Thinking of conception

to create automated control system of waste recycling plant, located at: Omsk




1 Automation System process

1.1 Structural diagram

1.2 Organizational diagram

1.3 Description of the composition of objects process automation

1.4 Subsystems automation

1.5 Process conrol room

1.5.1 Description of WinCC

1.5.2 Description of Servers

1.5.3 Display Media

1.5.4 SIEMENS Automation


3 Stages of work on introduction of APCS

4 Conclusion





In this Conception presents a set of solutions for the implementation of automation systems, structured cabling systems, remote monitoring systems and generate reports on the waste processing plant, located at: Omsk (hereinafter – the object).

The objectives of the Conception are:

– Simple and accessible language to convey to the end user the basic aspects of the construction of the process control system, network system gaskets;

– A summary of technical solutions to supplement an existing on-site automation systems with new measured parameters;

– Coordination with the service operation of the facility ways and means of implementing this modernization to avoid conflicts on the level of existing subsystems of the facility;

– The formation of ideas about the functions of the integrator of automated monitoring and reporting system with the transfer to the Customer the agreed list of changes.

– Ensuring the necessary and sufficient level of organizational staff, as well as minimizing the cost of maintenance of the entire system.

The objectives of this concept include:

– Description of the implemented system integration into existing automation systems at the facility;

– Ensuring a high level of ergonomics of using the facility, including the convenience of centralized management;

– Ensuring a high level of reliability of the individual components (hardware) and systems as a whole in the course of their operation and maintenance;

– The integration of all existing systems into a unified dispatch system;

– Reduction of costs of operation of the facility throughout its life cycle;

– Realization of engineering solutions in the most accessible and understandable form, including sketches.


APCS – automated process control system

SCS – Structured Cabling Systems

TOR – Terms of Reference

SCADA Supervisory Control And Data Acquisition – operator control and data acquisition

WinCC – Windows Control Center – a trademark of the SCADA-system

PLC – Software PLC

W – Workstation

ABH – Administrative Block Housing

1 Automation System process
This section of
Conception contains a description of the automation system process, the main function of which is to prevent the process working freelance events, as well as the formation of archives and analysis of the current settings.

1.1 Block diagram

Presented in Annex 1 to this Conception reflects the basic Structural diagram of a decision on the functional structure of the PCS facility in compliance with the hierarchy of the system and the relationships between the control and management functions, operational personnel and technological units.

The Structural diagram is a three-tier system of management object branched technological links between installations and sells network topology “Star”, the disclosure of which is presented in Section 2.1 of this Conceptoin.

Upper management level – level servers and SCADA-system.

Middle management level – the level of network devices and means of industrial automation, such as controller hub (switch), the visualization panel, placed on the cabinet doors automation.

The lower level of management – level field devices (sensors, actuators, air conditioning – all actuators).

Distributed-centralized architecture of the object based on the principle of high network reliability, as well as an open protocol based on the Profibus protocol. With this distribution is achieved a compromise between the reliability of the system components and the amount of features that are embedded in them.

Integration of all the premises of the object in a system based on Profibus protocol will output an indication of the system state on a display panel, and the effective management of the automation object. In this architecture, system automation object is scalable (expandable) for both signal structure, and composition of protocols and subsystems.

The main component of the automation system the process is SCADA-package WinCC. This three industrial computer with pre-installed Windows operating system. The operating system version must comply with the requirements of the software used (to be specified in the design).

Controller for shops and offices are asked to select a PLC SIEMENS S7-400 and Quadlog. Controllers of this type are placed on different parts of the object for the collection, management and transmission of information to different objects of automation. signals collection will be provided With the data controller with all necessary subsystems that control three-way valve heat exchange circuits, conveyors and control furnace heating areas.

1.2 Organizational diagram

The organizational diagram presented in Annex 2 to this Conception, shows the list of documents necessary to create a system of process automation and integration into it of all existing systems. Documents included in the organizational scheme, designed to reduce the influence of the human factor in the production of complex multi-tier systems.

These documents include:

Interface PLC Workstation

Interface PLC Workstation interface is the basic document for the design of data interchange (allocation of address space) between the members in the system PCS object controllers and SCADA-system servers.

Interface PLC Workstation describes the distribution of the variables at the addresses of memory devices. From this document, you can select part of the designed control and display functions. This document is the basis for the creation of the variables in the SCADA-systems.

