Concrete production stations

Application theme
Automation of concrete production stations, with variable number of silos.
Beneficiary requirements
The customer wants a software solution that can control a concrete production station. The software must be configurable to control stations with variable number of silos and 2 types of skippers. The program must be able to create recipes, control the equipment for concrete production according to the recipe and generate reports and receipts. The control must be carried out with the minimum intervention from the operators and to communicate to them in a simple way to understand all the damages and the conditions in which the station is.
Technical solution
For the client for whom we created this software, we used a PLC from Omron to control the station and a SCADA program created on the National Instruments platform. The recipes are saved in PC databases and sent to the PLC for dosing the materials and transporting them to the mixer. For each order received, the program issues reports and vouchers.
Results
• A software has been created that can be used for a wide range of stations
• A control has been obtained with minimal intervention of operators
• Operators can intervene very quickly and punctually when a fault occurs
• Tracking the status of the station and sensor calibration was made easy
• Operation monitoring can be done locally or remotely, rapid intervention on the system being possible

Assembly stations and assembly lines

Application theme
Automation of assembly stations and assembly lines in the automotive industry.
Beneficiary requirements
The customer wants a software solution through which the semi-automatic and automatic assembly stations and the assembly lines can be controlled, which involve the connection of several assembly stations. Each software must be designed for a specific station, stations that are usually unique.
Technical solution
We chose an automation with S7 300 and S7 1500 PLC and HMI from Siemens. For these works we decided to design the automation electrical panels. Each program created was unique, adapted to each theme. We have chosen to present here not a specific project but our experience in creating programs for the automotive industry, expanding the development area to other areas that require assembly stations.
Results
• We have created a programming standard for this type of applications
• We have created predefined functions with which we can quickly assemble the programs
• We deliver control software through which the operators' intervention on the machines is minimal
• Operators can intervene very quickly and punctually when a fault occurs
• It is easy to track the status of stations
• We have implemented a remote monitoring system for fast support provided remotely

Water pumping stations

Application theme
Automation of water pumping stations, with pressure and level control and remote communication.
Beneficiary requirements
The customer wants a software solution that can control the water pumping stations. It is desired to maintain a constant pressure, taking into account the water level. The stations must operate without the intervention of the operators and be monitored and controlled remotely.
Technical solution
We chose an automation with PLC and HMI Siemens and communication through GSM router, connecting the stations with the dispatcher through VPN tunnel. We chose to use frequency converters for PLC controlled pumps, to control the starting current and to maintain a constant pressure. The cascade of the pumps and the uniformity of the operating hours of the pumps were two conditions that we had to respect.
Results
• We have created a control of the pumping stations that does not require the intervention of the operators
• Their monitoring and control is done from the central dispatcher and they are notified about the occurrence of any damage
• The operators can intervene very quickly and punctually when an error occures
• The status of the stations can be easily tracked
• We have implemented a remote monitoring system for fast support provided remotely

Pelton turbine micro hydropower plants

Application theme
Automation of micro hydropower plants with Pelton turbine for non-polluting electricity production.
Beneficiary requirements
The customer wants a software solution that can control micro hydropower plants with Pelton turbine for energy production, which generates a power of 1 MW. The program must control the water jet that drives the turbine blades to maintain a constant imposed electrical power. The program will take into account the upstream water level. Control and monitoring through SCADA program with client server configuration is needed, with the possibility of remote connection.
Technical solution
We chose an automation with PLC and HMI Siemens, communication via GSM router and monitoring via SCADA Zenon. The program regulates the amount of water used to turn the turbine according to the electrical power that the generator must produce. Micro hydropower plants are built in cascade, so the water discharged by one plant is used by another plant, which creates the problem of monitoring the water level.
Results
• We have created a control of the plants that do not require the intervention of the operators
• Their monitoring and control is done from the central dispatcher and they are notified about the occurrence of any damage
• The operators can intervene very quickly and punctually when a damage occurs
• It is easy to track the status of the plants
• We have implemented a remote monitoring system for the rapid support provided remotely

Francis turbine micro hydropower plants

Application theme
Automation of micro hydropower plants with Francis turbine for non-polluting electricity production.
Beneficiary requirements
The customer wants a software solution that can control micro hydropower plants with Francis turbine for energy production, which generates a power of 1 MW. The program must control the water jet that drives the turbine blades to maintain a constant imposed electrical power. The program will take into account the upstream water level. Control and monitoring through SCADA program with client server configuration is needed, with the possibility of remote connection.
Technical solution
We chose an automation with PLC and HMI Siemens, communication via GSM router and monitoring via SCADA Zenon. The program regulates the amount of water used to turn the turbine according to the electrical power that the generator must produce. Micro hydropower plants are built in cascade, so the water discharged by one plant is used by another plant, which creates the problem of monitoring the water level.
Results
• We have created a control of the plants that do not require the intervention of the operators
• Their monitoring and control is done from the central dispatcher and they are notified about the occurrence of any damage
• The operators can intervene very quickly and punctually when a damage occurs
• It is easy to track the status of the plants
• We have implemented a remote monitoring system for the rapid support provided remotely

