Our engineers and designers are experienced in programming, design
and integration. At Rakurs we offer control and automation services,
from conceptual design through system configuration, assembly and onsite
commissioning to operator training, diagnostics, maintenance and upgrades.
We have experience in a multitude of control applications, including
batch, continuous, and advanced process control. Our services cover:
- Pre-engineering: inspection of automated objects, collecting data
and preparation of an initial inventory.
- Design: detailed specification of a proposed solution, preparation
of design documentation in accordance with Russian and international
standards.
- Development: software development at all levels of control (PLC,
NT, SCADA)
- Manufacturing, assembly and integration of control systems.
- Installation and start-up adjustments.
- Support and maintenance: warranty and post-warranty.
- Training: Onsite training for operators. Specialist engineers are
being trained at the Rakurs Authorized Training Center in St. Petersburg.
- Upgrades and modifications: modification to meet process changes,
reprogramming, reconfiguration and expansion of control systems.
We have designed and developed two unique Process Control Systems
(PCS). These two products stand at the base of the design and engineering
accomplishments of Rakurs. Our two Process Control Systems are:
- PCS Apogey
- PCS STC-ER (System of Technological Control-Electrosila Rakurs)
Our systems operate successfully at the largest industrial enterprises
in Russia and abroad. We have completed more than 200 turnkey projects
for satisfied clients.
Process Control System Apogey
PCS Apogey is a fully integrated remote distributed control and monitoring
system, which is used to operate boilers, turbine, generators and other
equipment of industrial enterprises and power plant.
Functions:
- Continuous automated management control of technical equipment
(e.g. boilers, turbine generators or production lines) during different
operational modes, such as start up, long runs with fixed operating
parameters or emergency shutdown. Allows the operator to set parameters
for automated operation, including remote management control of individual
equipment units.
- Provides all required interlocking and protection logic and
systems, as required either by the operator, conform manufacturer
specification and/or relevant operating manuals. Interlock and protection
can be disabled automatically using programmable algorithms or by
manual override; the system also includes a protector-testing programming
mode.
- The system monitors performance and processes data for use by
the operator: it sends out alerts when threshold parameters are
exceeded, monitors the state of the equipment, logs and archives operating
data, tracks operating conditions, and prints logs and graphs per
shift, day, month or other time sequence.
- Control of operating conditions using simple or complex regulators.
Design configuration is determined by the requirements of the automated
system, employing P, PD, or PID controls in combination with additional
mathematics intended to enhance their performance. From his terminal,
the operator can switch certain regulators between automatic operation
and remote operating control.
- Maintains an archive of parameters and events. The parameter
archive stores all analog signals coming into the PCS. Archiving discontinuity
does not exceed 5 seconds. The event archive stores commands generated
by the operator and by the PCS, it includes equipment performance
data, status of events triggered by the protection systems, and alarms
and system malfunctions. Discontinuity of information archiving does
not exceed 0.5 seconds; archived data is stored up to 4 days.
- Creates and keeps an accident data archive. This archive,
which can store up to 10 accidents, was designed specifically to conduct
accident analysis. In the case of an accident all data received by
the PCS is recorded at the highest frequency starting from 50 minutes
before until 10 minutes after the event ('last hour' algorithm).
- PCS Apogey shares information across the entire company.
Data access is built in during design configuration.
- The PCS troubleshoots all equipment and performs self-diagnostics.
Operational problems trigger an alert for the operator.
This PCS is used in building automated control and operating systems
- Dispatching Control Systems - with which to control and manage information
at the level of individual production units, or to integrate the systems
to manage and control the production process for an entire plant. The
system can be programmed for different operating conditions, ensuring
long-term accident-free performance efficiency and reduced running costs.
Background to the development of PCS Apogey
Implementation of automated systems of control is one of the ways to
increase the effectiveness of main and auxiliary equipment. The creation
of automated dispatching control systems provides the tools to manage
the resources of the organization as whole. Having worked in the automation
market since 1991, Rakurs accumulated extensive experience in solving
our clients' tasks in managing complex technological processes. Based
on this experience, we have created a multi-functional Process Control
System, which is used in building automated control and operating systems
for complex technical installations.
When asked by clients to solve automation and control issues in the
production process, Rakurs identified two main problems that needed
to be addressed: how to collect primary information necessary for managing
the entire production process, and how to get different systems to talk
to each other. Achieving this requires a fully integrated dispatching
control system, based on PCS Apogey that consists of a three level structure
with a distributed network responsible for collecting and processing
information. The first consists of a network of programmable controllers
that collects and processes primary information. The second is a dispatching
control system that controls and manages data for a specific production
unit. The third level represents the dispatching control system capable
of controlling and operating the entire plant.
The system checks connections in the entire network: programmable controllers,
sensors and servers and issues warning signals. In order to avoid data-loss
between data collector and server, the controller accumulates and stores
data, and passes it to a server after the damaged part of the network
has been repaired.
