Automated Process Control Research Articles

Approximate analytical method for calculating the heating process of concrete structures in heating formwork

The use of electric heating of concrete during construction in winter makes it possible to create an optimal thermal regime in which the hardening process takes place, and to obtain a structure of the required quality. When developing a system for automatic control of the heating process, it is necessary to determine the law of regulating the power of heaters. This article presents a method for calculating the thermal heating regime of concrete structures in heating formwork, the essence of which is to reduce the boundary value problem of thermal conductivity to a system of equivalent integral equations. To solve this problem, a theoretical study was carried out, a theoretical study of the heat transfer process in concrete structures heated during winter concreting was carried out, and a mathematical description of this process was presented in the form of a system of differential equations. After the transformations of the above system of equations and the application of the Green function of the second kind to it for the plate and rod, an approximate solution of the equivalent equation was obtained. As a result of the application of the asymptotic method to the solution of the integral equation, an analytical solution of the problem under consideration is obtained. The resulting solution makes it possible to determine the temperature fields on the concrete surface, as well as the value of the specific heat flux from electric heaters. In order to automate the process of performing the thermal calculation of heating concrete structures with the help of heating forms, a program for calculating temperature fields in heating forms has been developed based on the solution obtained, which makes it possible to effectively solve the tasks of monitoring and controlling the concrete hardening process. The developed program makes it possible to calculate temperature fields not only at constant heater power, but also when it changes with the help of regulators. The presented method of thermal calculation with a hardware and software complex for regulating the power of electric heaters allows solving a fairly wide range of tasks related to maintaining a constant temperature field.

Rehabilitation of the water supply network of Timişoara City from Timiş County in Romania

In such an urban centre like Timisoara (the largest one from the West of Romania), the problem of water treatment for drinking, respectively wastewater collection and treatment, have always been issues of strategic importance to the community. The policies of the European Union to support the financing of the member states in the field of environmental engineering and protection represented the basic pillar in the development of the water supply network also in this case. In light of the increasing and pressing need to efficiently manage scarce water resources, there has been renewed interest by water distribution network owners to develop and implement water management strategies and tools that would assist in the integrated and automated management of those networks. The modernizations made at the treatment plants can be summarized in a few basic ideas: the automatic control of processes, lower costs, and higher safety. The most commonly used rehabilitation techniques for reducing both types of water losses are pressure management and pipeline rehabilitation. In Timişoara City, this modernization, and the rehabilitation of the water supply network led to a significant reduction of the environmental pollution (water, soil, air), and to a better protection of human health. Investments in modern technologies for water treatment, which allow an automatic monitoring of the process, translate into more safety in exploitation, and, implicitly, a better-quality control. The main objectives pursued in this study aim at: improving the quality of drinking water supplied to the population, ensuring continuous supply of drinking water, compliance with the regulations in force, both Romanian and European, and ensuring the access for the majority of the population at this system. There were followed the rehabilitation systems for street drinking water supply networks, also those for street sewerage networks, with modern constructive solutions.

Study of modes and parameters of mineral raw material grinding process in ball drum mills

The paper presents the results of research on the vibration-acceleration signal of the ball mill drum bearing support depending on its load when grinding mineral raw materials. Investigations of vibration sensor readings, installed on the bearing support of the mill drum, and amplitudes of the vibration-acceleration signal from the volumetric filling of the installation drum have been carried out. The dependences of vibro-acceleration signal amplitudes on the frequency spectrum of Fourier series at different volumetric filling of the mill drum in the interval of loads from 0 t/h to 18 t/h are investigated. In research on the interrelation of a signal of vibro-acceleration and consumed power of an electric drive of a drum depending on the degree of its volume filling, their averaged values are established. According to the values of averaged numerical values of amplitudes of vibro-acceleration signal amplitudes, the graphs of their dependence on the frequency spectrum of Fourier series in the range from 0 to 30000 Hz are obtained, the dependences of the consumed power of the ball mill and the amplitude of the vibro-acceleration signal on the volumetric filling of the drum are established, the algorithm of determining the level of filling of the mill drum is developed, the dependences of the vibro-acceleration signal and consumed power on the level of filling of the ball mill in volumetric units are established. It is established that the filling of the mill drum by the consumed power of the electric drive can be controlled up to 0.7 of the volumetric filling of the mill drum. At the same time, the value of volumetric filling of the mill drum, expressed through the signal of vibration velocity of the bearing support, smoothly grows in the whole range of drum filling from 0.0 to 1.0. In this case the reliability of the received information on vibration acceleration of the mill drum support with deviation from the approximating curve, not exceeding 5–6%. Tracking of the level of filling of the mill drum is provided by the signal of the vibration sensor, which allows to maintain of optimal performance, grinding quality, and power consumption. The obtained results give grounds to use the vibration acceleration signal in the system of automatic control of the coal grinding process as a criterion for evaluating the degree of filling of the mill drum during its operation. Keywords: ball drum mill, grinding, vibration acceleration signal amplitudes, coal.

