Fashion track. SCADA TRACE MODE
Laboratory work No. 2.
Creating an operator interface and a control model in an instrumental environmentTRACE MODE 6
- purpose of work
Studying the principles of developing an operator interface and modeling an asset management systemSCADA-systems TRACE MODE 6.
- Tasks
Creating a project for a dynamic object management system using an integrated development systemTRACE MODE 6, simulation of the control system using a real-time debug monitor.
- Theoretical part
Project development in an integrated TRACE MODE 6 (IP) environment includes the following procedures:
- creating a project structure in the navigator;
- configuration or development of structural components - for example, development of templates for graphic screens of the operator, development of program templates, description of sources / receivers, etc .;
- configuration of information flows;
- selection of ACS hardware (computers, controllers, etc.);
- creating nodes in a layerSystem and their configuration;
- distribution of channels created in various layers of the structure among nodes and configuration of interfaces for the interaction of components in information flows;
- saving the project in a single file for subsequent editing;
- export nodes to file sets for subsequent launch under the control of TRACE MODE monitors.
The listed procedures (with the exception of the two final ones) and the operations included in their composition can be performed in any order. For example, you can start developing a project by developing templates for graphic operator screens, by creating nodes and their channels in a layerSystem (if the ACS hardware is known in advance), you can configure the channels and information flows after the distribution of channels among nodes, etc.
3.1. Classification of objects of the project structure.
3.1.1. Classification of components.
According to the functional purpose, the project components belong to one of the following types:
- channels - components that determine the algorithm of the project. Channels can be created in different layers, however, their final distribution among the nodes in the layerSystem obligatory - otherwise they will not be exported for RTM;
- patterns - components that, when operating in real time, can be called up by channels with the transfer of parameters. The transfer of parameters is configured during the development of the project in the IP by binding the template arguments to channels or sources / receivers;
- sources / receivers - templates of channels of exchange with various devices and applications. Devices here are understood as controllers, as well as external and internal modules / boards for various purposes, the exchange with which is supported by TRACE MODE monitors (including through drivers). TRACE MODE system variables and built-in generators are also created in the IP as sources / receivers;
- resource sets - sets of texts, images and video clips that can be used in the development of graphic screen templates;
- graphic objects - components, which in the general case are several graphic elements (from those available in the data presentation editor), grouped into one. Graphic objects can be used in the development of graphic screen templates;
- serial ports - parameters of COM ports;
- message dictionaries - sets of messages generated when various events occur;
- terminals - these components that describe electrical contacts (for example, enclosures) are elements of the ACS electrical connection diagram.
3.1.2. Classification of layers.
The predefined layers of the project structure have the following purpose:
- Resources - to create custom sets of texts, images and video clips, as well as graphic objects;
- Program templates - to create program templates;
- Screen templates - to create templates for graphic screens, graphic panels and mnemonic diagrams;
- Database Relationship Templates - to create patterns of links to databases;
- Document Templates - to create templates for documents (reports);
- Channel Base - This layer is the repository of all project channels. You can perform operations with channels (including creating them) in different layers, however, in all cases, these operations are actually implemented in the Channel base layer. In any other layer where a command is executed to perform an operation with a channel, its result is only displayed - therefore, there are commands to delete and destroy channels;
- System - to configure nodes and their components (a node is created as the root group of this layer);
- Sources / Receivers - to create built-in generators, templates of exchange channels with various devices and software applications, as well as to configure system variables TRACE MODE 6,
- Technology - for the development of a project from technology (i.e., with a grouping of components based on their belonging to a technological object). In this layer, the channel encoding is built automatically with the inheritance of the encoding of all higher-level objects into which the channel is included. When debugging a project, the Technology layer can play the role of a node - a command is defined for itSave node for RTM. In addition, teams for interaction with the technological database are defined for this layer;
- Topology - for project development from topology (i.e. with a grouping of components by location);
- Instrumentation - to describe the electrical connections of the ACS;
- Component libraries - to create libraries of objects - design solutions to individual tasks. This layer contains the predefined groups System and User.
3.1.3. Classification of nodes.
Project nodes are created as root groups of the System layer. The predefined node name indicates the family of monitors for which this node is intended. A node can contain only those components that are supported by monitors of the corresponding family.
In general, nodes can be run under various monitors.
Typically, a node runs on separate hardware. If two or more nodes are launched on the same hardware, it must be equipped with the appropriate number of network cards.
Node parameters are set in the corresponding node parameter editor.
Varieties of nodes:
- RTM . The RTM node is designed to run on a computer under control of the RTM family of executive modules (MRV) - monitors with support for displaying operator graphic screens, supporting exchange via a serial interface and a network with various equipment and recalculating channels of all classes except T-FACTORY channels.
- T-FACTORY . The T-FACTORY node is designed to run on a computer under the control of the T-FACTORY family of executive modules - monitors for solving automated control systems.
- MicroRTM . The MicroRTM node is designed to run on a computer or in a controller running Micro RTM family of executive modules. The main difference between these monitors from RTMs is the lack of support for displaying graphic screens.
- Logger . The Logger node is designed to run on a computer under the control of the Logger executive module (registrar) - a monitor capable of archiving through the channels of all project nodes.
- EmbeddedRTM . The EmbeddedRTM node is designed to run on a computer or in a controller under the control of the executive modules of the Embedded RTM family - monitors with support for graphic panels, support for exchange with equipment using various protocols and performing channel recounting.
- NanoRTM . The NanoRTM node is designed to run in the controller under the control of the Nano RTM executive module - a monitor similar to Micro RTM, but designed to work with a small number of channels.
- Console . The Console node is designed to run on a computer under the control of executive modules, which, unlike the RTM, do not recalculate channels designed to work with data. Consoles allow you to receive data from other project nodes on the network, display them on graphic screens and manage the process from graphics. Consoles cannot communicate with T-FACTORY nodes.
- TFactory_Console . The TFactory_Console node is designed to run on a computer under the control of executive modules similar to consoles, but also capable of interacting with T-FACTORY nodes.
- EmbeddedConsole . This node runs under monitors that support only graphic panels.
3.2. The principle of the monitor. Channel TRACE MODE 6.
At startup, the monitor reads the parameters of the node specified during the development of the project in the IP, as well as the parameters of other nodes for the correct interaction with them.
The operation algorithm of any TRACE MODE monitor consists in the analysis of channels - structures of variables created both during project development in IP and in real time. Depending on the class and configuration of the channel, according to the results of its analysis, the monitor performs one or another operation - writing the values \u200b\u200bof the channel variables to the archive, requesting the value of the data source via the specified interface and writing this value to the channel, calling the operator’s graphic screen on the display, etc. .
In general, writing a value to a channel means assigning a value to a variable (attribute)Input value this channel.
Two important properties can be configured for a channel -Communication and Challenge.
The first property means the ability of the channel to receive data from sources and transmit data to receivers - in other words, using this property you can configure information flows of ACS.
The second property means the ability of the channel to call (implement) a template with the necessary parameters passed to it (for a channel of the CALL class, the call property has advanced functions). On the basis of the property, the call is implemented, for example, a graphical operator interface, an exchange with a database, etc.
The set of channels of a node is called the channel base of this node.
A channel class defines its general purpose. For example, a channel of the FLOAT class is intended for operations with 4-byte real numbers, a channel of the class Unit of equipment is used for accounting for a unit of equipment, planning and monitoring its maintenance. When developing a project, channels of only predefined classes can be created.
Variables included in the channel are called its attributes. Channel attributes have a different purpose and a different data type. Boolean attributes and attributes that can take only two specific values \u200b\u200bare called flags. An example of a flag is a channel type that takes two values \u200b\u200b- INPUT (numerical channels of the INPUT type are intended to receive data from sources) and OUTPUT (numerical channels of the OUTPUT type are intended to transmit its value to receivers). Attributes that are used to pass values \u200b\u200bwhen the template is called are called channel arguments. Attributes are supplied with numerical indices (attribute indexing starts at 0, argument indexing starts at 1000). Attributes have a full name and a short name (mnemonic designation). Attribute identifiers are its index and, in some cases, a short name.
