spc «krug» · spc «krug» is a large diversified company operating in the industrial automation...
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Technical solutions
SPC «KRUG»
GAS: Storage, Transportation, Processing and Metering
SPC «KRUG» is a large diversified company operating in the industrial automation of the fuel and energy sector.The Company’s staff accounts for more than 170 skilled specialists. Branches and representative offices operate in a number of cities of the country. Since 2002, the quality management system complies with ISO 9001. More than thirty of certificates, licenses, permits and testimonial letters have been issued by the RF Rosstandart, the State Standard of the Republic of Kazakhstan and RF Rostekhnadzor. These certificates and licenses, as well as the SRO Certificate for design, installation and commissioning, accreditation at Gazprom OJSC, etc., ensure reliability and quality of products and services to be provided to our Clients.
Core activities• Production of certified hardware and software systems for building demanding production
automation systems• Creating integrated technical and commercial resource accounting systems• Manufacturing of software for industrial automation• Custody transfer gas metering station• Gas processing and gas transportation infrastructure automation systems (tank farms, gas
pressure reducing stations, flare systems, gas compressor stations, gas fields, etc.)• Console designs for creating operator and dispatcher automated workstations• Training of operational and technological personnel• Development of integrated plant automation system creation concepts• Development of design and estimate documentation• Engineering works• Commissioning works• Project management• Etc.
Since 1992, SPC KRUG in close cooperation with a number of its partners has commissioned more than 600 automated control systems in the fuel and energy sector, including more than 200 control systems in the oil and gas industry. Automation systems, developed based on SPC KRUG software and hardware, are in commercial operation at such companies as Gazprom, Rosneft, Surgutneftegaz, Gazpromneft, Tatneft, TNK-BP, E.ON Russia, as well as at enterprises operating in Belarus, Ukraine, Kazakhstan, Poland.
SCIENTIFIC PRODUCTION COMPANY «KRUG»
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Certificates and licenses
Clients
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Controlled objects
Gas field wells, preliminary gas processing terminal (PGPT) (manifolds, pumps, heaters, separators), pipelines for gas transfer to gas processing plants (GPP).
Implementation objectives
• Replace obsolete remote control systems with a multi-level DCS, which meets today’s response rate and reliability requirements
• Use wireless communication for covering distributed objects
• Provide automatic operation of wells, shutdown valves and other equipment remote from PGPT
• Improve the process mode quality and safety• Promptly identify equipment downtime causes • Reduce gas losses due to prompt actions taken by
personnel• Improve operating reliability of fields.
System functions
• Automatic equipment control from redundant controllers, located directly in a well, shutdown valve or PGPT
• Acquire and process information, received from wells and shutdown valve control units, at the PGPT level through radio communications
• Gather information from PGPT at the central control room level through radio communications
• Display information to operating personnel and to the supervisor in the digital, tabular or graph forms
• Generate light and sound alarms in case of parameter deviations from the preset warning and pre-accident boundaries as well as in case of other emergency situations
• Automatically generate and issue data to the operating personnel as well as print out deliverables automatically or on request.
Components
• Controllers with a 100% redundancy• Installation cabinets• AWP operators on the basis of 100% redundant
servers. • Supervisor workstation• Ethernet local area control network (100%
redundancy)• Radio modems • Radio stations • Integrated SCADA KRUG-2000®.
Results
The operating personnel is provided with more detailed, accurate and timely information about equipment operation. A deep self-testing level, in combination with a number of software and hardware solutions, enabled sophisticated monitoring and control logics to be implemented.Due to the use of radio communication, the system covers geographically distributed objects with a maximum distance between the subscribers of 28 km. Software and hardware solutions have allowed polling cycle to be reduced down to a few seconds.
This solution was used at the Astrakhan Gas Processing Plant, Astrakhangazprom, LLC.
Gas Field DCS
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Controlled objectsGas compressor units (GCU) driven by electric or gas turbine engines designed for compressing natural gas at trunk gas pipelines.
DCS implementation objectivesDevelop automated control systems (ACS) as a solution that is easily adaptable to any GCU and allows comprehensive solution of the following tasks:
• Monitoring, control, protection and diagnostics • Provide a long-term trouble-free and low-cost GCU
operation. Results
• Increased operating reliability and efficiency of the units
• Provide personnel with more comprehensive, accurate and timely information
• Improved operating equipment diagnostics • Dramatic decrease in the number of instruments
required in operation operates.