Real Time Automation and Ratio Control Using PLC & SCADA in Industry 4.0

Industrial Control Systems (ICS) and SCADA (Supervisory Control and Data Acquisition) systems play a critical role in the management and regulation of critical infrastructure. SCADA systems brings us closer to the real-time application world. All process and equipment control capability is typically provided by a Distributed Control System (DCS) in industries such as power stations, agricultural systems, chemical and water treatment plants. Instead of control through DCS, this paper proposes a SCADA and PLC (Programmable Logic Controller) system to control the ratio control division and the assembly line division inside the chemical plant. A specific design and implementation method for development of SCADA/PLC based real time ratio control and automated assembly line system in a chemical plant is introduced. The assembly line division is further divided into sorting stage, filling stage and the auxiliary stage, which includes the capping unit, labelling unit and then the storage. In the ratio control division, we have defined the levels inside the mixer and ratio of the raw materials through human machine interface (HMI) panel. The ratio of raw materials is kept constant on the basis of flow rates of wild stream and manipulated stream. There is a flexibility in defining new levels and the ratios of the raw materials inside the mixer. But here we taken the predefined levels (low, medium, high) and ratios (3:4, 2:1, 2:5). Control valves are used for regulating the flow of the compositions. In the assembly line division, the containers are sorted on the basis of size and type of material used i.e., big sized metallic containers and small sized non-metallic containers by inductive and capacitive proximity sensors. All the processes are facilitated with laser beam type or reflective type sensors on the conveyor system. Building a highly stable and dependable PLC/SCADA system instead of Distributed Control System is required to achieve automatic management and control of chemical industry processes to reduce waste manpower and physical resources, as well as to improve worker safety.

Algorithm and Software Implementation of the Diagnostic System for the Technical Condition of Powerful Units

This article discusses the software implementation of the diagnostic system for auxiliary equipment of power plants (on the example of smoke exhausters). The developed program of diagnostics of auxiliary equipment of electric power plants is given on the example of condition diagnostics designed for early detection and localization of certain defects and providing recommendations for their elimination in smoke pumps, which should ensure the issuance of appropriate protocols and, upon request, protocols of the current state of smoke pumps, quality assessment of repairs and special tests, as well as graphs of retrospective parameter values for the time period selected by the user, where the users of the task - there are heads and deputy heads of workshops, senior foremen, repair engineers, as well as specialists of the planning and technical department. The problem is considered, which was solved within the framework of the software and hardware complex of the automated process control system) of the 800 MW power unit No.1 of Talimarjan TPP and is intended for operational specialists, where the task operates under the Windows operating system and the program is written in the C++ programming language Builder 6 for the development of application tasks with client -server architecture. And also the composition of the program and the program menu are given: “Task Launch”, “Daily statements”, “Input data”, “Output forms”, “Diagnostics” and “Special tests” allow you to implement the required task function at the moment. In addition, the article presents elements and components, processes and conditions of a pumping plant, pumping station and pumping station cascade, potentially dangerous and processes and conditions potentially dangerous for a pumping plant, pumping station and pumping station cascade.