Channels contain predefined algorithms (some of them can be configured by the user), according to which some channel attributes are set or calculated by the monitor depending on the state or value of other attributes. For example, for most channels in the attributeChange time monitor records attribute change timeReal channel value (according to the clock of the device on which the monitor is running).
The execution of the channel’s internal algorithms and the analysis of its attributes by the monitor is called channel recalculation.
Based on the results of the analysis of attributes, the monitor performs the actions specified by the channel (for example, calling a template), this procedure is called channel refinement. Channel development after its recounting is performed under certain conditions. When recalculating the channel base, recalculation of a specific channel is also performed under certain conditions.
Channels of the same class have an identical set of attributes and predefined algorithms for their processing. There are also attributes that all channels have, regardless of their class (such attributes have the same indices in all channels).
A channel is a structure consisting of a set of variables and procedures that has settings for external data, identifiers and the period for recalculating its variables. Channel identifiers are: name, comment and encoding. For example, the name of the channel associated with the fifth channel of the analog input board located in the first footprint of the controller will be AI_-pe01-0005. In addition, each channel has a numerical identifier used internally to refer to this channel. Among the channel variables, four main values \u200b\u200bare distinguished: input (In), hardware (A), real (R) and output (Q). Using the settings, the input value of the channel is associated with the data source, and the output value is connected with the receiver.
Depending on the direction of information flow, i.e. from external sources (data from controllers, USO or system variables) to a channel or vice versa, channels are divided into:
- input (type INPUT) (Fig. 2.1),
- weekend (type OUTPUT) (Fig. 2.2).
Fig. 2.1. Channel typeINPUT
The input channel (Fig. 1.2) requests data from an external source (controller, another RTM, etc.) or the value of system variables (error counter, archive length, etc.). The resulting value is fed to the input of the channel and then converted into hardware and real values. The hardware value for INPUT-type channels is formed by scaling (logical processing for discrete channels) input values. The procedures used provide primary data processing (correction of sensor errors, scaling, temperature correction of cold junctions of thermocouples, etc.). Output values \u200b\u200bin INPUT type channels are not used.
Fig. 2.2. Channel typeOUTPUT
The output channel (Fig. 2.2) transmits data to the receiver. The receiver can be external (the value of the variable in the controller, in another RTM, etc.) or internal — one of the system variables (number of the sound file being played, number of the screen displayed on the monitor, etc.). Both external and internal data receivers are associated with output channel values. For channels of the OUTPUT type, their input value is formed in one of the following ways:
- procedure for managing this channel;
- procedures for managing or broadcasting other channels;
- techno IL metaprogram;
- remote host channel (for example, over a network);
- operator using control graphic forms.
For channels of the OUTPUT type, the hardware value is obtained from the actual translation procedure. The hardware values \u200b\u200bof the channels have such a name, since it is convenient to receive the values \u200b\u200bof the unified signals with which the input / output equipment works (4-20 mA, 0-10 V, etc.). Real values \u200b\u200bare intended for storing values \u200b\u200bof controlled parameters or control signals in real units (for example, kg / h,about C,%, etc.). The output value is defined only for channels of type OUTPUT. It is recalculated from the hardware value.
Data from external devices is recorded in channels, data from channels are sent to external devices. The operator enters control signals into the channels. Values \u200b\u200bfrom channels are recorded in archives, operator reports, etc. The channels are converted data. By changing the values \u200b\u200bon the system channels, you can control the information displayed on the screen, sound signals, etc., i.e. the whole system.
The input channel value is converted to hardware, real and output using procedures. Channel procedures are:
- scaling (multiplication and offset),
- filtering (peak suppression, aperture and smoothing),
- logical processing (preset, inversion, compatibility control),
- broadcast (calling an external program),
- management (calling an external program).
The sequence and content of the procedures may vary depending on the type of channel (input or output, analog or discrete). The set of procedures in the channel depends on the data format. Channels that work with analog variables use the following procedures:scaling, broadcast, filtering and management . In channels processing discrete parameters, are usedlogical processing, broadcast and management.
Procedure scalingused only in channels working with analog variables. It includes two operations:multiplication and bias . The sequence of these operations varies depending on the type of channel:
- for channels like INPUTthe input value is multiplied by a given factor and the offset value is added to the result. The result is assigned to the channel hardware value;
- oUTPUT type channelsthe offset value is added to the hardware value, then this sum is multiplied by a predetermined factor, and the result is assigned to the channel output value.
Broadcast Procedure defined for all channels regardless of their type and type of presentation. For input channels, the translation procedure convertshardware value to real , but on weekends - vice versa. To do this, the program is called. The called program is selected when setting up the procedure.
When setting up the procedure, the input and output arguments of the selected program are associated with the attributes of the current channel, as well as any other channels from the current database. Therefore, the translation procedure of one channel can also be used to generate the values \u200b\u200bof other channels.
An example of using the translation procedure is the integration of sensor readings.
Filtration - a procedure that is present only on analogue channels. The set of operations it performs is different for input and output channels. For channels of type INPUTfiltering is performed after the translation procedure until a real value is formed. Filtering includes the following operations:
- suppression of random bursts in the measurement path;
- scale control - tracking the output of the real channel value beyond the established scale boundaries.
OUTPUT type channelsthis procedure generates a real value for the input value. The following operations are performed:
- limiting the rate of change of the real value;
- suppression of small fluctuations in the channel value;
- exponential smoothing;
- scale control - trimming the magnitude of the control action to the borders of the channel scale.
Control - A procedure that is defined for all channels. It implements a management function. With its help, you can call a program in which you can program the required control algorithms. As arguments to the program, values \u200b\u200band attributes of any channels from the current database can be transferred. These arguments can be either input or generated. Formally, the control procedure is associated with the channel only by the recalculation cycle. It may not participate at all in the formation of its meanings, but may control other channels. This situation is often observed when using the procedure.Control on channels like INPUT.
A monitor is a multi-threaded process. Thread priorities are set by default, but you can change them. The main thread that runs cyclically is the threadCALC . Each cycle of this stream includes the following sequentially performed steps:
- sequential analysis of all included channels of the node (ascending ID) and setting the SV flag (not available to the user) to channels requiring recounting;
- recalculation of all channels (except CALL channels) of the INPUT type, which should be recalculated in the main stream, and, in some cases, processing of these channels;
- reset flag SV;
- recalculation and development of channels of class CALL of the main stream;
- recalculation of OUTPUT type channels, which should be recalculated in the main stream, and analysis of their output value. Set the Q flag to channels whose output value has changed.
The SV flag not reset in the main stream is a sign of the need to recalculate the channel in the corresponding stream.
The CALC cycle time (the time allotted for a single execution of the main thread tasks) is configured using two parameters that are set in the sectionRecalculation of the Basic tab node editor. ParameterResolution sets timer resolution in seconds (valuetick), the Period parameter - period of conversion in unitstick. The product of these parameters determines the CALC cycle time in seconds.
Timer Resolution (tick ) may vary within the following limits:
- in MS Windows - no less than 0.01c;
- in MS Windows CE - at least 0.001s.
By default, the resolution of the timer is 0.055 s, the period is 10.
3.3 Development of a graphical interface.
TRACE MODE 6 provides a graphical representation of the progress of the process, as well as process control using graphical tools.
The graphical operator interface is implemented in several forms:
- in the form of a set of graphic screens, the templates of which are developed in the data presentation editor (RPD), for nodes that are executed by monitors on hardware that have sufficient performance and other necessary characteristics (for example, when using volumetric graphics from the video system, OpenGL 1.1 support is required);
- in the form of a set of graphic panels, the templates of which are developed in the ERPD (modification of the RPD), for nodes that are executed by monitors on hardware with limited performance (for example, in controllers running Windows CE).