System functions
Information functions• Meter, process and visualize process parameters • Provide light and sound alarms in case of deviation of
monitored parameters from the preset warning and pre-accident boundaries
• Generate and visualize on-line, historical, hourly, shift and daily trends (current, average, total) for controlled parameters
• Generate and print out mode sheets, event protocols, accident development protocols, emergency protection settings
• Transfer information to the upper supervisory control level via OPC technologies.
Control functions• Remote control of process equipment in automatic
and manual modes • Safe urgent and emergency GCU shutdown both by
the operator command and by protection signals.
Self-diagnostics • Automatic control of a control command transmission• Automatic control of a correct choice of a controlled
object• Software and hardware diagnostics of controllers,
with information display to controller board indicators and to the upper level, with an accuracy of up to one input/ output
• Data link failure monitoring• Transmitter operation tests• Display diagnostic information to the operator station
and to the engineering station.
«Strategic survival» functions• Hardware redundancy of the master controller, which
controls and protects the unit in case of failure, provides for an automatic switch over to a backup controller, which ensures emergency shutdown of the unit. Following localization of a fault in the master controller channel, the operator may automatically bring it into operation, using GCU ACS, without technological process interruption.
• GCU ACS transfer from one controller to another controller in a manual mode by the operator.
Auxiliary functions• Urgent system resetting and software reconfiguration• Detailed screen support to the operator у• Register access of a person, operating GCU, and log
all his actions• Support system time unity.
DCS for Gas Compressor Shops
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Components• SCADA KRUG-2000®
• Control cabinet with two controllers, which control the same GCU
• Operator’s automated workstation• Emergency shutdown module (ESD) (integrated in
the control cabinet)• Control panel in the control room with a manual
control module.
This solution was implemented at the Pochinkovskaya CS for EGPA-235 c/w STD-12500 (2 shops, 14 units), Volgotransgaz LLC.
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Controlled objectsJet fuel, ethane-free condensate, liquefied gas tank farms, etc.
DCS implementation objectives• Bring control systems in line with existing fire and
explosion safety regulations and standards• Improve efficiency and operating reliability of
equipment• Improve equipment performance• Increase productivity and working conditions of the
operating personnel• Develop a system, considering the possibility of
further development and build-up of information capacities.
System functions• Parameter monitoring and alarms• Digital control• Emergency shutdown protections• Providing information to process engineers, DCS and
C&I departments• Process logging: event logs, mode sheets
• Calculations: accounting of running hours of pumps and fans, etc.
• Self-testing of DCS components • Archiving trends, printed documents, protocols.
SoftwareSCADA KRUG-2000®, including the development environment (database generator, graphic editor, script language, etc.) and the runtime environment (executable modules of operator/ archiving stations, servers and controllers).
Components• Controllers are designed with 100% “hot” redundant
processor parts • Digital level gauges, connected to controllers via
RS-485 interface• Installation cabinets• Operator control panels on the basis of the ConsErgo®
typical universal designs• Server-based operator – process engineer
workplaces (2 servers). Servers operate in a 100% “hot” redundancy mode and execute the real-time system and backup functions.
• Ethernet local area control network (100% redundancy)
• Laser printer.
DCS for Tank Farms
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ResultsDCS implementation enabled operating personnel to receive comprehensive, objective, accurate and timely information about the operation of the equipment. A deep self-testing level, in combination with a number of software and hardware solutions, allowed the implementation of sophisticated control and monitoring logics. Integration of digital level gauges into the system (e.g., Enraf CIU858, etc.), with the possibility of servicing level gauges directly from the operator station, is another important advantage. This solution was implemented at the following facilities:
• Jet fuel tank farm at the Surgut Condensate Stabilization Plant
• Ethane-free condensate tank farm at the Surgut Condensate Stabilization Plant
• Liquefied gas tank farm at the Rosneft-Tuapse Refinery LLC (Rosneft, OJSC)
• Feedstock tank farms at Kirishinefteorgsintez, LLC.