Контроль и поддержание параметров эффективного функционирования паровой завесы трубчатой печи

Purpose. A review of the structure of a modern automated process control system of an oil refining complex allowed the authors to identify the lack of technical means for remote control of the effective functioning of a protective steam curtain of tube furnaces. Numerical simulation of changes in steam pressure in a steam pipeline at the site of a diesel fuel hydrotreating unit depending on the steam mass flow was carried out. Based on the results of the review and simulation, technical solutions were developed that provide remote control of steam pressure, as well as automatic maintenance of the set steam pressure parameters for the effective operation of a protective steam curtain of a tube furnace of a diesel fuel hydrotreating unit. METHODS. To obtain the results, the authors used general scientific and special methods of scientific knowledge such as analysis, synthesis and generalization, which are based on the provisions of systems and information theories. FINDINGS. The results of numerical simulation of changes in steam pressure in a steam pipeline at the site of a diesel fuel hydrotreating unit depending on the steam mass flow were obtained. It was determined that with the simultaneous launch of protective steam curtains of five tube furnaces, it is possible to reduce the steam pressure values below the normative ones. RESEARCH APPLICATION FIELD. The obtained results of the research can be used in tube furnace protective steam curtain systems at oil refineries and petrochemical plants to automate the control of steam pressure parameters and automatically maintain the set parameters of steam pressure when the values drop below the set ones. CONCLUSIONS. Based on the results of numerical simulation of changes in steam pressure in the steam pipeline at the section of a diesel fuel hydrotreating unit, depending on the steam mass flow, technical solutions were developed that provide remote control of steam pressure, as well as automatic maintenance of the set steam pressure parameters for the effective operation of the protective steam curtain of a tube furnace of a diesel fuel hydrotreating unit. Directions for further research are defined.

АЛГОРИТМ ПРОВЕРКИ ПОДЛИННОСТИ ИСПОЛНИТЕЛЬНЫХ УСТРОЙСТВ В АВТОМАТИЗИРОВАННЫХ СИСТЕМАХ УПРАВЛЕНИЯ ТЕХНОЛОГИЧЕСКИМ ПРОЦЕССОМ

The paper proposes an algorithm for verifying the authenticity of automated process control system actuators based on the HART standard, which can act as the main or additional measure of protection against threats to the integrity of the system. The principle of operation of the HART standard is considered, a theoretical algorithm is given, additional technical solutions that increase its reliability are considered, as well as scenarios of possible attacks.

Аналитический обзор систем мониторинга электромагнитного поля установок получения первичного алюминия

This article discusses technologies that provide subsystems of automated process control systems (APCS) for obtaining primary aluminum. The paper presents a step-by-step analysis of existing technical solutions based on the global and Russian experience in the operation of electrolyzers. The analysis included studying the physical processes of the electrolyzer operation accounting for the influence of such physical processes on chemical processes. Attention is paid to the existing sensors and monitoring systems of the electromagnetic field. The analysis of the effect of the electromagnetic field on the technological process is formed. The results have revealed patterns of the studied effects. Thus, a method for assessing the technical condition of the electrolyzer based on the results of electromagnetic field diagnostics is proposed. The presented scientific research is a report published under the program «Philosophy of Science».

Performance optimization of 5G NR technology for industrial automation

Communication over the wireless has significantly evolved to the level where it is capable of supporting the essential controlling mechanisms of the high-definition automated industrial process. The Fifth-Generation (5G) mobile networking air-based interface, named New Radio (5GNR), is presently capable of adopting scalable control and subband data transmission for small data packets, which has made it efficiently compatible for the critical controlling application of industrial automation processes. The minimum cycle time is used as a reliable parameter for an indication of the healthy techniques for industrial wireless telecommunication, but it has not undergone deep investigation within the framework of modern 5G technology. For addressing such types of challenges, this paper has taken into consideration 5G-based industrial automation process control through wireless networking by using a delay optimization approach associated with data-base channel control using the Ant Colony Optimization (ACO) approach for solving the proposed evaluation of a reliable minimum cycle time over 5G network communication.

