Automated control system for reverse water supply plant No.3

Customer: Kirishi Oil Refinery
General designer & control system designer: SPIK SZMA, Saint-Petersburg

Automation objects: Reverse water supply plant #3 implemented as oil eliminator units, cooling towers, cold and hot water tanks, feedwater and reverse water treatment plant located in the inhibitory building and pumping station room.

Control system specification: DCS based on the Toshiba TOSDIC system, including PLC, V2000 series. The control system includes sensors and indicators from EMERSON PROCESS MANAGEMENT, VALCOM, VEGA and control valves from DVCD Masoneilan Russia.

Functionality:
a) monitoring of the process equipment and hardware status:
alarming on remote controlled electrical gates position;
alarming on the bactericidal plant status;
alarming on status of pumps, input/exhaust ventillation systems and self-cleaning filters;
alarming on fan motor status at cooling towers;
b) process variables monitoring:
measuring of hot reverse water temperature supplied to the cooling towers and hot water tanks of oil liquid and gas products cooling systems;
measuring of cooled water temperature supplied to cooled water plants and tanks I and II, direct and reverse heat extraction water;
measuring of cooled water temperature in cooler bowls;
measuring of air temperature in the pumping station, feedwater and reverse water treatment plant, control room, rack room, control system engineer room, of the ambient air temperature;
measuring of cooled reverse water pressure at pumps output and water headers supplied to the plants;
measuring of hot reverse water pressure at pumps output, in pipelines to the colling towers;
measuring of feedwater pressure for liquid and gas oil products cooling systems;
measuring of feedwater consumption after the ultraviolet irradiation, hot reverse water to coolers bowls, cooled reverse water to the plants, reverse water of liquid and gas oil products cooling systems at the treatment filter input, water for hydro washing away at the pump #15 input, direct and reverse heat extraction water;
measuring of level in cooling bowls and in cold and hot water chambers;
displaying of the motor current values for pumps, fans of cooling towers;
displaying of winding temperature, bearing temperature, fan motor vibration at the cooling towers;
c) audible and visual alarming, including:
increase/decrease of water level in cooler bowls, cold and hot water chambers and drainage pit;
increase of temperature in cooler bowls;
increase of hot reverse water temperature at coolers, hot water header at cooler at the oil eliminator output;
increase of cooled reverse water temperature supplied to the plants;
decrease of the hot reverse water pressure at the pumps output and in pipeline to the coolers;
decrease of the cooled reverse water pressure at the pumps output and in water headers supplied to the plants;
increase of the oil product vapour content in the air near the working area of oil eliminators and in the rack room of the pumping station;
increase of cooler fans motor vibration;
increase of bearings temperature and cooler fans motor windings temperature;
d) warning alarming on failures detected by process & equipment status diagnostic tools and system elements selfdiagnostic facilities, including:
power supply failures;
PLC failures;
no voltage at the UPS input;
low UPS voltage;
remote controlled gates jamming;
open & short-circuit of system buses, communication links from AI modules to sensors.
e) accounting of pumps and fan drives operating times.
f) data exchange via VLAN of the shop #13:
data exchange between PLC and OIS of the control room of the BOV-3 plant and redundant server in shop #13 dispatch room;
data exchange between PLC and OIS of the control room of the BOV-3 plant, servers of the shop #13 dispatch room and control system engineer station.

Control functionality:
autoamted control of the level in hot and cooled water reception chambers of the liquid and gas oil products cooling systems;
automated switch-on of the "low speed" of cooler fans motors at the warning upper temperature value and switch-on of the "high speed" at the pre-emergency maximum temperature value;
automated switch-off of the "low speed" of cooler fans motors at the pre-emergency minimum temperature value and switch-off of the "high speed" at the pre-emergency maximum temperature value and switch-off of the "high speed" at the warning minimum temperature value;
automated switch-off of the cooler fan motors in case of:
- pre-emergency maximum temperature values for cooler fans motor bearings;
- pre-emergency maximum temperature values for cooler fans motor stator windings;
- pre-emergency maximum values for cooler fans motor vibration;
automated remote control of pumps;
automated remote control of cooler fans motors;
automated remote control of gates.

Project design phases: one phase including design of technical documentation, dataware, and algorithms description.

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