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Controlled objectsGas pressure reducing station (gas reducing station, GRS), designed to reduce and maintain gas pressure at preset consumption levels.
Implementation objectives• Increase process equipment operating reliability,
reduce risks of severe accidents in a way so that equipment failures would not provoke hazards to human life and health and property damage
• Enable effective automated process control in routine, transient and emergency gas distribution modes
• Timely provide operating personnel with sufficient and reliable information on the process status and the condition of equipment and controls
• Reduce automation hardware operation and maintenance costs
• Provide commercial natural gas consumption metering.
System functions• Acquire and process data, received from temperature
and pressure transmitters, connected to orifice plates, and compute natural gas volume and mass flow rate in pipelines
• Automatically switch over differential pressure measurement ranges to increase flow measurement ranges
• Recover metering parameters after system outage, with the addition to the values, existed at the time of shutdown, of the product of the downtime by a contractual constant or a flow rate before the trip
• Compare parameter values with the settings, with the logging of violations and with the generation of the corresponding entry in the Messaging Protocol
• Control reliability of received information by limit values, rate of change and other criteria
• Receive digital information on the state of valves from local control cabinets
• Ensure operation of equipment emergency shutdown and interlocking hardware in accordance with the regulatory documents: gas pressure increase downstream of the GRS to Level 1 and Level 2; gas pressure decrease downstream of the GRS; transfer of gas reduction line to the modes “Operation”, “Automatic Transfer”, “OFF”; and a prohibit to control valves from two points
• Provide remote control of actuators• Compute natural gas volume and mass, going
through the metering station• Display information to operating personnel onto color
monitors in the form of mimic diagrams, with the indication of parameters in digital, tabular or chart forms
• Generate light and sound alarms in case of parameter deviations from preset warning and pre-accident limits as well as in case of other emergencies
• Indicate mimic images of motorized valves, with the dynamic indication of their status and possibility of remote control of these valves
• Input online input data manually• Automatically generate and issue data to the
operating personnel as well as print out deliverables automatically or on request
• Execute the “Winter-to-Summer” and “Summer-to-Winter” transitions
• Provide a multi-user mode of operation, with the distribution of the system access rights by passwords, register access and log person’s actions
• Automatically generate and print out system event logs
• Archive data on a PC hard drive• View the history of the process parameters in the
form of graphs and tables • View archives of paper documents on the display and
print out these paper documents
DCS for Gas Pressure Reducing Station
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• Display information about the status and operability of DCS components, and test DCS elements
• System time correction. Software
• Upper level software is implemented based on SCADA KRUG-2000®, including: development environment (database generator, graphic editor, programming script language, etc.) and runtime environment (executable modules of operator stations).
• Controller real-time system (CRTS), allowing creation of “hot” redundancy diagrams: 100% redundant controllers, redundant processor parts, redundant I/O module.
ComponentsGRS DCS is a two-level distributed system with a multi-stage failure protection to ensure high reliability.The lower level consists of up-to-date, high-reliability microprocessor controllers. Controllers are designed with 100% “hot” redundancy. Controllers are located in control and monitoring cabinets.The upper level consists of operator workstations (operator/ backup stations, server with a full-sized scope of graphic design, with a 100% “hot” redundancy and archiving functions).Communication with the lower-level controllers is made through a local area network, using fiber-optic lines (FOL), with a 100% “hot” redundancy.
ResultsGRS DCS implementation allows the followings:
• Optimize calculations through integration of a custody transfer natural gas metering station in compliance with all requirements set out by Glavgosenergonadzor and the Federal Agency for Technical Regulation and Metrology
• Increase reliability of the process protection
subsystem through structural redundancy and continuous diagnostics of hardware and software
• Provide personnel with comprehensive on-line and archival information about the operation of the system; provide broad opportunities to operators for controlling technological processes
• Ensure stable operation of process equipment control systems
• «System survivability» due to the use of mutually independent controllers
• Implement sophisticated monitoring and control logics.
This solution was implemented at the following facilities:• GRS-2 at the Kirishi Power Plant• GRS at Penza CHP-1, Penzaenergo OJSC• GRS-8, Kavkaztransgaz, Stavropol • GRS at Severodvinsk CHP-2• GRS at Arhangelsk CHP• Automated system of natural gas pressure
reducing at the Saransk CHP-2, Mordovia filial PJSC «T+».