Technological independence and safety of software for automated process control systems: Analysis and recommendations

The current analysis examines two important aspects of SW PCS software: process independence and process safety. Process independence refers to the flexibility and versatility of the system, which allows it to integrate easily with different technologies, devices and software. This allows organisations to choose from a wide range of hardware and software modules and ensures compatibility with other control systems. Technology security includes measures to protect the system from security threats and breaches such as data protection, user identification and authentication, access control, etc. It is recommended to conduct regular security audits and keep track of system updates and vulnerabilities. The analysis highlights the need to pay attention to the criteria of technological independence and technological security in the development and operation of SW PCS and recommends further research and exchange of experience in this area.

ДИНАМИЧЕСКАЯ ИДЕНТИФИКАЦИЯ ПАРАМЕТРОВ СХЕМЫ ЗАМЕЩЕНИЯ АСИНХРОННОГО ДВИГАТЕЛЯ НА ОСНОВЕ БАЛАНСА МГНОВЕННОЙ ПОЛНОЙ МОЩНОСТИ В УСТАНОВИВШЕМСЯ РЕЖИМЕ

The relevance Automated electric drive (AED) is one of the most important and most common control objects in automatic process control systems (ACS). The control of the output coordinate in the AED, for the implementation of feedback with an automated process control system, can be carried out both with the help of a speed sensor and without it, using the computing power of a frequency converter included in the AED. For the sensorless AED to work in an automated process control system, it is necessary to ensure adequate restoration of the vector of state variables of the induction motor (IM) in the frequency converter using a configurable mathematical model. To restore the vector of state variables, it is necessary to select coefficients in the system of differential equations that correspond with some error to the electrical parameters of the BP replacement circuit, i.e. to carry out the identification procedure. In fact, the procedure for determining the parameters of the PS is the process of finding the extremum of the objective function, built on the basis of data obtained during the operation of the PS. In electrical engineering, numerical methods for finding the extremum of the objective function have become widely used to identify parameters, but these methods have significant limitations and disadvantages. The problem of using numerical methods to find the extremum of an objective function with two or more arguments in AED microprocessor control systems is that it is necessary to calculate partial derivatives in discrete form for each argument of the function. Calculation of partial derivatives in ideal systems without noise and disturbances is a proven and easy-to-implement process, but noise and disturbances are present in real microprocessor systems. Because of this, when calculating partial derivatives for each argument, the probability of breakpoints of the first and second kind increases, the struggle with which presents a certain difficulty. One of the classes of methods that allow determining the extremum of an objective function without finding partial derivatives are metaheuristic algorithms, and in particular genetic algorithms. Aim of research Experimental study of the efficiency of a genetic algorithm in the problem of dynamic identification of parameters of an induction motor circuit with an open rotor winding without stopping and decommissioning an electrical complex. Research methods Metaheuristic algorithms, iterative procedures, genetic algorithm, discrete systems, optimization methods. Results The effectiveness of the genetic algorithm was experimentally tested and proved in the problem of dynamic identification of parameters of the induction motor replacement circuit with an open rotor winding without stopping and decommissioning the electrical complex.

Автоматичне управління шириною листа на станах гарячої прокатки

Controlling the sheet width using a computer on heavy plate mills (HPM) and roughing mill trains (RMT) of wide-strip hot rolling mills (WSHRM) must ensure the set width of the sheet (roll), rectangularity of the sheet (roll) in the plan characterized by the uniformity of the sheet width in the middle part along its length, as well as at the front and rear ends, and the minimal trimming of the front and rear defective ends of the sheet (so-called “tongues” and "swallow-tail"). Forming the desired sheet width is carried out either in jointly working vertical and hori-zontal mills in a reversible mode or in a continuous non-reversible group of mills (vertically-paired – horizontal). With the leading participation of the authors, there were carried out the development of the automated process control system (APCS) and studies aimed at regulating the width in the RMT of mill 560. Mathematical models describing natural and additional ex-pansion and the requirements for their accuracy are presented in famous scientific works. To assess the accuracy of the characteristics, experimental studies were conducted on a laboratory mill. The rolling conditions in the RMT of mill 560 were simulated during the research. The analysis of experimental data and data obtained through the calculation using various formulas provided in literary sources showed that all known models do not meet the accuracy require-ments set by the APCS for the RMT of mill 560. Therefore, new mathematical models of ex-pansion were developed. The paper presents the mathematical models for changing the width in the middle part along the length of the roll and the models for changing the width at the “head” and “tail” of the roll. A method for determining a roll gap is described, which implements the law of change of the gap of vertical rolls that eliminates deviations in the width of the roll from the initial (before rolling) value. The testing of the developed mathematical models under the conditions of the technological process in the RMT of mill 560 showed their ability to solve the problem of controlling the sheet width in real time.

