Development of PAS, ACS

PROCESS AUTOMATION SYSTEMS / AUTOMATED CONTROL SYSTEMS

Our experience – for the success of your business! WAITING FOR YOUR APPEALS!

“EC “Teredo” LLC provides a full range of services for the implementation of PAS (ACS). Development, design, manufacturing, integration of PAS (ACS) on a “turn-key” basis.

Read more about our experience with the development and implementation of PAS (ACS).


NAVIGATOR ON THE PAGE:
  1. Field Devices layer
  2. Automatic and Supervisory Control layers
  3. Functions of PAS
  4. Specialised performance
  5. Resistance to external factors of influence
  6. Safety, compliance with technical regulations (directives), certification
  7. Warranties
  8. Quality of PAS
  9. Advantages
  10. Examples of completed projects

Organisational scheme of automation of production management processes, marked PAS
Organisational scheme of automation of production management processes

PAS is a complex of technical and software means goals to control the technological processes in the industry (Industrial Automation).

The PAS in general has a three-layer architecture:

  1. Field Devices layer
  2. Automatic Control layer (using PLC)
  3. Supervisory Control layer (using SCADA)

1. Field Devices layer

At the field devices layer we work with sensors (converters, analysers) and actuators of any manufacturers, connected by using any analogue, digital (discrete), pulse, network communication interfaces.

More about analogue communication interfaces

We have direct experience (design, selection, assembly, connection, adjustment) with the following analogue interfaces:

  • potential: 0…10 V || -10…+10 V || 0…5 V || 1…5 V (differential connection, common wire connection)
  • current: 0…20 мА || 4…20 мА || 0…5 мА (differential connection, common wire connection)
  • thermocouples: K, J, T, E, N, R, S, B with isolated and non-isolated hot-junctions, differential thermocouples, connection with thermocompensation and copper conductors, cold-junction temperature compensation, thermostatting of cold-junctions, thermocouple batteries
  • ohmic: Pt100 || Pt1000 || jPt100 || 50П || 100П || 1000П || 50М || 1000М || Cu50 || Cu100 RTD’s etc. (2, 3 and 4-wires connection schemes), NTC || PTC semiconductor thermistors (thermistors) and rheostats
  • inductive: 0…10 mH || -10…+10 mH (2, 3 and 4-wires connection schemes)
  • frequency: 0…1/ 4/ 8/ 16 kHz
  • strain gauges: connection of strain gauge bridge sensors
  • potentiometric: potentiometers connection (voltage dividers, 3-wires connection scheme)

More about digital (discrete) communication interfaces

We have direct experience (design, selection, assembly, connection, adjustment) with the following digital (discrete) interfaces:

  • common: input / output signals 24 V DC/AC || 110 V DC/AC || 220 V AC (Galvanic isolation via intermediate relays; Commutation of resistive, inductive and capacitive loads; Small currents up to 10 mA; Integrity control; Electromagnetic compatibility [EMC], Contact bounce mitigation, Algorithms of sequential automatic commissioning of power supply units)
  • high-speed pulses: Input / Output pulse signals (control of frequency inverters, signals from encoders)
  • pulse width modulation (PWM): for stabilisation tasks, regulation
  • pulse-frequency modulation (PFM): for stabilisation tasks, regulation

More about network communication interfaces

The most common digital interfaces for field devices are 2- and 4-wire RS-485 / EIA-485 (topology bus) and CAN (topology bus). Slightly less common is the 4-wire RS-422 interface (point-to-point topology). We have direct experience (design, selection, assembly, connection, configuration) with the following protocols of the digital interface RS-485 / EIA-485:

  • Modbus: ASCII, RTU for sensors communication
  • Modbus: ModbusTCP for PLC’s communication, for communication between PLC and remote input/output modules, for communication between PLC and PC
  • Profibus: DP, PA for communication with sensors, for communication between distributed PLC’s, for communication between PLC and PC

We have direct experience (design, selection, assembly, connection, configuration) with the following protocols of the digital interface CAN:

  • CANopen
  • DeviceNet

We also use the HART protocol for communication with sensors.

Actuators are electric motors [of pumps, compressors, exhauster’s, gate valves, etc.], servo drives, electric, pneumatic, hydraulic valves, etc.

In the presence of technological conditions or specifications (installation location, working conditions, etc.), we carry out the selection of measuring equipment and actuators.

2. Automatic and Supervisory Control layers

Technical means of the automatic (middle) and supervisory (upper) layers are often combined under the name of SHC – software and hardware complex. The technical equipment of SHC in the complex perform functions of measurement, control, regulation, archiving and display (dispatching).

At the automatic layer programmable logical controllers (PLCs) are used. Controllers perform next functions: measurement, control, regulation, signalisation, diagnostics, protection, blocking.

Operator panels / terminals (HMI) are used for local information display and managing mechanisms and system settings. In our applications we have the experience of using the operator panels of the following manufacturers: Mitsubishi, Siemens, Omron, Weintek, Advantech.