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Control objectGas fractionation plant for processing gas gasoline coming from the installations of oil refining and production of propane, butane, isobutane, and others. The plant consists of feedstock tank farms, raw material purification unit from hydrogen sulfide, block compression, power rectification, and other auxiliary systems.
DCS implementation objectives• Bringing the technological process of oil product
processing in accordance with the current rules and regulations
• Ensuring high reliability and fault tolerance of the control and monitoring system
• Establishing communication with the plant’s CAM system
• Improving the working conditions of installation service staff.
System functionsThe DCS is a full-scale control system and includes an information subsystem, an emergency shutdown and lockout (ESD) subsystem, automatic regulation and remote control subsystems, data collection, visualization and archiving subsystems, etc. In addition to these subsystems, the DCS provides control signals to the fire-fighting and ventilation systems.
System architectureThe DCS is a three-level distributed control system using a client-server architecture.
The 1st (lower) level of the system includes: microprocessor controllers of the ESD subsystem, automatic regulation, remote control and information subsystem. Data is exchanged using an optical communication line. Microprocessor controllers used in the ESD and automatic regulation subsystems are made with 100% hot standby. The information subsystem controllers feature CPU module hot standby. A feature of this subsystem is the exchange of data via the RS-485 interface with an MTL8000 controller.
The 2nd (middle) level of the system includes two database (DB) servers - 100% hot standby. The database servers are designed for the collection and processing of the operational data from controllers and other system users, storage and display of archive information, and its provision to the top level users (operator stations) in client-server mode. Information exchange uses a Fast Ethernet LAN (100% hot standby).
In the 3rd (top) level of the system includes: operators automated workstations, DCS engineer station, Web-server, communication server, plant communication server, printing equipment.
Contact between the upper and middle levels of the DCS is implemented through a Gigabit Ethernet LAN (100% hot standby) technology.
Software• SCADA KRUG-2000® • Controller real-time operating system (RTOS).
The solution is installed at the Kirishinefteorgsintez, LLC.
Gas fractionation plant DCS
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Controlled objectsA methanol recovery plant includes a pretreatment module, distillation module, steam condensate extraction module, and hot water supply module.
The pre-treatment module is designed to remove suspended solids and oil products from produced water, coming from the tank farm (Site 1), due to adsorption of suspended solids and oil products on aluminum hydroxide and quartz sand particles.
The distillation module is designed to extract methanol from pretreated produced water by distillation in a distillation valve tower.
The steam condensate extraction and hot water supply module is intended to return steam condensate, produced due to water vapor condensation in the evaporator, to the boiler house, as well as to heat drinking water, to be used for the plant auxiliary needs, by the heat of steam condensate discharged.
DCS implementation objectives• Improve efficiency and operating reliability of
equipment• Improve system performance• Increase productivity and improve working conditions
of the operating personnel• Bring control systems in line with applicable fire and
explosion safety regulations and standards• Develop a system, allowing further development and
build-up of information capacities.
System functions• Parameter monitoring and alarms• Digital control• Emergency protections• Providing information to process engineers and to
the DCS and C&I departments• Process logging: event logs, mode sheets• Calculations: recording of running hours of pumps
and fans, etc.• Self-testing of DCS elements• Archiving of trends, printed documents, protocols.
SoftwareSCADA KRUG-2000®, including development environment (database generator, graphic editor, script language, etc.) and runtime environment (executable modules of operator/archiving stations, servers and controllers).
DCS for Methanol Recovery Plants
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Components• Controllers with embedded emergency shutdown
and interlock logics, with a 100% “hot” redundancy of their complete configuration.
• Level gauges, connected to the controller via the RS-485 digital interface
• Installation cabinets• Server-based operator – process engineer
workplaces (2 servers). Servers operate in a 100% “hot” redundancy mode and execute the real-time system and backup functions.
• Panel computer, built-in in the cabinet, which functions as an operator – process engineer workplace
• Ethernet local area control network (100% redundancy)
• Printing system, implemented based on a black-and-white laser printer.