Calculation and Analysis of Technical and Economic Indicators of the NPP Power Unit

Technical and economic indicators (TEI) characterize the efficiency, reliability, and durability of power equipment during its operation. Based on automating the determination of TEI directly during the production of electricity, objective information can be obtained on the efficiency of the flow of technological processes, as well as on the actual state of power equipment. The conditions for optimal operation of power plants are determined in the process of analyzing its technical and economic indicators. Therefore, the analysis of indicators is one of the most important tasks of automated process control systems (APCS) of nuclear power plants, which largely determines the efficiency of the power unit.

ОБЕСПЕЧЕНИЕ ИНФОРМАЦИОННОЙ БЕЗОПАСНОСТИ ОБОРУДОВАНИЯ ДОБЫВАЮЩЕЙ ПРОМЫШЛЕННОСТИ В КВАНТОВУЮ ЭПОХУ

The article considers the expediency of changing the methods of ensuring information security of automated process control systems (automated process control systems) of extractive industry enterprises. The analysis of foreign experience allowed us to say that the world's leading economies are preparing for the appearance of a cryptographically relevant quantum computer. Many countries have adopted mandatory and recommendatory documents on the transfer of critical information infrastructure to quantum-secure methods of information protection: quantum key distribution or post-quantum cryptography. Both of these methods have their advantages and disadvantages, which must be taken into account when implementing the automated process control system. The analysis shows that post-quantum cryptography, although it requires less economic costs to improve cryptographic information protection systems, but the cryptographic stability of these algorithms is conditionally secure. The study allows us to conclude that it is advisable to recommend quantum key distribution systems for use in the extractive industry...

Importance of the integrated manufacturing execution system for a metallurgical enterprise

The object of the study is Manufacturing Execution System. The relevance of the study is conditioned by the fact that the metallurgical industry has been demonstrating a high level of volatility in the global market over the past few years. The issue of the effectiveness of the metallurgical enterprise is directly related to ensuring environmental safety. The purpose of the study is to consider how the Manufacturing Execution System (MES) operates in the metallurgical industry and highlight its features, offering recommendations aimed at improving operational efficiency with the introduction of MES systems at enterprises of the metallurgical industry of the Republic of Kazakhstan. The following methods were used in the study: analysis, synthesis, comparison, graphical representation of data. Using the example of the Magnitogorsk Iron and Steel Works, the study examined the relationship between MES and APCS (Automated Process Control System), highlighted the requirements for the transition from individual management of particular cases of technological rules and restrictions to the digitization of general algorithms. It was defined that the advantages of a production system include its fast payback. Also, it was determined that the MES system allows automating production operations and information support, carrying out operational planning, accounting for production and quality of metal products, tracking the history of each product, managing equipment, and analyzing performance. In addition, the recommendations that can be used as a basis for creating an enterprise development program, increasing the level of productivity, therefore, reducing the cost of the enterprise's products, were developed

An Approach for Identifying Network Intrusion in an Automated Process Control Computer System

Technology and networks have improved significantly in recent decades, and Internet services are now available in almost every business. It has become increasingly important to develop information security technology to identify the most recent attack as hackers are getting better at stealing information. The most important technology for security is an Intrusion Detection System (IDS) which employs machine learning and deep learning technique to identify network irregularities. To detect an unknown attack, we propose to use a new intrusion detection system using a deep neural network methodology which provides excellent performance to detect intrusion. This research focuses on an automated process control computer system that recognizes, records, analyzes, and correlates threats to online safety. In addition, two different methods are used to detect an attack (the binary classification and the multiclass classification). One of the most promising features of the proposed technique is its accuracy (98.99 percent with the multiclass classification and the binary classification). The proposed method's first step creates a model for a multiclass intrusion detection system based on CNN. FOA (Fruit Fly Optimization Algorithm) is used in the process's pre-training phase to address the class imbalance issue. Each batch is obtained during the training process using the resampling method following the resampling weights, which are the results of the pre-training procedure.

