Modernization of Ilyichevsk Grain Terminal CJSC

ODESSA REGION

Company:

CJSC "Ilyichevsk Grain Terminal"

Location:

Ukraine, Ilyichevsk, Odessa region

Characteristics of the object

Modernization of grain dryer DSP-50x2. Modernization of SDAU.

Upgrading the remote control system

Project implementation period:

September 2009

Name of the project:

Modernization of the remote control system.

Primary goal:

Creation of a management system.
Management of technological and transport equipment.
Implementation of remote control over technological and transport equipment.
Control of upper levels in waste bins.
Signaling of boundary and emergency parameters.
Communication of the grain cleaning control system with the main system of the grain handling complex.

Scope of work:

Development of design documentation for an automatic control system.
Complete set of controls.
Manufacturing of control panels.
Development of algorithmic support.
Software development.
Installation of electric power control system.
Commissioning works.

Technical means:

Programmable logic controller Simatic S7-1200 with USO.
Control system cabinets.

All electrical switching equipment, as well as microprocessor control units, are housed in cabinets made of 1.5 mm thick steel coated with a polymer powder coating with preliminary phosphating. The boards are certified according to the international standard ISO 9001:2000 PRA 000 3966 dated December 1, 2005. The degree of protection of the cabinets is IP55.

The power distribution circuits are made on the basis of Moeller equipment, the main advantage of which is a high degree of time between failures, fire resistance (class V2 in accordance with UL94 according to IEC 695-2-2), vibration resistance, and dust resistance.

In control cabinets and push-button stations installed at the equipment site, controls (buttons, switches) in the IP65 version are used. On the front panels of the starting and protective equipment cabinets there are M-O-A operating mode switches.

In connection with the modernization of the technological process, there was a need to expand the existing automated remote control system implemented in 2003 on the basis of the INO-64 controller of the Innovinnprom IPP.

To accomplish this task, a design for an automated remote control system for the grain cleaning section was completed. The automatic control system is implemented on the basis of programmable controllers from Siemens Simatic S7-1200 consisting of:

CPU: CPU 1214C AC/DC/Relay.
Digital signal input modules: SM 1221 – 48 inputs.
Digital signal output modules: SM 1222 – 48 inputs.
Digital input/output modules: SM 1223 – 16 in/16 out.
Communication module RS-485.

The automated control system ensures that the equipment starts in the reverse order of the product and stops according to the order in which the product passes. The system also controls the aspiration network, which is turned on when the process or transport equipment is started, and turns off after it is turned off, gate valves and tilt valves, as well as process equipment. Integration into the existing remote automated control system was carried out using communication modules via the Modbus protocol.

Result:

In the shortest possible time, with minimal capital investments, the technological process was reconstructed with integration into the existing remote automated control system without stopping production.

Modernization of grain dryer DSP-50x2

Project implementation period:

June 2010

Name of the project:

Integrated automation of grain dryer chipboard 50x2.

Primary goal:

Management of grain transportation routes.
Control of grain drying process modes.
Collection, control, storage of information about the progress of grain drying and its parameters.
Optimization of the grain drying process; minimizing energy costs.
Implementation of remote control over the technological process.

Scope of work:

First stage:

Development of design documentation for an automatic control system.
Complete set of controls.
Manufacturing of control panels.
Installation of automation equipment.
Equipment restoration.
Development of algorithmic support.
Software development.
Commissioning works.

Second phase:

Introduction of algorithms for optimizing grain drying processes developed by researchers from the Department of Automation of the Odessa National Academy of Food Technologies.

Technical means:

The main control panel consists of several sections:

Power supply cabinet.
Starting and protective equipment cabinet.
Control system cabinet.

This project uses starting and protective equipment from the world's leading manufacturers "Schneider electric", "Terasaki", "Lovato".

The front panel of the starting and protective equipment cabinet contains equipment controls: operating mode switches "MANUAL/O/AUT.", control buttons in manual mode. An LCD panel is installed on the front panel of the control system cabinet, which is a means of interface with the operator.

The automatic control system is implemented on the basis of a programmable controller ICP DAS series I8000 consisting of:

CPU: i8811cr+i87K8.
220V AC digital signal input module: i8058cr + i87058 (32 inputs.
24V DC digital signal input module: i8053cr + i87053 (32 inputs).
220V AC discrete signal output module: i8064cr+i87064 (48 outputs).
Analog signal input module 0-10V DC: i8017hcr+i87017hcw (16 inputs).

A PC with SCADA installed on it, a proprietary system, is used as a station. The main screen contains elements of interactive controls for visualizing the technological process:

Selection of grain drying modes.
Selection of wet and dry grain storage facilities.
Inputting settings for temperature regulators of drying agents, grain in drying zones.
Plotting process temperature graphs.
Archiving these parameters.
Creation of reports on emergency situations.

Result:

Thanks to the implementation of this project, optimal modes of bringing grain to the required storage parameters, fire-safe drying of grain with minimized energy costs and minimal human intervention were provided.