ResultsDCS implementation enabled operating personnel to receive comprehensive, objective, accurate and timely information about the operation of the plant. A deep self-testing level, in combination with a number of software and hardware solu-tions, allowed the implementation of sophisticated control and monitoring logics. Integration of digital level gauges into the system, with the possibility of servicing level gauges directly from the operator station, is another important advantage. This solution was implemented at the methanol recovery plant, Site 1, at the Surgut Condensate Stabilization Plant (Surgutgazprom, LLC).
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Controlled objects
Diesel fuel hydraulic treatment plants U-1.732 (LCh-24/11-1000).
Implementation objectives
• Increase operating efficiency• Increase equipment reliability• Improve system performance• Increase productivity and improve working conditions
of the operating personnel• Meet safety requirements.
System functions
Information functions
• Measure and monitor parameters• Detect, alarm and record parameter deviations from
established ranges• Provide manual data input• Generate and provide online data• Backup parameter history on a hard drive• Solve calculation tasks • Analyze interlock and protection activations.
Control functions
• Effect direct digital control of analog regulators by a controller
• Issue, from the operator workstation, task signals to regulators and control signals to analog actuators control signals from a functional keyboard to the controller
• Issue discrete control actions from a functional keyboard to the controller.
Control actions are issued from mimic diagram snapshots.
Discrete actuators are controlled by pressing the buttons “OPEN/ ON”, “CLOSED/ OFF”, “STOP”. The system monitors how commands pass from the keyboard to the monitor and to the controller.
Control commands are of the highest priority as compared to other system functions. The value of control actions and logic status changes are recorded in the Event Log.
Diagnostics functions
• Monitor communication status with I/O modules (controllers)
• Test the state of the controller modules and I/O boards
• Test the level state of input signals, coming from sensors
• Test the status of communication with the system upper level subscribers
• Test communications and status of redundant database servers.
Secondary functions
• Test and perform self-diagnostics of DCS hardware• Reset the system (software reconfiguration)• Differentiate user access rights to control functions
of the system and register user’s entry and exit to/from the system
• Mirror databases and archives at the database server level
• Mirror databases at the redundant controller level• Automatically backup LAN for connection with the
system subscribers• Provide controller redundancy in the protections &
interlocks and control subsystem• Provide detailed screen help• Time correction.
DCS for Diesel Fuel Hydrotreating Plants
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Components
• Controllers are designed with 100% “hot” redundant processor parts
• Database servers with backup and hot redundancy functions, integrated with the operator workstation
• Ethernet local area control network (100% redundancy)
• Installation cabinets• SCADA KRUG-2000®.
Results
The implementation will allow the hydrotreating plant reliability and efficiency to be increased through:
• Implementation of a more sophisticated monitoring and control logic;
• Provide personnel with more detailed, accurate and timely information about turboset operation;
• Improve equipment and technological process diagnostics
• Ensure the possibility of creating an integrated information management system of the enterprise as a whole (at future development).
This solution was implemented at the U-1.732 (LCh-24/11-1000) diesel fuel hydrotreating plant at the Astrakhan Gas Processing Plant (Astrakhangazprom, LLC).
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Controlled objectsLiquefied petroleum gas (LPG) automated custody transfer metering station (ACTMS-LPG), LPG tank farms, LPG loading to tank trucks, truck scales.
DCS implementation objectives• Reduce losses through increased accuracy, validity,
reliability and objectivity of measurements during metering operations
• Timely provide operating personnel with sufficient and reliable information on mass flows during LPG receipt, storage and shipment
• Reduce automation hardware operation and maintenance costs
• Reduce labor intensity during control of LPG receipt, storage and shipment operations and quantitative metering of mass flows.
System functions• Using digital communication channels, acquire data
from the ROTAMASS mass flowmeters, controllers, Sh9329 digital recorders and TVI-023 weighing terminal
• Compute LPG masses and volumes, passing through the metering station
• Display information to the operating personnel onto a color monitor in the form of mimic diagrams, with the indication of parameters in digital, tabular in graph forms
• Generate light and sound alarms in case of parameter deviations from the preset warning and pre-accident boundaries as well as in case of other emergency situations
• Manually input online input data on mass flow movements
• Automatically record mass during at the tank truck entry to the scales, with an automatic net weight calculation
• Automatically generate and issue data to the operating personnel as well as print out deliverables automatically or on request
• Execute the “Winter-to-Summer” and “Summer-to-Winter” transitions
• Provide a multi-user mode of operation, using distribution of access rights to the system by passwords; registration and logging of actions of the persons, who accessed the system
• Automatically generate system event logs• Archive data on a PC hard drive• View process parameter history on a display in the
form of graphs and tables, and print out in a tabular form or as a screen shot copy
• View process parameter history on a display in the form of graphs and tables, and print out in a tabular form or as a screen shot copy.
