Used controller: Siemens Simatic S7-317 2PN/DP.
Used visualization program: based on General Electric Cimplicity.
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The factory produces arboreal granules, which are used as fuel. Such fuel in form of granules is an environmentally pure product, as is made of such raw materials as wooden sawdust and chips.
Technological equipment of the factory is comprised of 3 groups of machinery:
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- the set of technological equipment from "Sprout Matador" company (presses and granules production line);
- the set of technological equipment for raw materials drying from "Maguin Promill" company;
- the set of equipment for storage and transportation.
- An automated system is provided for the purpose of control and supervision of the technological equipment.
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The factory's personnel have 2 computerized control workstations at their possession, which operate as mutually replaceable units. They make it possible to supervise and control the technological processes of granulation, as well as raw materials drying and preparing, and finished product discharge, too.
The entire production process, starting from preparation of raw materials and ending with granules discharge to storage area, can be supervised by 2 operators.
The automated control system includes:
- programmable controller PLC1 (it controls the granulation and transportation processes);
- programmable controller PLC2 (it controls the material drying process);
- peripheral equipment: ET200.1…ET200.4, DP/AS, inverter "Danfoss";
- operators' computer workstations PC1, PC2.
For the purpose of remote monitoring and editing operation regimes and programs, the relevant opportunities of the Internet are used via Router device.
The technological process of granulation is controlled and supervised by an operator in automated control mode from one of the workstations (any).
The example of visualisation screen:
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An operator has at his possession:
- visualisation of equipment groups control: Press , Hammermill, charging lines, discharging lines;
- menu for setting technological modes of granulation;
- Press, Hammermill parameters-depicting diagrams screens;
- choice of menu for controlling individual devices and groups (Start/Stop).
The granulation line can be operated in fully automated mode, as well as in the mode of setting and controlling parameters of groups of devices by an operator.
Also, the system makes it possible to control each individual device in manual mode.
The granulation process is controlled by the following devices:
- controller PLC1(which contains the program for controlling the technological line of granulation);
- peripheral equipment ET2001, ET200.2, DP/AS, inverter "Danfoss" (placed in MCC1 cabinets).
Communication between the central controller and peripheral devices is arranged via the Profibus1 network.
Polling of sensors and control of some devices is arranged via the AS interface network.
Communication between controllers PLC1 and PLC2, as well as with computers PC1 and PC2 is arranged via the Ethernet network.
Thank to such networks' architecture, high rate of data transmission to/from control devices, as well as independent implementation of technological processes are guaranteed.
Technological process of material drying is controlled and supervised by an operator in automated mode from one of the workstations (any).
It is possible to use a single workstation for the both technological processes.
The example of visualisation screen:
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An operator has at his possession:
- visualisation of drying control devices;
- menu of setting technological regimes of a drier and a furnace;
- Furnace, Drying parameters-depicting diagrams screens;
- choice of menu for controlling individual devices and groups (Start/Stop).
For the purpose of setting technological regimes of drying, an operator has a wide choice of additional parameters and adjustments, including the parameters of automated regulators of rarefaction in the furnace, temperature of gases, the furnace and drier charging regimes.
The drier's control system is provided with several safety loops serving for emergency stoppages of the furnace in case of deviation of operational regimes from the set ones, and it corresponds to the algorithm of control supplied by the manufacturer of equipment "Sprout Matador".
The drying process is controlled by the following devices:
- controller PLC2 (containing the program of controlling the technological line of drying);
- peripheral equipment ET2003, ET200.4, inverter "Danfoss" (placed in MCC2 cabinets).
Communication between the central controller and peripheral devices is arranged via the Profibus2 network.
Communication between controllers PLC2 and PLC1, as well as with computers PC1 and PC2 is arranged via the Ethernet network.
The Ethernet network is connected through unauthorized access prevention device to the Internet.
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