Explanatory notes: for example, a value, a type of “Fan”, the personal name of this instance ‘the PV1 “. In the object there are three variables – word commands, status word, the word of violations. Each word is 16 bits. Status bits – the state of the properties of each object parameter. It is created not to get confused and at the same time agree with the customer the list displayed on the technological parameters of the process automation system.

HMI design

HMI design frame is a set of mimics, with the help of which will subsequently be carried out subject to the management.

HMI design frames created for fixation of decisions made when creating a SCADA-system and allows the early stages of working to solve a large number of issues related to the selection of the navigation model, composition elements on the video frames visualization panels and screens of the operator station.

Input-output table

Input-output table (symbol table) is a list of input and output signals, which include, for example, the measurement range, the threshold boundaries, types of devices, types of protection, and so forth. Without this document, not possible to assess the system volume, composition, facilities management, to the creation of the design documentation.

Description of algorithms

Description of algorithms – a graphical representation of control algorithms for object with reference to the input-output table. This document is required for the proper implementation of the code as much as possible controllers in accordance with the requirements of the customer. This document is the link between the customer and the programmer implementing application software.

Control algorithms should cover most of the object technology to the PLC programmer and / or automation systems programmer process had a clear understanding of the terms of reference.

In the description of the state of the control algorithms for all the objects must be taken into account, as well as any possible violations of the technological equipment.

Description of reporting forms

This program is a collection of related tables and / or graphic form. These tables receive data from the input–output servers and from the controller, designed for the collection of this information.

Tables provides fields in which the input expected values of process parameters manually.

The reporting program is implemented level of access to the report server, and also formed the requirements for organizational support (report destination).

The system of classification and coding
On examination, the object was revealed that the screen forms an existing automated control system is not clearly expressed in the classification of the automation objects (sensors, pumps, filters, etc.).
In this regard, the main purpose of this document is to define the rules for forming names of process parameters. Parameter name should clearly convey any representative of operation of the facility information about the physical and functional unit assignment.

1.3 Description of the composition of objects process automation

J – Jet №1;

J – Jet №2;

J – Jet №3;

DS1 – Dispenser №1;

DS2 – Dispenser №2;

DS3 – Dispenser №3;

AGR – Aglamerator;

BP – Briquetting press;

SC – Sorting conveyor;

MD – Magnetic drum;

CCM – a container for the collection of metal;

CU – control unit;

R – roar;

FWG – food waste grinder;

MCP – mineral crusher parts;

FC – feed conveyor.

Driving waste sorting complex: 1 – garbage truck unloading area and the reception of solid waste; 2 – feed conveyor; 3 – drum screen; 4 – a container for receiving the undersize fraction; 5 – Sorting cabin; 6 – bins for recyclable materials; 7 – sorting conveyor; 8 – a feeding conveyor; 9 – Magnetic metal separator; 10 – hydraulic press.

1.4 Subsystems automation

APCS of the object – a centralized system of control mechanical and electrical life support systems, accounting systems and monitoring.

This system includes the following functional application subsystem:

– Automated control systems of sorting of waste;

APCS kilns;

– APCS-gas cleaning system;

– Automation of power systems;

APCS water supply and sewerage, sewage treatment facilities;

– Automation of fire extinguishing systems;

– Automation of security systems (video surveillance, public address system)/

Optimization of system performance parameters are set by the operator on the basis of statistical data (reports).

All components of the ACS object is used as a communication channel fiber-optic network of the complex, which will be described in the “external network connections.”

The time delay between the event “readings” and “visualization”, as well as between pressing the control and the influence on the actuator must not be more than 2 seconds.

1.5 Process control room
All control functions are carried out subject to the central workstation, allowing you to have control over all engineering systems of the facility.
The ability of the operator to exercise control over the object of limited access rights. Access rights are defined by the regulations of the object, which is approved by the customer.
1.5.1 Description of WinCC
WinCC is a software to create a human-machine interface, which is an integral part of the family of the Simatic automation system, manufactured by Siemens AG. It is running the operating systems Microsoft Windows.
Main features of WinCC are:
– Visualization of the process;
– Configuration and setting the communication with controllers from various manufacturers;
– Mapping, logging and archiving of messages from the process;
– Displaying, archiving and logging of variables;
– Designing a reporting system;
– Easy integration of WinCC into the internal information network;
– A simple construction of systems “client-server”;
– Construction of redundant systems;
– Open OPC-interface.

