DESIGN OF APCS SYSTEMS

APCS – Automated Production Control Systems

Design and development of APCS systems is a process focused on increasing the productivity of industrial enterprises. In particular, an automated process control system is necessary when the technological processes used at the enterprise are of a complex cyclical nature and do not allow failures that can entail significant material losses.
The main types of enterprises for which the APCS are most relevant:
  • grain elevators;
  • oil extraction plants;
  • food processing plants;
  • oil industry enterprises;
  • enterprises for transshipment of ore, coal, etc.
The goals of creating an automated process control system are:
  • Ensuring reliable and trouble-free operation of production;
  • Stabilization of operational parameters of technological equipment and operating parameters of the technological process;
  • Improving the qualitative and quantitative indicators of products;
  • Reduced operating costs;
  • Prevention of accidents;
  • Automatic and automated equipment diagnostics.
Competent implementation of the ACS TP minimizes the likelihood of the human factor affecting work and, as a result, allows you to increase the quantity and quality of products. The company “Ksimex” has the necessary engineering and installation resources to provide services in the design of process control systems:
Design

Supply of equipment
for the control system

Assembly, installation and

commissioning of APCS

at the customer’s site

Technical and engineering support of the implemented system throughout the entire cycle

The result of the design and implementation of an automated process control system is a completely ready-made infrastructure that is maximally adapted to the customer’s facility.

APCS DESIGN STAGES

COMMUNICATION WITH THE CUSTOMER
Before the implementation of the project, a mandatory stage is contact with the Customer, setting the task, researching the object and drawing up the technical task. In this case, the mandatory points are:
  • Justification of the need to create an automated process control system;
  • Formation of target requirements for APCS;
  • Object research and data collection about the automation object;
  • Formation of the Customer's requirements for the APCS:
  • acceptable development costs;
  • commissioning and operation;
  • the expected effect from the introduction of the APCS system.
  • Development of the concept of the APCS;
  • Development and approval of technical specifications for the creation of an automated process control system together with the customer;
  • Formation of a forecast for increasing productivity, as well as economic efficiency from the introduction of APCS
DESIGN
At all stages and stages of designing an automated process control system designers are guided by state standards Unified system of standards for automated control systems (ESS ACS).
An automation project usually consists of the following sections:
  • technical specification (requirements);
  • structural and functional diagrams of automation systems;
  • electrical schematic diagrams;
  • connection diagrams;
  • assembly drawings;
  • plans for the location of equipment and laying cable routes;
  • Bill of materials and equipment;
  • local estimate for installation and adjustment of automation equipment;
  • explanatory note;
  • passports and operating manuals.
TECHNICAL SPECIFICATION (REQUIREMENTS);

The most important document in the design is the terms of reference (TOR). TK is a document that provides comprehensive information on how exactly the work should be done. The Terms of Reference is drawn up in close cooperation between the Contractor and the Customer and must be performed in such a way that:

 

  • The customer, after the execution of the project, received exactly the product he wanted;
  • The customer spent a minimum and sufficient amount of funds on the modernization;
  • The contractor completed The work for The minimum and sufficient time for this.
SCHEME STRUCTURAL AND FUNCTIONAL SCHEME

The structural diagram of a complex of technical means is developed at the initial stages of design and precedes the development of other types of circuits. The diagram defines the main functional parts of the product, their purpose and the relationship between them. The diagram shows the principle of operation of the product in its most general form.

 

The functional diagram is intended to explain the processes occurring in individual functional circuits of the product or the product as a whole. The diagram shows the functional parts of the product (elements, devices, functional groups) and the connections between them. The graphical construction of the diagram clearly reflects the sequence of functional processes occurring in the system.

ELECTRICAL DIAGRAMS
Basic electrical diagrams are the most demanded document among operating units (power engineering service, instrumentation service). The diagrams determine the full composition of instruments, apparatus and devices, as well as the connections between them, the action of which ensures the solution of problems of control, regulation, protection, measurement and signaling. They serve as the basis for the development of other project documents: assembly tables for switchboards and consoles, external connection diagrams, etc. Each schematic diagram is completed with a list of elements indicating the manufacturers and articles of the equipment used, which allows, in the event of a repair, to quickly determine the necessary equipment.
ASSEMBLY DRAWINGS
An assembly drawing is a document that is executed at the stage of development of working documentation based on a general view drawing and which indicates the location of all component parts of the product, for example, all electrical components (contactors, relays, frequency converters) on the control panel mounting panel. The drawing is the main document for the assembly of switchboard equipment.
CONNECTION DIAGRAMS
The connection diagrams show all connections between the system elements (panels, sensors, junction boxes, etc.), indicating the types and lengths of cables, as well as the numbers of terminals and terminal groups. Together with the plans for the location of equipment and the laying of cable routes, this document is the main one at the stage of installing the control system and laying cable communications.
PLANS FOR EQUIPMENT LOCATION AND CABLE LAYING
The plans for the location of equipment, electrical wiring, panels, consoles are drawings and sections of industrial premises and outdoor installations with an indication of the location of all instruments and automation equipment, as well as the ways of laying electrical and pipe wiring at each specific site.
Bill of materials and equipment;
The BOM is the main design document, which indicates absolutely all products and materials that make up the designed system. In addition to the quantitative composition, the specification also indicates the manufacturers and articles of the equipment used, which makes it possible to unambiguously determine the required delivery set and generate the necessary documents for ordering products.
ESTIMATE DOCUMENTATION
In the local estimate, the cost of purchasing equipment, products and materials is calculated according to the current cost, as well as the cost of installation and commissioning works according to the state resource element estimate standards for installation and commissioning work.
EXPLANATORY NOTE
The explanatory note to the project describes in detail the principles of project implementation, namely:
  • Goals and tasks solved by the control system;
  • Work principles;
  • The applied system of connections between the components of the system, as well as connections with external systems;
  • The types of equipment used;
  • The advantages of the solutions used;
  • System development opportunities for potential upgrades.
PASSPORTS AND OPERATING MANUALS

With large multi-level control systems, which include a large number of components – control panels, operator stations, data processing and storage servers, each large product is completed with a passport (PS) and an operation manual (OM). The OM describes the purpose of the product, its place and functions in the general control system, describes the purpose of the controls and indicators, and provides equipment control schemes.

 

In addition, the OM describes in detail the menu systems, as well as the sequence of operator actions for the correct commissioning of the equipment, correct operation throughout the entire period of operation, as well as the operator’s actions in case of emergency situations.

 

The operating manual is completed with the necessary diagrams, illustrations and drawings necessary for a complete understanding of the principles of correct, efficient and safe operation of the product.

 

In the passport for the product, the necessary marks are indicated that the device has been tested at the technical control site of the contractor, all the parameters of the product fully comply with the requirements stated in the design specification. Also in the passport for the product, the delivery set is described and the warranty obligations are indicated.