (120-150 ºC) and turns into crashed mass. At the exit of the extruder the mass swells , due to the large pressure drop. The starch contained in the end feedstock turns into dextrin, which is easily assimilated by the animal organism, and a large part of the micro flora (bacteria, fungi) is destroyed.

Developed management system provides fodder production with:

• continuous operation and equipment control of the unit;
• manual and automatic control of transport (conveyors, bucket elevators, valves, changeover valves) and process (crusher, extruder) equipment of the unit;
• control of the silos filling level(with the use of level sensors with analog & discrete signals);
• crusher smooth start(200 kW);
• regulating of feedstock supply to the crusher depending on crusher load level;
• display of equipment operating modes status and emergency situations.

In development of the control system was performed integration into extruder automation system which is unique for Ukraine – ExtruTech, Bliss (USA) performance 6 t/h.

Advantages of the implemented steam boiler control system:

• full boiler workflow display of all subsystems;
• sensors data collecting and processing, and transfer of key performance indicators to the operator display;
• automated major boiler systems performance monitoring, including security systems;
• alarm in case of emergency situations;
• ability of quick reaction and control actions performance in automatic mode to prevent emergency situation diffusion;
• recording, archiving and storing of the process data of abnormal situations and operator actions.

Feedstock weighing and receiving unit

Consists of truck scales (load capacity 30 tons), unloader, transport mechanisms (conveyors and bucket elevators) and aspiration systems. Unloading and reception process is performed in the local mode, in coordinartion with overall management system and is displayed on the screen of the operator automated workplace.

Storage unit

Grain storage consists of few units:

• silo type metal storage;
• working elevator tower.

Both storages have transport equipment (conveyors, bucket elevators) and the mechanisms of the feedstock directed flow (rocker valves, gate valves). Technological routes and equipment control system is constructed the way that ensures uninterrupted plant feedstock supply in case of emergency on any production line. System of mechanism control allows to pump the feedstock from one storage to another. The storage is equipped with top-level and temperature sensors and ventilation.

Dryer unit

Dryer unit is designed for drying of high moisture content feedstock – if there is no way to dry it by means of storage ventilation. Feedstock supply and selection is done by the transport mechanisms (conveyors, norias). If it is impossible to reduce feedstock moisture content in one dryer pass, drying process can be looped until desired moisture content is reached with the help of reversible valve.

Control system is equipped with one operator workstation. It is flexible and can be performed remotely from the operator workstation or from local control mechanisms (in the case of production necessity or emergency situations).

Advantages of the implemented control system of the grain reception, storage, prepararion and processing:

• full operational process display;
• optimization of the process control system;
• control of storage feedstock filling;
• feedstock temperature and moisture level control;
• equipment process control;
• alarm signals of equipment stopping/locking ;
• simplification of abnormal situation causes search;
• equipment and machinery flexibility – ability to work in manual mode in case of emergency – for the smooth operation of the complex.

Structure of the work done:

• Project documentation for technological automation section, power equipment;
• Design documentation for the automation system cabinets:
  • Technological automation cabinet (based on SIMATIC PLC S7-400);
  • Cabinets of remote input/output signals (stations of distributed input/output ET-200M, analog and digital modules of input/output);
  • motor control cabinets (automatic switches for motor protection, contactors, automatic and manual control schema);
  • local cabinets of control mechanisms (control cabinets of rocker valves and gates, fan control and stripping screws silos).
• Introductory and power distribution cabinets design documentation;
• Assembling and installation of cabinets for automation system, electricity input and distribution;
• Installation of cabling and wiring of power and data circuits;
• Development and adjustment of plant control software based on TIA Portal (STEP7 and SCADA system Win CC);
• Adjustment works, staff training and commissioning of automation system.

Obvious advantages of the embedded control system:

• full technological process operational display;
• optimization of the plant control process;
• display and record of the amount of raw materials and finished products;
• technological equipment operation control;
• alarm in case of stopping or locking of technological equipment by the product ;
• emergency causes finding simplification;
• flexibility and the ability of separate units, equipment and machinery to work in manual mode in case of emergency, to ensure smooth operation of the plant.

During the construction of an oil extraction plant our company has carried out:

• Development of power supply project documentation;
• Development of design documentation on electric power equipment and process automation;
• Manufacturing of electrical equipment, according to sections of the project (Siemens , Eaton, Schneider Electric, ABB and other components);
• Power supply equipment installation;
• Installation of electrical equipment of oil-press unit, Elevator, boiler and process facilities automation systems;
• Development and adjustment of software control of the plant based on TIA Portal STEP7 and SCADA system Win CC);
• Integration into the overall technological equipment automation system of the following manufacturers:
  • ExtruTech, Bliss (USA) –soybean processing line;
  • Harburg-Freudenberger Maschinenbau GmbH (Germany) – press and air conditioning;
  • Büköhler AG (Germany) – separators;
  • Monsun, Komsomolec – transport equipment, dryers;
  • Alfa Laval (Sweden) – oil filtration line ;
  • Desmet Ballestra (Sweden) – soybean preparation line Communication setup between the plant control system and existing document management system;
• Staff training and further support of the object.