Forecasting for Chaotic Time Series Based on GRP-lstmGAN Model: Application to Temperature Series of Rotary Kiln

Rotary kiln temperature forecasting plays a significant part of the automatic control of the sintering process. However, accurate forecasts are difficult owing to the complex nonlinear characteristics of rotary kiln temperature time series. With the development of chaos theory, the prediction accuracy is improved by analyzing the essential characteristics of time series. However, the existing prediction methods of chaotic time series cannot fully consider the local and global characteristics of time series at the same time. Therefore, in this study, the global recurrence plot (GRP)-based generative adversarial network (GAN) and the long short-term memory (LSTM) combination method, named GRP-lstmGAN, are proposed, which can effectively display important information about time scales. First, the data is subjected to a series of pre-processing operations, including data smoothing. Then, transforming one-dimensional time series into two-dimensional images by GRP makes full use of the global and local information of time series. Finally, the combination of LSTM and improves GAN models for temperature time series prediction. The experimental results show that our model is better than comparison models.

Разработка математической модели газотурбинной установки с малоэмиссионной камерой сгорания и особенности ее интеграции в среду SimInTech

The results of the development of a mathematical model of a gas turbine plant (GTP) SGT5-4000F with an annular low-emission combustion chamber are presented. This plant has a low NOx emission and a high coefficient of performance (COP). The obtained results of mathematical modeling are integrated into the domestic environment of dynamic modeling of technical systems "SimInTech". The obtained results were verified by comparing the model values with the trends of the real technological parameters of the gas turbine unit taken from the archive of the automated process control system of the power plant. According to the results of the experimental studies carried out on the model with changes in the electrical load from 280 to 160 MW, it is shown that the model allows you to control the combustion process in the combustion chamber, depending on the composition of the fuel, evaluate the change in NOx emissions and provide an analysis of the stability of the gas turbine compressor according to surging in conditions of changing temperature and humidity of the incoming air.

Achievements and prospects of creating systems for determining the orientation of small space satellite

Advances in the development of small satellites, combined with the availability of low-cost launches, have led to an increase in the number of space flights. As space becomes more accessible than ever before, new and innovative missions are emerging.
 A set of achievements in the field of automatic systems, control system devices, computer systems, control system executive bodies, methods and methods of control system integration, which made it possible to create multi-purpose, multi-mode systems with a long active life cycle, systems with maximum autonomy and automation of control processes, is shown.
 This article presents the achievements and prospects of spacecraft control systems over the past three decades. The problematic issues of increasing the accuracy of orientation and stabilization are considered.

CONSTRUCTION AND REGULATION OF STATIC CHARACTERISTICS FOR CONTROL OBJECTS

This article discusses the issues of digitalization in stream generation systems, as well as their shortcomings in existing Industrial Ethernet solutions, which were addressed using a new innovative approach. In addition, such solutions are often limited in their flexibility. However, these aspects are becoming increasingly important in the future. Existing control systems are characterized, as a rule, by branched hierarchical structures, and the quality of their functioning is assessed according to vector criteria. Such systems include the national economy as a whole, its branches, industrial enterprises, information systems, targeted programs in various subject and applied areas. It should also be noted that from the point of view of the system approach, any systematization is a fragment of a more general hierarchy of such systems. Automation of control processes and their analysis of modern complex control systems more and more often uses hierarchical models, which makes the problem of their development and research more relevant today. The method proposed by the authors for solving such problems does not seem unnecessarily cumbersome, since it is necessary not only to automate processes at each level, but also to carry out interlevel control. The conclusion is that none of the existing solutions is suitable for meeting the challenges of the future regarding scalability, flexibility or reliability.