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Main:  Software & hardware for automatic process control systems

  SOFTWARE & HARDWARE FOR AUTOMATIC PROCESS CONTROL SYSTEMS
 

SOFTWARE & HARDWARE FOR AUTOMATIC PROCESS CONTROL SYSTEMS AT HEAT AND NUCLEAR POWER PLANTS
TPTS components-module, crate, cabinet
TPTS components-module, crate, cabinet

The largest non-defense area of the Institute is the design, serial production and maintenance in the operation of the automatic process control systems (APCS) for the industrial and power-generating facilities. The control systems produced at VNIIA are based on the software & hardware of the TPTS type, developed and improved by our experts. This system was created on the platform of the leading technologies obtained by VNIIA under the license of Siemens. All the equipment, assemblies, devices, including the printed boards and modules with the surface mounting, are produced in Russia according to the design documents based on the domestic regulations and standards. The components used are the highly reliable semiconductor devices from the world's leading companies in this area.

The control systems produced by VNIIA comply with the most stringent international requirements and compete with the similar systems on the world's market.

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Commercial video "VNIIA-made software and hardware for APCS"

The advantages of the control systems produced by VNIIA are:

  • The software & hardware APCS implement the philosophy of the distributed control, when each module communicating with the facility's equipment has its own microprocessor and is capable of performing the control functions independently of the status of the whole system;
  • The advanced components and fabrication technology of the surface mounting provide for the best performance of the system and reduce the number of the required equipment;
  • The flexible self-diagnostics of the equipment and the communication lines in the real time;
  • High reliability and availability factor;
  • Low consumed power <350 W per cabinet;
  • Large scope of the measured parameters: receipt, processing and output of up to 2,000 analog and discrete signals by one cabinet;
  • Highly automated process at the moderate cost;
  • Opportunity to readjust and improve the APCS during the operation by the operating staff;
  • Flexible operator's control;
  • Redundancy;
  • Powerful CAD that ensures the best design of the system and the easy communication between the APCS designer and the process engineer.

The TPTS-based APCS has proved itself at Russian conventional power plants (Berezovskaya plant - 2 units per 800 MW, Perm plant - 2 units per 800 MW, Kaliningrad plant-2, Ivanovskaya plant, Mutnovskaya geothermal plant, etc.). The APCS designed by VNIIA are competitive on the world market. In particular, the APCS for the following heat power plants were designed: Suijun (China) - 2 units per 800 MW, Kostolaz (Serbia), Ghorazal (Bangladesh), Zmijev (Ukraine), Aksu (Kazakhstan) - 2 units, Obra (India) - 2 units, etc. All projects were won at tenders with the participation of the Russian and foreign suppliers (Emersson, ABB, etc.). In 2005 the TPTS-based APCS was commissioned at Kalinin NPP unit 3.

Since 2006 the Institute has been using the TPTS-E software & hardware, which is the modified and upgraded version of the TPTS equipment. In 2009 the further upgrade of the equipment, generation TPTS-EM, was completed.
Dedication ceremony of the APCS production shop
Dedication ceremony of the APCS
production shop

The TPTS-E (-EM) widely extends the level of the automation and improves the performance; the advanced communication system is implemented based on the common industrial standards.

The TPTS-E (-EM) is used to design systems that process up to several thousand signals with the signal surveillance cycle within the millisecond range.

The TPTS-E (-EM) is certified by the Russian RosTechNadzor for application at NPP. The quality system that covers the design, production and servicing has an internationally recognized Certificate TÜV SÜD, reconfirmed annually.

The TPTS-E (-EM) operational cost is insignificant due to high reliability and good level of maintenance.

The application of the TPTS-E (-EM) in the APCS seriously reduces the amount of equipment in the system, because the process control and the safety channels, the turbine regulation and the generator temperature monitoring can be implemented on one and the same equipment type.

The high operational quality and the technical performance of the TPTS-E (-EM) allow to apply this equipment almost in all any kind of industry for the automatic process control, including the critical production facilities.

The equipment is remarkable for record reliability - real operation demonstrated that the error-free running time for any type of module, which has more than 1000 components installed, is over 70 million hours.
APCS assembly shop APCS equipment for NPP
APCS assembly shop APCS equipment for NPP

Designed and manufactured control systems are thoroughly tested at the test facility in presence of the Customer and the oversight authority. During the testing the operational personnel of the Customer is trained.

VNIIA delivers the complete system, carries out the installation and commissioning on the "turn-key" basis, and provides the warranty and post-warranty maintenance.

In 2011 we are starting the serial production of the new generation of equipment - the TPTS-NT system.

The TPTS-NT is the hardware system that meets the modern requirements to the lower-level APCS for the heat and nuclear power plants. The TPTS-NT has accumulated the experience in designing the automatic control systems for over 40 heat and nuclear power units and the state-of-the-art achievements in the electronics.

The TPTS-NT is the result of the TPTS equipment evolution, it is informational compatible with the previous generations TPTS-E and TPTS-EM. All the generations of the TPTS, including the TPTS-NT are based on the same design aid GET-R, thus making the adaptation of the designers to the new equipment easier.

The capabilities and performance of the TPTS-NT give the designers the new opportunities that significantly enhance the effectiveness of the APCS and reduce the labor cost for its design.

The advantages of the TPTS-NT are:

  • System response time within 100-200 ms;
  • Possibility to accomplish the local missions with the limited number of input signals (10-30) and more stringent requirements to the response time (5-10 ms);
  • Territorial distribution of the equipment at site;
  • Local control stations;
  • Remote controllers, built into the equipment of other suppliers;
  • Connection of any field cables with the cross-section 0.1 to 2.5 mm2;
  • Implementation of the functional cabinets with one- or two-sided servicing;
  • Flexible layouts that ensure the reasonable utilization of the equipment for the automation of the different size facilities from the stand-alone process installations to the nuclear power units;
  • Short measurement cycle for the unified analog signals, 5 ms and more;
  • Time resolution of the input discrete signal frequency 1 ms;
  • Communication with the smart sensors using the RS-485 network via standard networking protocols.
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