Compressed air production

Application theme
Compressor automation for compressed air production.
Beneficiary requirements
The customer wants a software solution through which compressors for the production of compressed air can be controlled. The installation contains 4 air compressors that must constantly supply compressed air at a pressure of 6 bar. Depending on the demand for compressed air, the compressors will run one at a time or all at once. The cyclicity of the compressors and the uniformity of the operating hours must be observed.
Technical solution
We chose an automation with PLC and HMI from Omron for the small number of inputs / outputs and communication through web server to HMI for a remote control. The program gives the possibility to choose which of the 4 compressors to work, and starts them according to a sequence established according to the demand for compressed air. In case of continuous operation, the program ensures that all compressors are started in turn, operating for a period of time, to standardize operating hours.
Results
• We created a control of the compressors that do not require the intervention of the operators
• Monitoring and control is done locally and remotely
• Operators can intervene very quickly and promptly in the event of a fault
• Status of compressors can be easily tracked
• We have implemented a remote monitoring system for fast support provided remotely

Heating control of technical rooms

Application theme
Temperature control in the technical rooms where the air compressors and the adjoining rooms are located.
Beneficiary requirements
The client wants a software solution through which the temperature inside the technical rooms can be controlled. Compressed air compressors produce heat in the compression process. This heat can be used to heat the technical rooms during the winter. A heating system at a set temperature of the technical rooms using the air heated by the compressors is desired.
Technical solution
We chose an automation with PLC Schnider and control with blinds. The system measures the indoor and outdoor temperature, and based on the temperature set for the interior, the blinds for the heating or cooling of the technical rooms act proportionally.
Results
• We have created a temperature control that does not require operator intervention
• The heat produced by the compressors can be used for heating, which reduces the consumption of additional resources.

Air control in Magurele laser building

Application theme
Control of temperature, humidity and pressure in the clean rooms of the laser building in Magurele.
Beneficiary requirements
The client wants a software solution that can control the temperature, humidity and air pressure in the clean rooms in the laser building in Magurele. Control of rooftops and fans intended to supply air to these rooms was requested.
Technical solution
We chose an automation with PLC and SCADA from Honeywell. The automation system consists of central PLC and distributed I/O modules with Ethernet communication. The SCADA program has the role of monitoring and control, facilitating remote access and connecting the system to the central dispatcher.
Results
• We created an air control that does not require the intervention of operators
• Monitoring and control is done remotely
• Operators can intervene very quickly and punctually when a fault occurs
• Values for each room can be easily tracked
• The program generates reports and warns about anomalies

Monitoring the power supply panels at the children's hospital in Bucharest

Application theme
Monitoring the condition of the fuses in the power supply panels.
Beneficiary requirements
The customer wants a software solution that can monitor the status of the fuses in the power supply panels.
Technical solution
We chose an automation with PLC and SCADA from Adam. The automation system consists of central PLC and distributed I/O modules with Ethernet communication. The SCADA program has the role of monitoring and control.
Results
• The maintenance team sees in real time the state of the fuses in the panels
• The monitoring is done remotely
• Operators can intervene very quickly and punctually in the event of a fault
• The condition can be easily tracked for each safety
• The work of the maintenance team is facilitated

Gas control in Silistea and Onesti gas compression stations

Application theme
Control of gas transport in gas compression stations in order to raise the gas pressure to be transported on the bus.
Beneficiary requirements
The customer wants a software solution to ensure the safe transport of gas to and from gas compressors, depending on established scenarios. It is necessary to provide a safe operation in all cases of damage that may occur.
Technical solution
We chose an automation with PLC and SCADA from Allen Bradley. The automation system consists of two central PLCs and I/O modules. One PLC is in a redundant configuration for station isolation scenarios in case of emergency and the other for measuring gas parameters and transporting it through the station. The SCADA program has the role of monitoring and control, facilitating remote access and connecting the system to the central dispatcher.
Results
• We created a gas transmission control that requires a minimum intervention of the operators
• We created the monitoring of the gas parameters with the real-time analysis of the measured values
• We have created a quick warning system for an accident, which helps operators to quickly identify problems
• Redundant communications were used between equipment so as not to be affected by damage on the route
• The program generates reports and warns about anomalies
• The status of stations can be tracked remotely through web applications