Process Control System STC-ER
"There is no reason to economize on diagnostics; repairs turn
out to be more expensive."
PCS STC-ER: System of Technological Control-Electrosila Rakurs
is a control and monitoring system expressly created to run turbine
and hydroelectric generators and their auxiliary systems. The system
was developed jointly with Electrosila, the largest turbine manufacturer
in Russia. It provides continuous control of operating and external
conditions; provides alarms and warnings when threshold parameters are
exceeded; and provides interlock and protection and accident prognosis.
Systems operating on the basis of PCS STC-ER have wide capabilities.
Functions:
- PCS STC-ER provides continuous control of operating conditions
and performance of turbine units. It has the ability to shut down
the unit in the event of an emergency and sends out alerts when threshold
parameters are exceeded. The system can be set for five levels of
control and protection for each given parameter.
- Calculates set parameters based on recorded measurements.
- Performs continuous sensor-diagnostics and system troubleshooting.
Diagnostics cover the entire spectrum of sensor functioning from overload,
short-circuit or measurement malfunction to interface with the PCS
programming.
- Issues onscreen warnings and alarms on operator terminals
and at the plant central control station. Any deviation from normal
operating conditions of the generator and auxiliary equipment is automatically
registered on paper and magnetic tape information carriers.
- Programmable terminals permit operators to display and input
information in a dialog mode.
- Provides graphical representation of all technical or computed
parameters recorded; graphs can be shown for any selected time period.
- Provides work shift reports and registers abnormal conditions
('last hour' algorithm).
- Includes/excludes a measuring channel from data processing. If
a sensor becomes non-operational the channel will be automatically
removed from the system until repaired while all other channels remain
operational, thereby preventing false alarms and warnings. The operator
resets the sensor after repairs.
- PCS STC-ER is an integrated component of the process control
system of the entire plant.
Additional functions (optional):
- Forecasting of potential emergency situations, with alerts
issued and recommended solutions proposed.
- Providing calculations and storage of statistical data on
equipment and system reliability, operating conditions and creation
of diagnostic algorithms.
- Keeping an archive with stored-data analysis and operating
performance evaluations.
- Monitoring of weather conditions and equipment diagnostics.
Introduction and Background: the idea behind the PCS STC-ER
The life expectancy of hydroelectric and turbine generators and their
control systems can differ drastically. Whereas a complete overhaul
of hydroelectric and turbine generators typically is needed every 30
to 50 years, the control systems become old and outdated in 8 to 15
years. The most crucial phase for the means of control of technological
equipment begins when the technical life of the main generator comes
to its end.
In fact, during the early stages of a generators' exploitation, the
means of control tend to indicate a small number of defects and help
to protect the equipment from errors committed by personnel. After operating
the equipment for many years however, the number of defects increases
and their nature becomes more varied. If, during the first years of
operation the use of diagnostic algorithms can predict the character
and possible time for the occurrence of faults relatively easily, by
the end of the technical life of a generator such operations demand
thorough analysis of its operating history.
Given the different life expectancy of turbine generators and their control systems,
by this time the latter has become outdated a long time ago. It then
becomes very difficult or practically impossible to achieve the main
goal of diagnostics - to receive full and reliable information about
the condition of the generator and to plan repair work and maintenance
correctly.
How PCS STC-ER solves the problem
The majority of Russian companies and a number of foreign clients do
not have the ability to buy diagnostic systems together with generators.
They are much more expensive than control systems. In order to overcome
this barrier, the measuring channels of control systems must measure
information not only for control but also for diagnostic purposes. The
solution to this problem is to create the means of control with increased
capability and high reliability, which incorporates the possibility
to reconstruct the process being controlled, without losing accumulated
information about the generator' exploitation, and including the possibility
to add programming modules to the basic setup to accommodate the changing
goals of control and diagnostics. The Process Control System STC-ER
is an example of a system that meets with all these requirements.
The capabilities of PCS STC-ER are not limited by the ongoing goals
of monitoring and diagnostics. The same equipment is used for testing
and function diagnostics, i.e. work performed by personnel on a non-working
generator. Another important advantage of the system is the possibility
of storing data about the condition of the generator and its auxiliary
systems. Finally, it should be noted that the launch of the system takes
only two days; it amounts to checking whether the external cables are
connected properly and putting all necessary parameters and set points
into operation.
The Result
From the launch of the system 8 years ago, it has proven its reliability
and ability to work under the adverse conditions that are characteristic
for the functioning of hydroelectric and turbine generators. Today PCS
STC-ER is being mass manufactured and successfully functioning in the
largest Russian enterprises, such as Kolskaya Nuclear Power Plant, Biblinskaya
Nuclear Power Plant, Tianwan Nuclear Power Plant (China), Krasnoyarksya
Hydro Power Plant, Karmanovskaya Power Plant, Kanakovskaya Power Plant
and many others.
In total Rakurs has developed, produced and launched more than 60 systems
for hydro and turbo generators from 6 MW to 1000 MW.
