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Process Control System for Foam Polystyrene Granule Production Plant

This project involves the implementation of a process control system for a foam polystyrene granule production plant. The automation system includes I/O signals, control loops, redundant controllers, safety system modules, operator stations, and network equipment. The project was developed by Toyo Engineering Corporation, with software and equipment supplied by SIEMENS AG. The implementation includes the use of SIMBA software and PCI modules for debugging and validation purposes.

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Process Control System for Foam Polystyrene Granule Production Plant

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  1. Customer:Penoplex TownKirishi Process / plant name “Process control system for the foam polystyrene granule production plant” Automation object properties I/O signals – 900 Control loops – 35 (including complex cascade control loops) Automation system properties Redundant controllersSimatic S7-417H-F Decentralized peripherySimaticET-200M, safety system modules – F-modules,AddFEM modules Redundant operator stationsSCADA WinCC (PCS7) Network equipment – Simatic Net Industrial Ethernet Adjacent systemsPeletizer – protocolProfibus (Y-Link – module) BONO (Italy) - protocolModbus About the project About the project

  2. Process flowsheet Process flowsheet Notes

  3. Process flowsheet Process flowsheet

  4. Automation system architecture Engineering station Operatorstations Alarm panel Color printer Report printer Alarm message printer Laser printer Automation system architecture Industrial Ethernet (ESM) – Ring type bus AS 417HF Safety System F – modules Remote I/O signals DCS system ESD system (SIL 3 /AK 6)

  5. Polystyrene production plant was developed by Toyo Engineering Corporation (Japan) The project – initial data was prepared in Japan Software and PCS7 equipment were supplied bySIEMENSAG (Germany) Partner – SPIK SZMA, Saint-Petersburg, Russia Features SIMBA software and PCI module were used to debug and validate the DCS and ESD programs. The same tools were then used to demonstrate the working applications to the customer during FAT.. Implementation of H-F system Redundant PID Control Loops were implemented using redundantAddFEM modules Specific requirements to the alarm massage protocol and emergency alarm algorithm (first out alarm): alarm source detection, alarm grouping by priorities. Notes Notes

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