1.5.2 Description of Servers

The automation system of the technological process is based on server-based industrial design (see. Fig. 1).


Figure 1. Industrial server iROBO

At the facility offered to install five identical interchangeable servers with pre-installed software. Such an arrangement allows the system in emergencies quickly recover the system by combining two servers into one. Also it is convenient when ordering components for those servers as they are unified within the system.

Each server has its own functionality.

The first server – IO server WinCC.

The second server – dubbed IO server WinCC.

The first two servers receive signals from automation objects and on the operator output information screens.

The third server is an archive (Historian) and provides up to three years of continuous accumulation of all possible historical data.

The fourth server – video surveillance and video archive.

Fifth – a reserve.

These servers are inserted into racks with transparent door (see. Fig. 2).


Figure 2. Rack for production servers

1.5.3 Display Media

These funds will be drawn from the two 19-inch monitors (see. Fig. 3).


Figure 3. Monitor 19 ”

Means of visual control are assumed to placement on the operating point, which will be located in the 1st ABA.

Each screen is interchangeable and allows you to distribute objects so that the operator was convenient to carry out the monitoring. For example:

1st monitor: overall view;

2nd monitor: the approach to the place where the violation occurred.

To ensure the object of life is only three operators working in three shifts.

The task will be to alert the operator of operating personnel (electrical, automation specialist, engineer, chief engineer) of the contingency situation at the site, if necessary, intervention in the situation – security.

For the convenience of the control circuit hardware maintenance facility will be created “prompter” in a pop-up dialog box on the screen with buttons confirm the acceptance of the message.

All warnings and alarms issued by the operator, will be a sign of the priority from 1 to 999. Each message priority is divided by the degree of importance of a past event. This breakdown of events by priority allows the operator to more efficiently influence the process from the point of the importance of the event, as well as reduce the human impact on the management of the facility.

1.5.4 SIEMENS Automation

As a basic means of automation offered by SIEMENS controllers. The equipment of the firm selected by the Customer of the tender.


This section of Conception contains descriptions of all the main features of the construction of the object topology networks.

The presence of a dedicated SCS system allows you to send a video stream to a video surveillance system with no loss of proper quality, which ensures a guaranteed response automation equipment one second after pressing the button on the operator workstation and to reverse acting on the actuator object.

IO Server WinCC (AWP operator) shall forward packets to the appropriate addresses in the network. If there is no connection with the object of automation operator workstation generates a diagnostic message, giving an idea of ​​the nature of the fault.

Diagnosis of connections between network components will be provided by the system «S-7 communication». It’s a programmatic way of interaction between network components, when one element of it passes the value to a variable component related to the network, which increases the value by one, and returns to the sender telegram.

Thus, the whole network becomes self-monitoring of any part of it, even in the complete failure of the central carrier of the village.

3 Stages of work on introduction of APCS

1. Object survey

1.1. Communication with the object;

1.2. Generic introduction to the subject;

1.3. Introduction to the process;

1.4. Preparation of initial information about the object on an electronic medium.

2. Establishment and approval of the Concept

2.1. Creation of the main theses of the Concept;

2.2. Creating an object block diagram;

2.3. Creating an organizational chart.

3. TK Description

3.1. Creating a list of measurable parameters that the integrator and the customer have agreed to introduce a system for monitoring and reporting;

3.2. Description of the composition and volume of project documentation for the creation of APCS;

3.3. The description of the conditions and requirements for the installation of devices and automation.

4. Design APCS.

4.1. Create and agree on a set of documents (for organization chart object), which allows to carry out installation of automation and operation of the facility to provide the service required of executive documentation;

4.2. Matching installation features during the installation of necessary equipment.

Supply of cabinets and installation of equipment.
Commissioning works.

4 Conclusion

Proposed in this concept the main technical solutions allow for the implementation of the automation system of the technological process, structured cabling systems, remote monitoring systems and generate reports at the enterprise, allows to identify a number of problems that have expressed laborious.

This concept is intended to flesh out a number of engineering solutions, previous design, and is made in the manner understandable to the customer’s representative.


Structural diagram

* Denote the diagram are arbitrary, without reference to the actual premises


Organizational diagram

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