The project structure created in the channel database editor is loaded into the RPD (eRDP). Having selected the required project node, you can edit its graphic base. This database includes all graphic fragments that are displayed on the monitor of this operator station.
RPD and ERPD contain a large number of built-in graphic elements (respectively, GE and USE), allowing you to depict almost any technical process, display all the necessary information about the progress of its implementation, as well as manage the technical process. In addition, TRACE MODE 6 includes a large number of resources - texts, images, video clips, various graphic objects - that can be used in the development of the operator’s graphical interface. Resources can be created by the user.
The set of all screens for data presentation and supervisory control included in the graphic base of the project nodes make up its graphic part. The screens in the graphic databases of the project nodes are divided into groups. Each group has its own name. The grouping of screens is convenient to use based on their functional purpose. For example, in one group you can collect mimic diagrams, in another - screens for adjusting regulators, in the third - overview screens, etc. Only one screen can be displayed on the monitor at a time, each of them is a fixed-size graphic space on which static drawing and display forms are placed. It has its own name and a set of attributes (settings). Such attributes include: Size, Background color, Wallpaper, Access rights, Specification of the window for viewing the alarm report.
Graphic screens are developed by placing graphic elements on them. Distinguish between static and dynamic elements. Static elements are independent of the values \u200b\u200bof the monitored parameters, and no actions are taken to control the information displayed on the screen. These elements are used to develop the static part of graphic screens, for example, for the image of filled tanks, boilers, motors, etc. Therefore, they are called drawing elements.
Dynamic elements are called display forms. These elements are associated with channel attributes to display their values \u200b\u200bon the screen. In addition, part of the display forms is used to control the values \u200b\u200bof channel attributes or information displayed on the screen. Some forms may also combine both functions.
On the screens, you can place complexes of static and dynamic elements, designed as graphic objects used to duplicate ready-made solutions in the field of creating an operator interface.Graphic object called the combination of display forms and drawing elements, which is framed as a single graphic element. Decorated in the form of objects, typical graphic fragments can be inserted into the screens of graphic bases of any projects.
There are two types of graphic objects: “Object” and “Block”. The first of them can refer to 256 channels, and the second - only to one.
To create and edit objects, the same windows are used as when working with screens. Object development is identical to the screen development process. The difference is only in setting the display forms on the channels. In an object, display forms are associated with its internal channels. When placing an object on the screen, these channels are tuned to the real channels of the edited node.
TRACE MODE allows you to perform a number of operations with graphic objects: copying, saving and pasting into other projects or graphic databases of the same project, output to separate windows on other screens, etc.
Graphic libraries are used to store graphic objects. Each library has a name and a list of objects included in it. To use the created library in the future, it must be saved in a file. To access the previously saved library, you must load it into the data view editor.
3.4. Programming Algorithms.
Any ACS requires mathematical data processing - as in measuringinformation flows (sensor \u003d\u003e USO \u003d\u003e controller \u003d\u003e operator station), and in control (operator station \u003d\u003e controller \u003d\u003e executive device).
The following tools are provided for mathematical data processing in TRACE MODE 6:
- internal algorithms of numerical channels;
- programs. Languages \u200b\u200bare built into IP for software developmentTechno ST, Techno SFC, Techno FBD, Techno LD and Techno IL , which are modifications of the languages \u200b\u200bST (Structured Text), SFC (Sequential Function Chart), FBD (Function Block Diagram), LD (Ladder Diagram) and IL (Instruction List) of IEC61131-3 standard. Programs developed in the IS allow the use of functions from external libraries (DLLs).
These tools provide the ability to mathematically process data at any link in the information stream.
Programs and some of their components (SFC functions, steps and transitions, etc.) can be developed in any of the built-in languages \u200b\u200bin the corresponding editor, while the languages \u200b\u200bfor the program and its components are independently selected.
For creating and editing the properties of arguments, variables, functions and structural types of the program, as well as for using functions from external libraries in the program, special table editors are built into the integrated project development environment.
TRACE MODE 6 also has tools for debugging programs.
The main programming language of TRACE MODE 6 is Techno ST. Programs developed in Techno LD, Techno SFC and Techno FBD languages \u200b\u200bare translated into Techno ST before compilation. IL programs are partially translated to ST before compilation, and partially to assembler. It follows, for example, that the Techno ST keywords are also for all other languages.
Using the program is possible only after its successful compilation. To compile the program, do one of the following:
- execute commandCompile from the Program menu (or press the F7 key or press the LC on the iconCompilation (F 7) debugger toolbar) - this command creates only code for debugging the program in the IS. Debugging code is saved in a subdirectory created in the% TRACE MODE 6 IDE% \\ tmp directory. If the compiler detects errors, it displays the corresponding messages in a window, which in this case opens automatically. If compilation was successful, the message box does not open;
- execute project export - this command creates both debugging and executable code in the folder of the node containing the program call channel. If errors are detected in the program, a message is displayed stating that it cannot be exported.
To run the program in real time, a CALL class channel with the call type Program must be created in the node, configured to call the program template.
A similar CALL channel of type INPUT is processed with its conversion period in the corresponding stream.
A similar CALL channel of type OUTPUT is worked out, in particular, when using the control functionRun graphic element.
- Description of used software systems
The TRACE MODE 6 tool system is launched by double-clicking the left button (LC) of the mouse on the Windows desktop icon or from the “START / All Programs /Trace Mode 6 / TRACE MODE IDE 6 ".
The final result of the work of the TRACE MODE 6 tool system is a set of files intended for the performance of ACS tasks in real-time monitors on workstations and in controllers. In laboratory work, a profiler with support for graphic screens will be used as an RTM for AWPrtc.exe located in the directory of the TRACE MODE 6 tool system. The profiler allows you to run one node of a developed project on a computer with the tool system installed.
The IC shell has a main menu including a menuFile, View, Windows and Help , and toolbar.
Editors built into IPs have their own menus and toolbars, which when you open these editors are partially or fully added to those available in IPs. When opening the editor, it is also possible to modify the list of commands on the IP menu.
If several editors are opened, the toolbars and menus of the IP correspond to the editor whose window is currently active.
IP shell menus and toolbars are available in all cases.
The tools of all editors and windows are equipped with tooltips.
To set general settings for IP and template editors, a dialog is opened that opens upon commandIP settings of the File menu.
Saving a project for editing is performed by commandSave (Ctrl - S) or Save As (Ctrl - Shift - S) from the File menu . The project is saved in a binary file with the prj extension for subsequent editing in the IP. When these commands are executed, user component libraries are saved in the tmdevenv.tmul file (in the IP directory). The IS provides backup of the previous version of prj and tmul files - when the command is executed againSave the extension of files saved earlier is changed respectively to ~ prj and ~ tmul.
Saving the project to run is performed by commandSave for RTM File menu or by pressing a similar button on the IP toolbar. All nodes are exported to file sets for their subsequent copying to the hardware on which they must be run under the control of TRACE MODE monitors. Before exporting nodes, the project must be saved in the prj file.
When executing a commandSave for RTM a subdirectory is created in the directory containing the prj file<имя файла prj без расширения>in which a folder with a set of files is created for each node. The node folder has the name specified for the node when it is configured in the IS (with spaces replaced with "_" characters). Files of nodes that have the same name in the IP are exported to one folder.
A prerequisite for exporting a node is the presence of at least one channel in it.
On command Save node for RTM from the Project menu or the navigator’s context menu, the selected node is exported to an arbitrary folder, and when the export is repeated, the node’s backups are not created.
