Heating Center #1 Automated Control System

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

Automation objects:
· Heating Center #1: network pumps, charging pumps, condensate reservoirs, heat exchangers for heating of industrial heat extraction water, condensate fridges, deaerator;
· condensate station: rotary pumps, accumulator tanks, shutdown valves.

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

Functionality:
a) equipment and hardware status monitoring, including:
· alarming on the remote controlled gate valve position;
· alarming on the shut-off valve position;
· alarming on the pumps, fans drive motors;
· alarming on failures of the input ventilation systems;
· alarming on voltage at the input of automated power backup switchboard;
· alarming on status of automated power backup switches;
· alarming on batch ventilation system switch-off in case of fire from the buttons located at the emergency exits;
· alarming on the condensate station pumps status.
b) modification of process variables, such as:
· water, condensate and steam temperature;
· tempretature in tanks;
· ambient air temperature;
· water, condensate and steam pressure;
· water, condensate and steam consumption;
· steam consumption at the deaerator;
· level at tanks;
· level at the column;
· level at the deaerator.
c) audible and visual alarming, including:
· increase/decrease of the condensate level at tanks;
· increase of condensate level at tanks;
· increase/decrease of the deaerator level;
· decrease of the feedwater pressure in the pipeline at the pumps output;
· increase/decrease of the tanks level;
· increase/decrease of the column level.
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 jammaing;
· gate valve failure at mazut accounting stations;
· open & short-circuit of system buses, communication links from AI modules to sensors.
e) accounting of pumps and fan drives operating times.

Safety System Functionality:
· issuing automated shut-off valve opening sygnal at the upper limit value of the aerator level;
· issuing automated pump shutdown sygnal at the lower limit value of the aerator level;
· issuing automated pump shutdown sygnal at the lower limit value of feedwater pressure in pipeline at pumps output.

Control functionality:
· automated control of direct heat extraction water temperature;
· automated control of reverse heat extraction water pressure;
· automated control of steam pressure at the deaerator input;
· automated control of feedwater pressure inpipeline at pumps output;
· automated control of the tanks level;
· automated control of the column level;
· automated control of the deaerator level;
· issuing of automated decelaration signal to 20% speed of the pumps at the upper limit value of the deaerator level;
· issuing of automated decelaration signal to 20% speed of the pumps at the lower limit value of any tanks level;
· issuing of remote pump shutdown signals by the operator command;
· issuing of remote valve gate control signals by the operator command.

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

     Control & Information System Architecture