Technical means of automatic layer, as a rule, are performed in the form of electrical cabinets, panels, control desks.

The heart and brains of the PAS | ACS of our production are analog, discrete and digital Input / Output modules of aggregated complexes (controllers):

  • Mitsubishi Electric: F, iQ-F, L, Q, iQ-R series
  • Siemens: S7-1200, S7-1300, S7-1500 series
  • Omron: CJ, CS, CP series

To reduce the cost of PAS for less critical objects, we can use Input / Output modules of Advantech, ICP DAS (and other similar) and controllers Danfoss, OWEN (ОВЕН).

On the Supervisory Control layer servers and computers of industrial or non-industrial performance are functioning. In our applications, we have experience of using servers and computers of the following manufacturers: HPE, Advantech, NEXCOM.

Servers and computers are the platform for the functioning of the Database Management System (DBMS) and Dispatch Program. We build our Dispatch Programs based on SCADA. In our applications, we have experience of using the following SCADA: CitectSCADA, IgnitionSCADA, Intouch, OpenSCADA.

The connection between technical means of the Supervisory Control layer and Automatic Control layer realises via network interface Ethernet.

Measurement channels of SHC, if necessary, undergo the procedure of metrological confirmation in accordance with the procedure established by law with documentation formalisation.

3. Functions of PAS

Functions to be performed by the PAS depend on the task and the conditions for they implementation. The list of functions is usually stated in the Technical Specifications.

TEREDO has experience in the development and implementation of PAS with the following functions:

  • measurement, conversion and primary processing of input analogue and digital (discrete) signals;
  • information exchange (reception / transmission) via different network communication interfaces and protocols: Ethernet (TCP/IP, UDP/IP, Ethernet/IP, CC-Link etc.), RS-485 (Modbus, Profibus, CAN etc.), HART etc;
  • reliability control of input analogue, digital (discrete), network signals;
  • on-line diagnostics of process equipment;
  • alarming and signalisation;
  • technological protection;
  • blocking;
  • parameter regulation and stabilisation
  • execution of calculation and diagnostic tasks;
  • Scheduling and Recipes;
  • archiving of technological, technical and diagnostic indicators;
  • information displaying (tables, graphs / trends, bars, etc.);
  • registration of events, malfunctions and violations;
  • displaying and archiving messages about events, malfunctions and violations;
  • alert about violation;
  • generating, displaying, storing and printing of operational and archival protocols / reports;
  • manual / automatic remote actions with actuators;
  • control and fixing of operator’s actions;
  • management of technological journals, manual input of technological parameters;
  • time synchronisation;
  • metrological support;
  • information support;
  • technical diagnostics.

4. Specialised performance

We have experience in the development and implementation of automation systems (and their components) of the next execution, based on the specifics of the task:

  • Redundant systems: redundancy schemes 1оо2, 1oo2D (according to IEC 61508)
  • More about redundancy systems 1oo2, 1oo2D

    Achieved the implementation of the reservation principle for applications that are important for the safety.

    The reservation includes both technical and software tools.

    Systems with architecture 1оо2 or 1оо2D consist of 2 independent hardware kits functioning in parallel in such a way that each of kits independently capable to perform system functions. Failure of one of the kits does not lead to loss of functions of the system – this is stability of the systems to a failures. For system failure, necessary failures simultaneously in both kits of the system.

    The architecture of 1oo2 and 1oo2D differ in the influence of the diagnostic subsystem on the result of the system’s operation. In the 1оо2 architecture, the diagnostic subsystem only reports the occurrence of failures. In the 1oo2D architecture, the diagnostic subsystem influences the result of executing system functions according to established algorithms: or adjusts the output of a system with a diagnosed failure to the values obtained from the results of the workable kit, or transfers the managed object to a safe state by executing manipulations with controlled actuators.

    Reserve system kits can be based both on homogeneous or heterogeneous hardware. Thus the implementation of the diversity principle is achieved.

  • Power supply redundancy
  • More about power supply redundancy

    We apply next approaches to power supply redundancy: use Automatic Transfer Switch (ATS) and / or diode modules.

    ATS are used to provide reliable power supply of technical equipment ~ 220 V AC. Switching time from one input ~ 220 V power supply to another does not exceed 20 ms. We use both modular ATS and independently developed schemes of transfer switching.

    Power supply redundancy via diode modules is used when all hardware components receive power supply in the range of 12 V to 48 V DC. From the height of our experience, this is the most efficient way for power supply redundancy. For its application, we perform the selection of the corresponding components.

  • Redundancy of individual components, elements, connections
  • Resistant to electromagnetic interference (EMC)
  • More about EMC

    We have experience in the development of electrical cabinets resistant to electromagnetic influences. If necessary we make an EMC examinations of our equipment in accredited laboratories. We accumulate an experience in exploiting the technical means of different manufacturers in the conditions of negative influence of electromagnetic interference.