- Security measures
During laboratory work, you must:
- comply with the rules on and off computing technology;
- do not connect cables, connectors, or other equipment to your computeryu teru;
- when the mains voltage is on, do not disconnect, connect or touch cables connecting various devices tom of computer;
- in the event of a malfunction in the operation of the equipment or a violation of safety regulations, inform handsabout laboratory worker;
- do not try to fix equipment malfunctions on your own;
- at the end of work, tidy up the workplace.
ATTENTION! When working at a computer, you need tom thread: life-threatening stress is applied to each workplace. Therefore, during operation, you must be extremely careful and comply with all safety requirementsoh sti!
- The task
6.1. Create an operator interface for a control system containing one AWP node, a control object model, a PID controller, a comparison element for negative feedback, elements for setting the PID controller settings and parameters, as well as elements for displaying values \u200b\u200busing various operator interface and graphical tools elements.
6.2. Introduce a program in the language into the systemFbd to implement a dynamic model of a control system.
6.3. Realize the operation of the control system in real time, remove the transition characteristic of the control object as a reaction to a step change in the set point.
6.4. The options for tasks on the parameters of the control object are given in table 1.
Table 1. Options for tasks on the parameters of the control object
Option Number |
Gear ratioK |
Time constantT |
Delay N |
SNS interference |
adding to the output signal a random variable in the range from 0 to 1% |
||||
peak formation of 25% of the output value with a probability of 0.01 |
||||
random gain increase in the range from 0 to 2% |
||||
random increase in time constant in the range from 0 to 2% |
||||
random change by 1 delay |
||||
adding a sinusoidal signal with an amplitude of 2% of the output value to the output |
- Methodology for completing the task
7.1. To comply with paragraph 6.1. tasks to do the following.
7.1.1. Create a new standard project.
7.1.2. Explore the Help section QUICK START - PART TWO - Create workstation screens.
7.1.3. In the Resources layer, create the Pictures group. In this group, create the Image_Library component and import several textures into it.
7.1.4. In the Resources layer, create the group Graphic_elements. In this group, create a graphic_object. Using available graphic tools, create a conditional image of the control object, consisting of at least two three-dimensional figures with superimposed texture.
7.1.5. Create a node in the System layerRTM in which to create the Screen component. Place graphic elements of the operator interface on the screen:
- elements for entering values \u200b\u200band displaying setpoint values,
- controller image
- image of the control object
- communication lines between them,
- elements for inputting values \u200b\u200band displaying values \u200b\u200bof controller parameters,
- elements for displaying control values \u200b\u200band the output coordinate of the object in numerical and graphical form.
Create the necessary arguments and auto-construct channels on them. Follow the help section FAST START - PART ONE.
7.2. To perform paragraph 6.2 of the task, do the following.
7.2.1. In the RTM node create a program component and set a programming language for itFBD
7.2.2. Explore the Help topic Programming Algorithms - EditingFbd -programs. View descriptionFbd -blocks. Learn blocksPID and OBJ (section "Regulation").
7.2.3. Using Subtraction blocks,PID, OBJ , make up a control system model. Create the necessary arguments for the program, bind them to the channels. Bind the input and output signals of the blocks. For blockObj parameters of the control object — transmission coefficient, time constant, delay — set by constants in accordance with the task option. For block interference parameterObj use constant 0.
7.3. To perform paragraph 6.3 of the task, do the following.
7.3.1. Connect the blocks according to the “setpoint - control object” scheme (without regulator and without feedback).
7.3.2. Compile the program, if there are errors, eliminate them. Run the project using the RTM.
7.3.3. Enter a non-zero value of the setpoint and obtain the transient response of the control object. Take a screenshot of the transient response.
- Requirements for the content and design of the report
The laboratory report should contain:
- brief theoretical information;
- wording of the assignment for laboratory work;
- a description of the sequence of work;
- images of working windows obtained as a result of modeling the system;
- conclusions on laboratory work.
- test questions
9.1. What opportunities does it provideSCADA-system Trace Mode to create an operator interface?
9.2. What are the main types of resources that can be used to create an operator interface in the system?Trace mode?
9.3. What is a programming language?Fbd?
9.4. What are the main blocks of the compositionFbd can be used to simulate control systems?
9.5. What parameters should be set for the model of the control object?
9.6. What parameters need to be set for the PID controller model?
9.7. How is the system launched in real time?
- Laboratory Performance Assessment Criteria
Laboratory work is considered completed if:
- the student completed all tasks in accordance with the presentationnnoy technique;
- performance results presented in the form of reportse that correspond to the requirements presented to them;
- the student answered all the control questions correctly and can interpret the results.
- Literature
Analogue (FLOAT)
A source
move
Scaling
Hardware
Broadcast
Filtration
The real
Control
Control
The real
Broadcast
Hardware
Logical processing
entrance
A source
Discrete (HEX)
The real
Broadcast
Hardware
Logical processing
Exit
Receiver
Discrete (HEX)
Control
entrance
Filtration
The real
Broadcast
Hardware
Scaling
Exit
Analogue (FLOAT)
Control
entrance
During the implementation of this laboratory work, the student must master the sequence of creating the project in the Scada-system Trace Mode and create his own project according to the individual task of the teacher. We proceed directly to the creation of the TRACE MODE project.
You can open the program window by double-clicking on the corresponding icon on the Windows desktop or find the program in the "Start" menu.
To create a project, select the “File \\ New” item, select the project type “Simple” in the window that appears, and click the “Create” button (Figure 1).
Integrated Development Environment TRACE MODE 6
After that, the project navigator window will automatically be filled with the minimum required layers (Figure 2).
To solve our problem, only two layers will be sufficient - this is the "System" and "Sources / Receivers". An “RTM” node (Real Time Machine - a real-time monitor) has already been created in the “System” layer, inside which there is a “Channels” folder and a graphic screen.
Project navigator
Let's start by creating a signal source. To do this, right-click on the “Sources / Receivers” layer, thereby calling up the context menu in which we will go along the path “Create Group \\ PLC” (Figure 3.). A folder called “PLC_1” will appear in this layer. It is necessary to right-click on this folder and create the “Siemens_PPI_Group” group (Figure 4).
Creating a group in the Sources / Receivers layer
Creation of the Siemens_PPI_Group
In the group “Siemens_PPI_Group” we will create three components:
- “Siemens_PPI_MW2_R” - to read the 2nd word from the memory area of \u200b\u200bthe Memory Word;
- “Siemens_PPI_MW2_W” - to record the 2nd word of the memory word Memory Word;
- “Siemens_PPI_DW0” - to read the zero word of the Discrete memory area.
The screen form of the Siemens_PPI_Group components is shown in Figure 5.
Components of the Siemens_PPI_Group
Double-click on the “Siemens_PPI_MW2_R” component to open its properties window (Figure 6).
Component Properties Window “Siemens_PPI_MW1_R”
Fill in the fields as follows:
- name: Siemens_PPI_MW2_R;
- port: 0 (“0” corresponds to COM1, “1” corresponds to COM2, etc.);
- address: 2 (PLC address in the PPI network);
- offset: 0x2 (to read the address of MW2);
- area: Markers (WORD);
- name: Siemens_PPI_MW2_R;
- port: 0;
- address: 2;
- offset: 0x0 (read from zero address);
- area: Discrete Input (WORD);
- direction: Input (i.e. reading data from the controller into the Trace Mode environment).
Auto Channel Creation
In the upper window, open the “Channels” group, which belongs to the “RTM_1” node of the “System” layer, and in the lower window, open the “Siemens_PPI_Group_1” group, which belongs to the “PLC_1” group of the “Sources / Receivers” layer. To automatically create channels, we use the Drag-and-Drop method, just drag and drop all components except “Siemens_PPI_MW2_W” into the “Channels” group.
Double-click to open the “Screen # 1: 1” component belonging to the “RTM_1” node of the “System” layer. A rich dashboard for working with graphics is offered to choose from, including control elements, various types of lines and geometric shapes, as well as trends, diagrams, and gauges.