SoftwareSCADA KRUG-2000®, including: development environment (database generator, graphic editor, programming script language, etc.) and runtime environment (executable modules of the operator station).The library of drivers provides the interaction of the SCADA KRUG-2000® real-time system with various intelligent devices.
ComponentsACTMS-LPG is a two-level distributed system.The lower level includes advanced intelligent devices mounted in controls & instrumentation cabinets.The upper level consists of the operator workplace (operator/ backup station - server with a full scope of the graphic project, with archiving functions).Communication with the lower level hardware is made via the HART, RS485 interfaces.
Automated Custody Transfer Liquefied Petroleum Gas Metering Stations
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ResultsImplementation of the ACTMS-LPG allows the following to be provided:
• Optimize settlements during commercial LPG metering in accordance with all requirements established by the Federal Agency for Technical Regulation and Metrology
• Reduce total error and improve system measurement reliability through the use of a Coriolis flow meter, which directly measures LPG mass flow and outputs data on instant and total LPG mass flow, density, temperature via a single twisted pair.
• Provide personnel with comprehensive operating and archival information about operation of the system
• Minimal maintenance: due to a long-term stability of regulatory metrological performance data of Coriolis flowmeters, there is no need to conduct extraordinary verifications and periodical mounting/ dismantling for preventive maintenance
• “Survivability” of the system, provided by hardware and software solutions, allowing data storage during metering station outages or power interruptions.
This solution was implemented in the LPG tank farm at the Rosneft-Tuapse Refinery LLC (Rosneft, OJSC).
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Controlled objects
Natural gas metering stations.
Implementation objectives
• Ensure effective on-line control over rational use of natural gas due to reduced time required for collecting and processing automated metering data across the whole structural hierarchy of the enterprise, with spreading this control to each concerned department, service and the company management
• Minimize production and non-production costs, reduce natural gas imbalance by key consumption areas through decreased process and commercial losses as a result of increased accuracy of measurements
• Streamline and accelerate mutual financial settlements for natural gas output/ consumption due to early detection of excess consumption and objective automated commercial metering on the basis of applicable standards and regulations.
System functions
The system is designed to effectively monitor natural gas output and consumption, to monitor rational use of natural gas, to optimize mutual financial settlements between gas suppliers and gas consumers on the basis of automated natural gas commercial and check metering.The subsystem provides execution of the following key functions:
• Measure instant and calculate averaged gas temperatures and pressures for specified time intervals
• Measure and monitor quality indicators of consumed natural gas (calorific value, moisture content, etc.), delivered by a gas supply company, through subsystem integration with high-precision gas analyzers and chromatographs
• Calculate thermophysical properties of natural gas, such as density in operating and normal conditions, compressibility factor, dynamic viscosity and other parameters, using the AGA8-92DC and VNITsSMV methods at a known (measured) component composition, and the GERG91 and NX19 methods at the unknown (incomplete) component composition
• Calculate natural gas quantitative parameters f by applying differential pressure methods, using standard orifice plates and averaging pressure tubes (AnnuBar, ProBar, etc.), including: instant and averaged gas flow, gas volume and gas weight values at working and normal conditions for reported time intervals, with the value correction for temperature and pressure
• Calculate natural gas output/ consumption balances by gas consumption areas, and determine regulatory and actual gas loss in each line
• Automatically generate natural gas metering reports for reported time intervals for each gas consumption area.
Components
Controlled object level (gas reducing station (GRS), gas distribution station (GDS)):Equipped with data acquisition and transmission units based on microprocessor controllers, which measure, acquire and process analog and digital signals received from control and measuring transducers (sensors) and intelligent data acquisition and transmission units.