    We have practical experience in eliminating the following negative manifestations of electromagnetic influences:

    • failures because of impulse overloads, that resulted in transferring to safe modes, shutdown or reboot of hardware;
    • significant fluctuations or deviations of measured values;
    • illumination of indicators in the OFF-state;
    • false tripping of relays;
    • false tripping of protection elements against overcurrent and voltage.
    • We confirm the compliance of our equipment with the technical regulations on electromagnetic compatibility.

  • The combination of electrical components with pneumatic, hydraulic, gas components (in one production)
  • Systems with remote access

5. Resistance to external factors of influence

Requirements of resistance to external influences are formed taking into account the real situation at the place of exploitation of technical means and usually formalising (setting) in the technical specifications.

If necessary (for example, for enterprises whose activities are controlled by regulatory authorities) we confirm the resistance to external factors of influence by conducting laboratory tests in accredited laboratories or in the process of voluntary certification (essentially in the same accredited laboratories).

Generally the following external factors of influence are set:

  • operational and marginal (minimum and maximum) environmental parameters: temperature, pressure, humidity, dust content, evaporation content of caustic substances, content of corrosive agents, content of combustion products
  • power supply deviation
  • electromagnetic effects (ЕМС)
  • the influence of special environments that are subject to technical equipment during specific operations or situations: detergents, solutions of alkalis and acids, etc.
  • mechanical impacts: blows, vibrations, seismic fluctuations
  • momentary and integral radiation loads
  • etc

6. Safety, compliance with technical regulations (directives), certification

Our products corresponds to the requirements of electrical, mechanical and fire safety. The requirements of electrical, mechanical and fire safety are usually formalising (setting) in a technical specifications.

If necessary (for example, for enterprises whose activities are controlled by regulatory authorities) we confirm the safety requirements by conducting laboratory tests in accredited laboratories or in the process of voluntary certification (essentially in the same accredited laboratories).

We confirm the equipment conformity with the requirements of technical regulations:

  • The Low Voltage Directive (LVD)
  • Electromagnetic Compatibility (EMC) Directive

If necessary, perform laboratory tests of our equipment in accredited laboratories to confirm compliance with the requirements (Directives) not only of safety, but also sanitary norms, resistance to external factors of the enfluences (environment, seismic, vibration, impact, changes of power supply parameters, etc.).

We pay considerable attention to the issues of non-exceeding of sanitary requirements for technical means, which are located in the operational rooms, and the emissions (we ensure that our technical means are not sources of negative influences: electromagnetic, radio, vibration, etc.).

7. Warranties

Depending on the project specifics, we provide for up to 3 years warranty on our products from the moment of commissioning or 4 years from the moment of delivery (which will come first).

During the warranty period we ensure repairing and renewal of accessories and spare parts.

In addition to the term of warranty service, the term of warranty storage is set.

8. Quality of PAS

The quality of an automated system is a complex concept and is determined by the following factors:

  • quality of object researching
  • the quality of formation of technical requirements to equipment
  • quality and flexibility of conceptual technical decisions
  • the quality of the organisational decisions
  • the quality of system-wide decisions
  • quality of circuit-technical solutions
  • the quality of mathematical and algorithmic solutions
  • the accuracy of the components selectio
  • quality of equipment manufacturing
  • quality of software
  • quality of packaging
  • compliance of storage and transportation requirements
  • compliance with installation and adjustment requirements

Experts of “EC “Teredo” LLC are as responsible as possible to all stages of the development and implementation of PAS (ACS). There are no trifles.

In the questions of equipment selection (sensors, cabinets, controllers, power supplies, relays, terminals, wires, filters, indicators, automatic switches, etc.), we prefer the proven manufacturers. For example, Phoenix Contact, TRACO POWER, Weidmuller, MOXA, Mitsubishi, Siemens, ABB, Rittal, etc.

Remember that cheaper products often leads to the degradation of technical solutions. This, in the short and medium term, leads to an increase in maintenance costs, repairs, upgrades and worsens the convenience and safety of the operation of automation systems.

9. Advantages

“EC “Teredo” LLC provides the following advantages:

  • our quality policy in the field of electrical, mechanical, sanitary and fire safety is guaranteed to correspond to the policy of technogenic and human safety of your company;
  • high quality of production at all production stages, accumulated experience and taking into account the production culture of your enterprise contributes to increasing the aesthetics of the operation of our equipment and increases the motivation of your staff;
  • qualified and high-quality service support;
  • solutions flexibility and possibility of the future modification of our systems;
  • our systems are easy to integrate into the automation complex of your enterprise;
  • training your staff;
  • high degree and quality of documentation;
  • we provide software codes with products;
  • compliance of the equipment with the requirements of laws, technical regulations (directives) and normative documentation.

10. Examples of completed projects

To view reports on the completed projects click here.


Our experience – for the success of your business! WAITING FOR YOUR APPEALS!