You can also insert images created by the user into the project, which, in turn, can perform control functions or indications.
Create three elements of the "Text" type. To do this, click on the toolbar icon, left-click in the selected location of the graphic field and, without releasing, stretch the object to the desired size. In the same way, create a button and a light bulb (Figure 8).
GUI creation
In the first text field, enter the name, for this we call the properties window by double-clicking the left mouse button on the text field. In the “Text” column, enter “Data exchange with SIMATIC S7-200 PLC”. Using the appropriate fields, change the color and font of the text, as well as the color of the outline and fill (Figure 9).
Graphic Properties Window
Call the "Screen Arguments" window from the "View" main menu. Using the Create Argument button, we create three arguments, according to the number of channels. The data type of all arguments is changed to "INT", and for the second argument, we change the type to "OUT". The argument names will be left unchanged (Figure 10).
Screen Arguments Window
Next, bind the screen arguments to the graphic elements. To do this, drag and drop the first and third arguments onto text fields using the Drag-and-Drop method. After that, the properties window of the graphic element automatically opens, where “Type of indication - Value” and “Binding - name of the corresponding argument” appear in the “Text” column (Figure 11).
Binding a Screen Argument to a Graphic Element
Now we will create an event for pressing the button “Change MW2 value”. To do this, double-click to open the properties window of the graphic element and go to the "Events" tab (Figure 12). It is possible to set the reaction of the system to two types of events - clicking on a graphic element and releasing it. Select the click, right-click on “MousePress” and in the pop-up menu that appears, select “Transfer value”.
A sub-item of the same name appears with its own properties. Choose: "Type of transmission - Enter and transmit." In the “Result” property, click on the empty column of the “Value” column. The screen argument table appears. Select the second argument (ARG_001) and click the Finish button.
Events tab of the graphic item properties window
We call the properties menu of the graphic object "Lightbulb" by double-clicking the left mouse button on this object. Fill in the values \u200b\u200bas follows (Figure 13): binding:<2> ARG_002; display type: Arg \u003d Const; inversion: True; constant: 256.
Window of the properties of the graphic element "Lightbulb"
At the initial moment, the light is off (red). When the value of the binding is equal to the value of the constant, the light will turn on (turn green). Applying a signal to the input of the controller I0.0 will set the value of the zero word of the Discrete Input memory area to 256, which will turn on the light. Thus, the I0.0 toggle switch on the front panel of the laboratory bench can be controlled by a light on the computer screen.
Now you need to create a binding of the screen arguments to the channels and components of the Sources \\ Receivers layer. To do this, in the project navigator, go along the path the “System” layer, the node “RTM_1”, “Screen # 1: 1”. We right-click on the “Screen # 1: 1” component and select the “Properties” item in the context menu that appears (Figure 14).
Calling the Screen Properties Window
In the screen properties window that opens, go to the “Arguments” tab (Figure 15).
Arguments tab of the Screen Properties window
To create a binding, for each argument, double-click on the empty “Binding” column opposite the corresponding argument to call the communication configuration window (Figure 5.16). In this window, for the first and third argument, select the appropriate channels (System \\ RTM_1 \\ Channels), i.e. "Siemens_PPI_MW2_R" and "Siemens_PPI_DW0".
And for the second argument, select "Siemens_PPI_MW2_W", but already directly from the "Sources / Receivers" layer (\\ PLC_1 \\ Siemens_PPI_Group_1 \\ Siemens_PPI_MW2_W).
Communication Configuration Window
After each selection made, you need to click the "Bind" button. Save the created project: “File \\ Save”. Returning to the “Project Navigator” window, it can be called up from the “View” main menu. Select the “RTM_1” node of the “System” layer and click the “Save for RTM” button of the “Project” main menu. At the time of saving the project for the real-time monitor, the node folder “RTM_1” is created in the project folder.
This completes the creation of the graphical interface, but before starting the runtime, it is necessary to create a COM port configuration file for the driver to work correctly, allowing data exchange between Trace Mode and PLC SIMATIC S7-200. We’ll open the program for creating the COM port configuration file, which comes with the base version of Trace Mode 6 and is located in the folder where this SCADA system is installed (C: \\ Program Files \\ AdAstra ResearchGroup \\ Trace Mode IDE 6Base \\ Drivers_with_Setup \\ Siemens \\ PPI \\ The executable file and the configuration file itself are located in this directory. Run the executable file PPIconfig.exe (Figure 17).
Port Configuration Window
In the port list, each line consists of eight parameters:
1. COM port number. Re-declaring the same port will result in an error message when trying to save the configuration.
2. Baud Rate, from 300 bps to 115200 bps. For PPI network devices, the default is 9600 bps.
3. The number of data bits (Data Bits). The default is 8 bits.
4. Parity transmission control, can take the values \u200b\u200bNone, Odd or Even. By default, even PPI is accepted for PPI network devices.
5. The number of stop bits (Stop Bits): 1 or 2. By default, 1 stop bit.
6. Timeout time for this serial port (in ms). The default is 1000 ms;
7. Flow control. The converter used may require flow control. For its correct operation, it is necessary to correctly indicate the signals (RTS, DTR) that will be given before each parcel and removed after it is sent.
8. Trace Mode address in the PPI network. According to the principles of data exchange in the PPI network, each device must have a unique address.
The specified serial port parameters must match the corresponding parameters of all other devices in this PPI network segment. Otherwise, the driver will not be able to exchange data or the received data will not correspond to reality and may lead to unpredictable system failures.
To create a new record, click the “Add” button, the “Delete” button will delete the record, the “Edit” button or double-clicking on the list item will bring up the recording parameters editing window (Figure 18).
The option "Log events" provides the ability to conveniently debug the system. On the specified path, 2 files will be created - PPImedia.log and PPIproto.log - in which the protocol of the driver’s work and messages about failures and their possible reasons will be saved accordingly. The specified directory must exist before starting Trace Mode. After successfully configuring the system, this option can be disabled, reducing the time and disk space.
So, the configuration file is created. Let's go back to the Trace Mode development environment window. In the project navigator, select the “RTM_1” node of the “System” layer and start the profiler by pressing the button. The runtime window opens. In this window we see the graphical interface that we created and the buttons for controlling the runtime environment: “Open”, “Start \\ Stop” and “Full Screen”.
We start our project by pressing the "Start \\ Stop" button or use the keyboard shortcut Ctrl + R. If all the settings were made correctly, then the appearance of the screen form will correspond to that shown in Figure 19.
The final screen form of the project for the exchange of data between the PLC and Trace Mode
Switch the I0.0 toggle switch on the front panel and check the indication - change the color of the bulb from red to green. Click on the “Change MW2 value” button and in the window that appears, enter a new value, click “Finish”. Verify that the value in the text box has changed. You can use this value in your program for the PLC, and depending on it, the controller will generate various control actions.
The article discusses the properties of SCADA Trace Mode 6, simplifying the development of ICS projects. Examples of building automation and ACS of a power unit are given.
Adastra Research Group, LTD., Moscow
Integrated SOFTLOGIC-SCADA-system Trace Mode 6 of the Russian company AdAstra Research Group, Ltd. For more than 15 years it has been the best-selling software for automating technological processes in Russia and the CIS. The unique combination of the Trace Mode 6 system properties makes it the basis of modern process control systems for optimal process control.
The integrated production management platform Trace Mode 6 consists of an Integrated Development Environment, in which the creation of ACS projects and a set of executive modules that ensure the operation of the system in real time are carried out. The integrated environment includes a full set of development tools for process automation systems (ACS TP), namely the means of creating:
Operator Interface (SCADA / HMI);
Distributed camera systems;
Real-time industrial database;
Programs for industrial controllers (SOFTLOGIC).