Integrated Custody Transfer Natural Gas Metering Systems
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Supervisory power metering station level:• Communication servers • Dedicated database servers (power metering servers)• Supervisory personnel automated workstations
(power metering АWS), typically developed using the Client-Server architecture
• Automated commercial power metering system engineer AWS
• Web-server.
Software
• The software is implemented based on SCADA KRUG-2000®, including: development environment (database generator, graphic editor, programming script language, etc.) and runtime environment (executable modules of servers and workstations).
• System lower level software is implemented based on the controller real-time system, which allows development of 100% “hot” redundancy diagrams for controllers, processor parts, measuring modules.
Results
The implementation will provide:• Increased reliability and survivability of the system
due to structural redundancy and continuous diagnostics of hardware and software
• Provide operating personnel with comprehensive online and archive information about actual output of consumed gas
• Possibility of integration with a heat metering subsystem and a gas equipment control and monitoring subsystem.
This solution was used for the following projects: • Saransk CHP-2, Mordovenergo OJSC• Saratov Refinery, CRACKING OJSC • Novysalavat CHP, Bashkirenergo OJSC • Penza CHP-1, Penzaenergo OJSC• Mittal Steel Temirtau Metallurgical Plant
(Kazakhstan) • Saratov Heating Lines • Kursk Heating Lines.
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Controlled objectsFlare infrastructure of oil and gas processing plants.
DCS implementation objectives• Bring control systems in line with applicable fire and
explosion safety regulations and standards• Improve efficiency and operating reliability of
equipment• Improve system performance • Increase productivity and improve working conditions
of the operating personnel• Develop a system, allowing further development and
build-up of information capacities. Key system functions
• Parameter monitoring and alarms• Digital control• Emergency protections• Providing information to process engineers, DCS and
C&I departments• Process logging: event logs, mode sheets• Calculations: recording of running (downtime, repair)
hours of pumps and fans, etc.• Self-testing of DCS elements• Archiving of trends, printed documents, protocols.
SoftwareSCADA KRUG-2000®, including development environment (database generator, graphic editor, script language, etc.) and runtime environment (executable modules of operator/ archiving stations, servers and controllers).
Components• Controller with 100% “hot” redundant processor
parts• Flowmeters, connected to controllers via the RS-485
digital interface
• Installation cabinets• Operator control panels developed based on the
ConsErgo® typical universal designs• Operator process engineer workplace (performs the
real-time system and archiving functions)• Ethernet local area control network (100%
redundancy)• Laser printer.
ResultsDCS implementation enabled operating personnel to receive comprehensive, objective, accurate and timely information about the plant operation. A deep self-testing level, in combination with a number of software and hardware solutions, allowed the implementation of sophisticated control and monitoring logics. Integration of intelligent flowmeters into the system is another important advantage.
This solution was implemented for flare systems at the Surgut Condensate Stabilization Plant (Surgutgazprom, LLC), Rosneft-Tuapse Refinery LLC (Rosneft, OJSC).
Flare System DCS
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Implementation objectivesOperating personnel training.
To improve quality of operating personnel training to emergency response assistance plan actions (ERAP), training ERAP subsystems may be embedded in the DCS. This allows personnel training directly at the workplace, without shut down of the control system.
The ERAP training subsystem allows the following
• Train personnel at the workplace• Improve quality of perception of the ERAP
requirements• Analyze wrong actions• Managers at any time at the workplace may check
maintenance personnel skills on ERAP.
Each emergency study case of the training subsystem is a piece of the process flow diagram, with the indication of valves, isolation valves, pumps. Valves, isolation valves, pumps and other equipment are controlled from the monitor screen, using virtual keys. Following completion of all operations, it is possible to automatically evaluate actions, taken by personnel, having compared the result with the correct version.
This system is in operation at facilities belonging to:• Rosneft-Tuapse Refinery LLC (Rosneft, OJSC)• Krasnodar Refinery LLC (Krasnodareconeft,
OJSC)• Novoshahtinsk Refinery Plant, OJSC.
Emergency Response Simulator Integrated in the DCS
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Address: SPC «KRUG» 1, German Titov st., Penza, 440028, Russia
Tel.: +7 (8412) 49-97-75, 49-94-14, 49-72-24, 49-75-34
Fax: +7 (8412) 55-64-96
КР1.80201.БМ.И2.0516