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Best Project Competition 200 8 -20 10 Automatic Control System

This project highlights the implementation of an automatic control system for the separation of shale oil particles, resulting in improved product quality, enhanced safety measures, and efficient data analysis. Our partnership with Schneider Electric and other collaborators has contributed to the successful realization of this project.

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Best Project Competition 200 8 -20 10 Automatic Control System

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  1. Best Project Competition 2008 -2010 Automatic Control System for shale oil particle separation process EKTACO AS Akadeemia tee 21E 12618 Tallinn, ESTONIA Phone +372 654 2150 ektaco@ektaco.ee www.ektaco.ee

  2. Automation As a result of the work performed and as a sign of partnership Schneider Electric granted us Modicon's quality and training certificates for control engineering and technology in 1999. 2004 Schneider Electric Eesti AS granted us the certificate of control system integrators

  3. Automation Application overview • Infrastructure • Shale oil production • Application main task • Produce from heavy shale oil lighter high quality oil • ACS main tasks • Providefaultless and economical as possible automatic control of application processes • Fast and accurate reaction to possible emergency situations in processes • Displaying and saving process data for better quality and later analyze • Main difficulties • Ex environment • Preserve maximal capability to work of system while faults appear in system or devices related to system

  4. Automation Process overview • Heavy oil and petrol will be pumped to blending tank • Particles separation module (centrifuge) will be started with light oil • Heavy oil blended with petrol will be pumped to centrifuge while centrifuge is ready for production • Light (clean) oil goes from centrifuge to light oil tank, heavy fraction (sludge ) to sludge tank • Most of separated heavy oil (sludge) will be transported to factory for reprocessing, little part will be mixed with blended heavy oil for separating process (back to centrifuge)

  5. Automation Process architecture Light oil to storage Centrifuge Petrol Light oil Heavy oil Sludge Mix no 1 Light oil Start tank Sludge Sludge to reprocessing

  6. Automation ACS implementation methodology • For its high work capability and good efficiency Unity Quantum CPU65150 was used to guarantee realization of system requirements. Configuration of PLC includes backplane expansion • For satisfying system high safety requirements Preventa XMF3502 was used • For displaying process data, notifying about emergency situations and saving meter’s data Monitor Pro was used • For displaying process in operators computer was used one picture over 4 monitors • New Workstation with 2 monitors was added for supervisor of main control room

  7. 140CPS22400 140DDO35300 140DDO35300 140DAI75300 140DAI75300 140DAI75300 140DAI75300 140DAI75300 140DDI35300 140DDI353000 140XBE10000 140XBE10000 140ACO13000 140ACO13000 140ACO13000 140ACI04000 140ACI04000 140ACI04000 140ACI04000 140ACI04000 140CPU65150 140CPS22400 x x x x x e e e e e Automation ACS architecture Process control room Main control room Switch MOXA Switch 499NES25100 Operator workstation Monitor Pro client Supervisor workstation Monitor Pro client MonitorPro server Safety PLCPreventa UPS XPS MF3502 + MF2DO1601 230 VAC/ 24 VDC TWDLCAE40DRF TWDLCAE40DRF MODBUS MODBUS MODBUS MODBUS Process Sensors and actuators E+H flowmeters E+H flowmeters Sensorsand actuators

  8. Automation Realization • Main services provided • ACS design • ACS control cabinets’ design and implementation • Meters supply and mounting • PLC and SCADA algorithms design and coding • System tests, employees training and start–up • Main products used • Unity Quantum CPU65150 with backplane expansion • Unity Pro XL V3.0 • Safety PLC Preventa XPS MF3502 with MF2DO1601 • ELOP II Factory • OPC Factory Server V3.2 • Monitor Pro 7.6 server and 2 clients • Microsoft Server 2003 for system server and XP Pro for clients

  9. Automation Gallery Block of heavy oil particle separation Control cabinet 1 with Quantum Backplane no1 and Twido Control cabinet 2 with Quantum Backplane no2 and Preventa Operator’s workstation

  10. Automation Customer benefits • Automatic control over process improves product quality • Automated monitoring and control of process increases safety of employees, environment and process related devices • Continues saving of process data allow later analysis and through analysis results enhance the system • System is scalable if necessary • Competent support is phone call and if really necessary few hours drive away

  11. Automation Our Partners We thank all our partners in this project, especially: • Schneider Electric – our long time partner and supplier of automation products and support • EE Tehnoloogiatööstus AS – mounting of meters and actuators • EE Elektrotehnika ja automaatika AS – in field cable works, electrical connections of meters and actuators Thank You!

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