A huge advantage of the Trace Mode 6 software package is its large library of built-in drivers, which comes free even with the basic version of the system. Support for a large number of equipment of both domestic and foreign manufacturers allows you to create highly reliable process control systems in a distributed architecture. A perfect example of this thesis is the automated control system for the Intel office building, which was developed on the basis of the SCADA-system Trace Mode 6 by specialists of the Protect company, Nizhny Novgorod.
Fig. A function that allows you to create both a single and a double reserve for a project node with one click of the mouse
Intel office building automation system covers the following devices: chillers, drycoolers, cooling station, frequency converters of pumps, exhaust fans, central air conditioners, fan coils.
At the hardware level of the system, the following equipment was used:
Advantech I / O Modules
Converters of temperature / humidity of firms Sauter and S + S Regeltechnik;
Sensors and relays of a leak of liquid of Jola firm;
Electric energy meters СЭТ 4ТМ;
Sensors of temperature, humidity, pressure, electric actuators of control valves, as well as controllers in the refrigeration, ventilation and air conditioning system of York;
Schneider Electric frequency converters.
According to Protect experts, “The use of the SOFTLOGIC-SCADA-system Trace Mode 6 with developed support for information exchange with equipment of various brands made it possible to comprehensively solve the issue of building an automated control system and ensured comfortable operation of the building’s engineering systems.”
An important role in ensuring the reliability of process control systems is played by technical means that prevent emergency situations and minimize losses from malfunctions in the process control system. These functions can be divided into several groups:
Protection against accidental errors during the development of industrial control systems;
Timely diagnosis of failures;
Hot redundancy of components and units of industrial control system;
Automatic recovery after failures;
Protection against unauthorized access and unskilled user actions - the so-called human factor.
From the list of these functions, the most important is the hot redundancy of components and nodes of industrial control systems. The reservation of the elements of the automated process control systems created is dictated either by the existing regulatory industry documents (for example, for facilities potentially hazardous to the environment and / or production personnel - nuclear industry, chemistry, military industrial complex), or the nature of the process, the violation of which can lead to serious economic losses ( power industry, metallurgy, etc.). Trace Mode 6 implements a unique function that allows you to create both one and a double reserve for a project node with one click of the mouse. Moreover, an identical node is created with preservation of all internal and external links of the channels with data sources. Trace Mode 6 is designed to meet all reliability requirements and supports various types of hardware and software redundancy at all levels - from a single sensor to an enterprise-wide archive server.
Fig. Library of built-in drivers, which comes free even with the basic version
Reliability and fault tolerance of an automation system depends on its hardware, software components, personnel discipline, security policy, etc. Ways to improve the reliability of ACS by hardware are more obvious and, as a rule, lead to a rise in the cost of the system. At the same time, software affects the reliability of process control systems no less than sensors, controllers or servers. Moreover, the often high cost of the SCADA system does not guarantee the availability of the necessary functions of fault tolerance and redundancy in it.
The solution to large-scale automation tasks in Trace Mode 6 is facilitated by unique technologies that increase the productivity of developers. Among them:
Integrated development environment;
Unified database of a distributed project;
Group editing
Rich libraries of free drivers, algorithms and graphics;
Auto construction project.
One of the projects where Trace Mode technology enabled the implementation of the highly reliable process control system project as soon as possible (beginning of design - January 2007) was the process control system of the second power unit with a capacity of 215 MW of the Pskov State District Power Plant (OGK-2 OJSC branch). Already in August 2007, the system was successfully put into trial operation by specialists of the Russian company CJSC PIK “ZEBRA” under the technical supervision of OJSC “Engineering Center of the UES - Firm ORGRES” (Moscow). At the hardware level of the automated process control system, the PTK KRUIZ manufactured by CJSC PIK ZEBRA was used (ISUP Magazine 2 (14) _2007).
Work on the creation of automatic process control systems was carried out as part of the second stage of automation of control and management systems for power units at the Pskov State District Power Plant (Order of RAO UES of Russia dated September 18, 2002, No. 824). The first stage was completed in December 2004 with the introduction of the automated control system of the first power unit of the Pskov State District Power Plant, which was also developed on the basis of the PTK KRUIZ and SCADA Trace Mode.
The objects of control and management of automated process control systems were the main and auxiliary equipment of power unit No. 2, as well as the station-wide heating equipment.
In addition to the automatic process control system itself, the automation project of the second power unit of the Pskov State District Power Plant (OGK 2) included the commissioning of a full-scale simulator of the power unit designed for effective education and training of OGK 2 personnel.
A fundamentally new approach to the automation of industrial facilities was the creation of functional group management programs (FGU), which carry out sets of standard technological operations, which facilitates the work of GRES operating personnel.
PJSC “ZEBRA” CJSC has long and successfully applied the integrated and group development technologies of large-scale automated process control systems implemented in Trace Mode, which allows you to create projects using common tools in a short time and has the privileged status of an Authorized System Partner AdAstra Research Group, Ltd.
General information. TRACE MODE® 6 consists of a tool system - Integrated development environment and from a set of executive modules. The instrumental system is installed at the workplace of the ACS developer. It creates a set of files called the TRACE MODE project. Using the TRACE MODE® Executive Modules, the ACS project is launched in real time. TRACE MODE allows you to create a project immediately for severalexecutive modules - project nodes.
Integrated Environment Includes full setdevelopment tools for process automation systems ( APCS), namely the means of creation:
· Operator interface (SCADA / HMI);
· Distributed control systems (DCS);
· Real-time industrial database;
· Programs for industrial controllers (SOFTLOGIC);
as well as management business processesproduction ( ASUP):
· Asset management systems and equipment maintenance (EAM);
· Production management systems (MES).
Executive Modulesfor process control systems and automated process control systems differ. Modules for process control systems (class SOFTLOGIC and SCADA / HMI) are included in the complex TRACE MODE®, and executive modules for automated process control systems (class EAM, MES) - as a set T-FACTORY.exe ™.
Together, TRACE MODE® and T-FACTORY ™ provide solutions for integrated real-time process control and manufacturing business management, forming integrated production management platform.
TRACE MODE® 6 convenient and simplein use. Nevertheless, the system architecture allows you to create large enterprise-class ACS. The generalized structure of process control systems (SOFTLOGIC, SCADA / HMI), which can be developed on the basis of TRACE MODE® 6, is shown in the figure.
Moreover, Integrated Development Environmentallows you to create an automated control system for automating the tasks of production execution management (MES), personnel work (HRM) and enterprise fixed assets (EAM).
The solution to such large-scale automation tasks in TRACE MODE®perhaps thanks to special technologies that increase the productivity of developers.
Among them: a single database of a distributed project; auto construction project; rich libraries of drivers, algorithms and graphic objects; powerful debugging tools; built-in hot standby system; own report generator; real-time industrial database; rich libraries of drivers, algorithms, graphic objects, multimedia and document templates.
TRACE MODE 6 includes record amountresource libraries (professional line only), ready for use in application projects. Among them: free drivers for 2422 controllers and input / output boards; 1116 graphic images of technological objects and processes; 596 animated objects; more 150 data processing and control algorithms; complex technological facilities.
The synthesis of HMI is quite simple. Take the “pump” object from the TRACE MODE 6 library and drag it onto the PC icon where the mimic diagram should be located - that’s all you need to do! TRACE MODE 6 itself will create a screen and record control algorithms. Now drag the icon of the controller you selected onto the PC icon and the desired driver will automatically connect to the project. Click " Start"and the real-time information will be displayed on the mnemonic.
