Used controller: S7-315 (Siemens).
Used visualization program: PcVue.
1. Goal of the Project
Task of the Project - perform automation of grain terminal for company "Danstore" at Liepaja port.
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Fig. 1 - Grain bunker
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Fig. 2 - Equipment on Port.
Goal of the Project - develop a management system ensuring that devices of the terminal are controlled by one operator.
2. Stages of the Project
The execution of the project can be divided into following stages:
- Formation of the technological diagram of the devices (cooperation with company "Monsum");
- Development of list of devices to be managed (cooperation with company "AE Partner");
- Management principles forming the basis for recipes;
- Preparation of work plan;
- Structural diagram of the automation;
- Electrical project (schemes of control panel and assembly);
- Ordering and procuring component parts (management system, sensors, etc..);
- Algorithm of the management system work;
- PLC programming (programmable controller S7-315);
- SCADA programming (visualization using PcVue);
- Assembly of control board;
- Testing of the management system before delivery to the Contracting authority;
- Delivery of the control board to the object;
- External installation of electrical devices at the object;
- Testing of the management system at the object;
- Staff training and submission of project documentation to the Contracting authority;
- Putting into operation.
3. Production technology
Production consists of the following parts:
- Group of devices for loading of products into machines;
- Group of devices for loading of products from a train wagon (including 2 scales);
- Group of devices for loading of products from a warehouse;
- Group of devices for loading of products from a container;
- Group of devices for loading of products from a ship;
- Group of devices for unloading of products into warehouse;
- Group of devices for unloading of products from a container;
- Group of devices for unloading of products into wagons;
- Group of devices for unloading of products into ships (including flow-scale);
- Group of devices for aspiration;
- Group of devices for ventilation of containers.
Equipment productivity is 400 t/h.
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Fig. 3 - Production technological scheme
4. Management system
Management system consists of:
A. Computer with installed software package PcVue.
B. Programmable controller Siemens S7-315
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Fig. 4 - Production control system structural scheme
Group management of the devices, including management of frequency transformer and eventual lowering device, is done through PLC "Profibus" network. To format information on the weight Siemens communication module as part of ET200s station is used. The production process is divided into three route groups and all of them can be controlled by one operator.
5. PLC software
Control software is developed on the basis of the Siemens Step7 software package
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Fig. 5 - Illustration of device control algorithm in PLC software.
6. SCADA software
Visualization of the production process and management system is developed on the basis of the "PcVue" software .
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Fig. 6 - Operator station screen photo - visualization of work at the site.
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Fig. 7 - Operator station screen photo - actual route 1(ship-to-tank, the active route highlighted in green).
7. Project feature
This project is a modernization of an existing management system installed by a Danish company. It involves complete replacement of management interface and software. Product movement route reports are included in the management system. It allows editing and adding new routes, without changing the body of the software.
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Fig. 8 - Fragment of route table
The system includes a set of parameters for management of separate devices. Therefore it is possible to change operation intervals of the devices. Existence of information archive ensures efficient editing of route recipes and forming reports on performed tasks. Operator interface of the system is multilingual.
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