Engineers of the Tyumen based company Control System Technology (CST) are successfully promoting power engineering efficiency with integrated SCADA/HMI and SOFTLOGIC system TRACE MODE. The team has completed a monitoring system for boiler No.8 and a control system for boiler No.3 at Tobolsk heat & power plant, and  is currently delivering innovations to Surgut district power plant #1.
CST company has been using SCADA/HMI and SOFTLOGIC software TRACE MODE since 2003. Their first project - the highly reliable thermal control system for TGMP-428 (К-8) boiler and TG-135/165-15 (TG-4) turbogenerator, was implemented at Tobolsk heat & power plant, a subsidiary of Tyumenenergo region power supply company (RAO UES of Russia).
The boiler control has the following features:
- reading the boiler process parameters from primary sensors and secondary instruments;
- control of threshold deviations with alarming;
- history data logging;
- HMI displaying of the boiler technology parameters;
- browsing history logs for unlimited depth.
The boiler control system hardware is based on 2 "Octagon 6030" controllers with Micro TRACE MODE runtime software inside. The system is acquiring signals from 16 discrete and over 200 analog sensors of various types. Controllers communicate with the redundant real-time TRACE MODE (Double Force RTM) monitor with 512 input/output points performing as a robust hot-standby server, as well as the main operator's workstation. The additional workplace is based on the NetLink Light console. The TRACE MODE Documentation Server maintains manufacturing reports based on the boiler history data accumulated by the SCADA. Development of the whole system was achieved in 4 months.
The successful TRACE MODE implementation at the boiler assured the power plant management about its reliability and efficiency. In 2004, the CST company completed an even bigger project - the control system of TGMP-428 (K-3) boiler at Tobolsk power plant including:
- 5 PC-based Octagon 2050 controllers with Micro TRACE MODE software inside connected to I/O cards I-7000;
- 28 Elemer 5920 measuring loops communicating via RS-485;
- 2 robust SCADA/HMI servers controlled by TRACE MODE runtime modules featuring automatic hot standby Double Force RTM with 512 input/output points;
- 2 TRACE MODE RTM-based engineer workstations (RTM) and NetLink Light GUI console;
- 1 integrated control panel with pre-installed NetLink Light GUI console.
The TRACE MODE SCADA/HMI servers and Soflogic software featuring hot-standby functions are installed on industry-class ROBO series computers by ICOS that complies the boiler No.3 control system with all requirements for controls of the hazardous processes.
All the control system nodes are connected via 100 Mbps Ethernet. (fig.). Just as with the first project, the TRACE MODE Documentation Server plays a major role in generating reports. The best practices from that very first project, the monitoring system for the boiler No.8, helped to implement this new system much faster. Although the job was obviously much harder, the team made it within 5 months.
By implementing the TRACE MODE based highly reliable control and monitoring systems, the Tobolsk heat & power plant ensured:
- better fault-tolerance;
- promoted environment safety;
- higher operation reliability and longer service life of the equipment;
- lower maintenance costs.
 The industry competence gained by CST staff helped the team deliver new TRACE MODE-based control projects more easily, making good use of all its competitive advantages.
They are currently busy with deploying another robust control system. This time, it will be Surgut district state power plant 1, one of the largest European power producers, who benefits largely from TRACE MODE SCADA/HMI and Softlogic-based technology. Similar to Tobolsk heat & power station Surgut power plant is also owned by Tyumenenergo.
The SCADA/HMI TRACE MODE-based water chemistry control system is to be deployed at sixteen power units with 210 MW capacity each. Each power unit has a pre-installed Octagon 6030 controller, I-7000 modules for collecting data from the chemical control instrumentation and variable speed drives of the pumps that proportion chemical reagents and are also driven by the controller.
The redundant Ethernet connects the controllers at the power plant units with the robust redundant TRACE MODE SCADA/HMI server. The server is connected with NetLink Light- based GUI consoles developed for an operator of the water chemistry control and Deputy Supervisor at the chemical shop. The TRACE MODE server translated data to the main SQL Server. |