MRV is the main real-time server of the SCADA level.The main real-time SCADA / HMI servers in TRACE MODE 6 is monitor real time (RTM) and RTM +. МРВ TRACE MODE 6 receives data from controllers, input / output boards and telemechanics systems (RTU) through built-in protocols, drivers, OPC or DDE clients. In RTM 6
Real-time monitor 6 performs the primary processing of information coming from controllers or telemechanics systems (filtering, scaling, border control, etc.), control and regulation of technological processes, redistribution of data over a local network (I-NET TCP / IP), visualization information on animated mnemonic diagrams and trends (HMI), real-time calculation of statistical process parameters (SPC - statistical process control), maintaining historical archives, managing your own industrial real-time DBMS SIAD / SQL ™ 6, generating ment report documents and provides connectivity to databases and applications via SQL / ODBC and embedded OPC-Server (optional).
There are real-time monitors with a different combination of the above properties. In addition, SCADA TRACE MODE includes versions of the Real-time Monitor with automatic hot standby, adaptive regulation, with an integrated OPC server, GSM-server, etc.
The composition of the Real-time Monitor includes a graphical HMI console that provides visualization of information about the process on dynamic mnemonic diagrams. The real time monitor has powerful graphicopportunities.
MRI with adaptive self-tuning of regulators.SCADA TRACE MODE real-time monitors with support for the automatic (adaptive) PID controller self-tuning system are called Adaptive Control МРВ . Adaptive Control RTM based on original, technology, exclusive rights to which belong to the company Adastra.
The program provides periodic or continuous adjustment of regulators in automatic or semi-automatic mode. Adaptive Control RTM is capable of adjusting control loops in the presence of interference, and also eliminates the appearance of unstable modes. Using adaptive SCADA / HMI TRACE MODE 6 regulators provides the best quality control at any time for a wide class of stationary and non-stationary automated objects. In addition, the adaptive SCADA / HMI TRACE MODE 6 regulators allow working with a significantly lower amplitude of the test signal at the input of the object (up to 2-4%) while maintaining the adaptive properties of the system. Such small test oscillations practically do not increase the degree of wear of the actuators.
Adaptive Regulation in RTM +
Adaptive МРВ + is a type of SCADA executive modules of the TRACE MODE 6 system, designed to automatically calculate the optimal settings for PID and SDA regulators directly to the operator’s workstation.
This product differs from the usual MRV + by the support of functional blocks of the FBD language that implement adaptive self-tuning of PID controllers at the operator's automated workstation (AWP). The calculated settings can be loaded into the controller to perform regulatory tasks.
Adaptive PID control technologies allow:
· Automatically determine the optimal settings for PI and PID control algorithms for objects with different dynamics;
· At any time to carry out the self-adjustment process in a closed loop, while maintaining control over the process;
· Conduct the process of self-tuning with a minimum level of the test signal, which does not lead to a violation of the normal operating mode of the object. The amplitude of the test signal at the output of the control object is not more than 0.3-0.5%, at the input 1-5%;
· Start the self-tuning process simultaneously on all the regulators installed in this production;
· Control the process of self-tuning on the operator's workstation, adjust the received settings, vary the amplitudes of the harmonics of the input and output;
· Adaptive МРВ + provides the ability to automatically control the self-tuning process on the workstation in order to eliminate unstable operation of the system;
· Test vibrations are often useful for the process;
· By the drift of settings, you can judge the state of the equipment of the technological process.
Adaptive MPV + supports the following adaptive algorithms:
Adaptive PID controller ( APID);
Adaptive traffic rules regulator ( APDD);
· Object Identification ( IDNT);
Modal regulator ( MREG);
· PID controller tuning by object parameters ( CALC);
· PID tuning for task jump ( Rjmp).
The principle of operation of the adaptive controller is as follows: from the operator's computer AWP, along with the controller signal, an additional test sinusoidal signal with a small amplitude is supplied to the input of the control object. The amplitude and phase of the harmonic component in the output signal of the object is used to calculate the controller settings. The calculated settings are loaded into the controller.
Adaptive regulation can be carried out both in the mode of constant adjustment of the regulator coefficients, and periodically, or on command from the operator's workstation.
Modal regulator implemented in the form of a digital model of the regulatory object and a full-order astatic observer. The adaptive controller settings are calculated taking into account the polling period of this channel in the workstation node.
In addition to modal and adaptive regulators in Adaptive MRI + Support for other functional blocks is also implemented:
PID controller ( PID);
· SDA regulator ( PDD);
Three position controller ( PREG);
Fuzzy knob ( FZCTR).
SCADA TRACE MODE 6 in the integrated automation of OJSC Polyplast-Novomoskovsk.Polyplast-Novomoskovsk OJSC (Novomoskovsk) specializes in the production and sale of additives for concrete, mortar and chemical products of various industries. The production capacity of Polyplast-Novomoskovsk OJSC is 36,000 tons of products per year. The company is part of the Polyplast Group, which occupies a leading position in the market of concrete additives.
Polyplast-Novomoskovsk OJSC is constantly working to expand the range of manufactured products, as well as to search for new opportunities for their application. By improving existing products and technologies, the company achieves the result that the consumer expects.
The first system managed by SCADA TRACE MODE at Polyplast-Novomoskovsk OJSC appeared relatively recently. In March 2007, industrial control systems for the production of superplasticizer SP1 and a dispersant were put into commercial operation. The company developed the new process control system based on SCADA TRACE MODE 6 Center- Authorized system integrator AdAstra.
The controllers were selected as the hardware platform of the new process control system of OJSC Polyplast-Novomoskovsk SLC-500 Allen-Bradley(USA), as well as sensors and actuators of the best domestic and foreign companies - Elemer(Moscow city), Oval(Japan), Takeoff(St. Petersburg), Siemens(Germany), Sensor(Moscow city), Armagus(Gus-Khrustalny town).
Communication between the SLC-500 Allen-Bradley controller and SCADA TRACE MODE is carried out through the free built-in DeviceNet driver at a speed of 100 Mbps. Communication of SCADA TRACE MODE 6 with registrars РМТ-59 is carried out through the OPC server via the RS-232 interface. Remote graphic consoles are connected to the TRACE MODE RTM via an Ethernet network at a speed of 100 Mbps.
The control system manufactured by Superplasticizer manages the following technologies:
Sulfonation;
Condensation
· Neutralization;
· Regulation of steam pressure and temperature of the vapor condensate at the outlet of the heat exchanger .
Operator Level Automated Process Control System Superplasticizer, created in SCADA TRACE MODE 6, includes 2 Automated Workstations (AWPs) of an operator-technologist and 4 Remote Workstations for senior staff, technologists and quality laboratory of OJSC Polyplast-Novomoskovsk. Workstations of operators are developed on the basis of TRACE MODE MRV +. A convenient photorealistic operator interface has been created at all workplaces in the graphical editor of the TRACE MODE 6 Integrated Development Environment.
For each of the stages of the manufacturing process of the Superplasticizer, as well as for each of the regulators, a separate mnemonic screen was created. In addition, the project created a common graph screen, pop-up alarm screens and controller settings. On the main workstation with three monitors, mimic diagrams of the sulfonation, condensation and neutralization stages are constantly displayed, respectively, one on each of the monitors. The second operator can choose which screen to display.
Remote workstations of process control systems manufactured by Superplasticizer are remote graphic consoles based on the TRACE MODE 6 NetLink Light software module. From these workstations, monitoring of process parameters and events is carried out. Such conditions are used by the laboratory, the service of technologists and the management team - the production manager and general director of Polyplast-Novomoskovsk.
The process control system for the production of liquid additives for concrete and mortar works efficiently and stably ... The introduction of this process control system has significantly improved the quality and quantity of products, effectively organize the process and staff work, reduce downtime to a minimum.
After the successful start-up and operation of the process control system for the production of Superplasticizer at OJSC Polyplast Novomoskovsk, it was decided to continue to use SCADA TRACE MODE to automate its production. By August 2007, the Center’s specialists had already launched several systems under the control of SCADA TRACE MODE 6. Automated process control systems for the production of liquid complex additives - the third automated industrial control system based on SCADA TRACE MODE 6, implemented by Center LLC at Polyplast-Novomoskovsk.
The new automated process control system for the production of liquid complex additives for concrete was also developed on the basis of SCADA TRACE MODE and the Allen-Bradley SLC 500 controller. ICP DAS modules I-7000 were also used as DCS modules for the storage of liquid chemical raw materials, which are also supported in SCADA TRACE MODE 6 through built-in free driver.
Branch liquid mixingcarries out the production of liquid complex additives for concrete from the main raw materials - Superplasticizer (SP1).
The essence of the production of liquid additives is as follows: from 6 storage tanks with various raw materials and semi-finished products, the necessary components are poured into the reactor at predetermined proportions (corresponding to the receipt of a product at the outlet).
The process control system for the production of liquid complex additives for concrete at OJSC Polyplast-Novomoskovsk performs the following functions:
· Preparation of additives (dosed loading of all components and mixing with time delay);
· Monitoring and registration of all necessary technological parameters;
· Shipment of a given amount of product;
· Shift records of the preparation / shipment of products by name;
· Shift commercial accounting of the consumption of raw materials;
· Issue of an invoice for the actual shipment of the product.
The operator level of the control system for the production of liquid complex additives for concrete OJSC Polyplast-Novomoskovsk was developed in the TRACE MODE 6 Integrated Development Environment and is an automated workstation of the operator under the control of TRACE MODE DocMRV + 6 for 10 document templates and 4 remote workplaces under the control of TRACE MODE Netlink Light . Technological data is archived in the Access DBMS using the free ODBC protocol driver built into SCADA TRACE MODE 6, as well as in the SIAD / SQL 6 archives. The automated process control system for the production of liquid complex additives for concrete provides function of automatic documentation of the invoice for shipped products and the finished product is shipped to the consumer in railway and tank trucks or sent to storage tanks.
According to the general director of LLC Polyplast-Novomoskovsk Lotts A.A. " After the system was put into operation, positive feedback began to be received from end consumers related to improving the quality of additives, high-precision shipment and high speed of preparation of additives. ”
Due to the growing demand for products, Polyplast intends to further develop process control systems based on SCADA TRACE MODE and PLC SLC 500 Allen-Bradley at large production capacities.
SCADA TRACE MODE in the dispatching system of the Atyrau refinery.Company specialists "Integrated information systems" KIS " (Kazakhstan) together with Namip Sectorial Solutions (Russia) completed the implementation of the first stage of the dispatching system at the Atyrau Refinery.
For the development of ASDU Atyrau refinery was used SCADA TRACE MODE 6. The control room of the new automation system of the oil refinery consists of two parts:
The server on a dedicated PC runs under the control of the TRACE MODE real-time monitor with support for data archiving (MRV +);
Operator workstations are based on the TRACE MODE 6 client modules - three remote NetLink Light graphical consoles (NLL).
At the hardware level, the system uses YOKOGAWA controllers, which are connected through an OPC server.
The new ASDU of the Atyrau Refinery controls the following technological subsystems:
· Installation DIESEL;
· Installation HYDROGEN CLEANING;
· Installation HYDROGEN PRODUCTION;
· Installation PRODUCTION OF SULFUR;
· Installation of the COOLING Tower;
· Isomerization;
· Installation HYDRAULIC CLEANING GASOLINE;
· Installation AMINE GAS CLEANING;
· MATERIAL BALANCES PRODUCTION RELEASE
Data from TRACE MODE is written to DBMS ORACLE- One of the most powerful and widespread DBMS in the industry. The new ASDU of the Atyrau Refinery under the control of SCADA TRACE MODE in real time makes dozens of SQL queries to the DBMS, based on the data on the characteristics of various petroleum products from the base of the central laboratory of the plant, recalculates for the actual temperature and generates material flowsfor eight installations to create a common material balance of the plant.
It is possible to work both fully in automatic mode and in manual mode with operator input of laboratory data.
Currently, the specialized units of the Atyrau Oil Refinery receive operational information about the process at the main production facilities and the results of their on-farm activities.
The development of a dispatching system for oil refining at the Atyrau Refinery was carried out by highly qualified specialists who knew not only the SCADA system and information technologies, but also deeply understood the production processes of oil refining. As a result of the work, the technological services of the Atyrau Oil Refinery received a modern instrument for monitoring, analyzing and managing production facilities.
An example of implementation of a small-sized automated process control system NPU-20 refinery based on SIMATIC. System structure: Small-sized oil refinery (NPU-20) is designed for the processing of low-sulfur crude oil or gas condensates in order to produce motor fuels to provide oil products to remote and inaccessible areas.
The refinery allows you to get a fraction of straight-run gasoline, summer and winter diesel fuel. The installation includes the following process units:
Knot of the furnace;
The main technological unit is a column unit, a cooling unit, pumps for pumping);
Control block.
The general scheme of NPU - 20
Description of the technological process: petroleum feed from the raw material tanks that are part of the plant economy is pumped to the T-1 heat exchanger. In the T-1 heat exchanger, the feedstock is heated to 50-80 (depending on the type of feedstock) with a side stream of a distillation column. Further, the raw material is sequentially heated in heat exchangers T-2, T-3 to a temperature of 80-150 ° C and enters the furnace.
The furnace is designed to heat raw materials to 215-360 ° C and superheat water vapor to a temperature of 360 ° C. The distillation column K-1 is intended for the separation of crude oil into fractions. The distillate of the K-1 column (gasoline vapor, water vapor, hydrocarbon gas) enters the cooling unit, where it condenses and cools to 40 ° C, and then to the E-1 reflux tank. Capacity E-1 is designed to separate the distillate of the column into gasoline, gas and water vapor condensate. Part of the gasoline is fed to the distillation column.
The side shoulder strap of the K-1 column is discharged into the stripping column K-2. The steamed side stream (diesel fuel) enters the cooling unit and then is removed from the installation.
The bottom product of the distillation column (in case of operation on oil - fuel oil, on gas condensate - diesel fuel) enters the cooling unit and then is removed from the unit.
Requirements for the automation system: The automated control and management system for a small-sized oil refinery NPU-20 should provide:
Remote control and automatic control of technological parameters of the main technological unit;
Remote monitoring of the operation of mechanisms and equipment status of the main technical unit;
Remote control of technological parameters of the furnace unit;
Remote monitoring of the condition of the equipment of the furnace unit;
Formation of reporting replaceable documentation on the operation of the installation,
Formation of a database (history) of the parameters of the technological process and the operation of mechanisms by calendar periods.
Solution and characteristics of the automation system: Functionally, the system consists of two cabinets (control cabinet and control cabinet), an operator console, sensors and actuators located in place. The control and management cabinet (ШКУ), the power cabinet (ШС) and the operator panel are located in the control room. The control cabinet contains: programmable logic controller (PLC), discrete signal input modules, SIMATIC ET 200S distributed input-output station (1), power supplies, spark protection barriers, auxiliary relays, flame control sensor-relay, circuit breakers. The operator panel contains a touch panel operator and control buttons. The power cabinet contains: SIMATIC ET 200S distributed I / O station (2), circuit breakers, non-reversing contactor, power supply.
Separately placed sensors and actuators are installed locally. During the operation of the system: the PLC, using input modules, a set of its own inputs and a SIMATIC ET 200S station (1), collects data from sensors. The collected data is transmitted for display on the operator panel. Also, the PLC receives commands from the panel, executes a program for processing data and commands, transmits commands to actuators using its own set of outputs and SIMATIC ET 200S station (2). The touch panel displays the current state of the system, receives commands from the operator and the PLC. The system provides control of 63 parameters, among which:
Temperature - 12 points;
Pressure - 7;
Consumption -2;
Level - 7;
Equipment operation and condition of mechanisms - 16;
Emergency -3;
Manual entry of parameters - 16;
The number of regulatory analog parameters is 6.
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