Implemented projects of MPS Software

Gas transmission

February 2015 г.

Назначение системы

From December 2014 to February 2015, commissioning was carried out for the distributed integrated Process Control System (PCS) of the compressor shop and two Automated Control Systems (ACS) for gas pumping units (GPUs, turbine type: GTU-6-750). Individual and integrated tests were conducted in February. The system is currently in the pilot operation phase. It is designed for automatic monitoring, control, and regulation of a compressor shop consisting of six gas pumping units (GPUs).

Задача реализации новой системы

The objective of the new system implementation project was to develop an efficient solution for the automatic control and management of a compressor shop housing six gas pumping units (GPUs). The core challenge was the integration of diverse process components into a unified system that would ensure reliability, flexibility, and compliance with Gazprom's Corporate Standards (STO). The system was required to provide not only process monitoring and control, but also advanced equipment diagnostics and protection capabilities.

Внедрение новой системы также включало ряд других целей:

Integration with existing corporate systems and infrastructure;

Development of automatic control functionality;

Data diagnostics and processing;

Implementation of fault-tolerance mechanisms for instrument channel failures;

Report generation.

Решение

The automated control system comprises:

7 main control cabinets (CC, communication, connection node, 2 I/O cabinets, server rack, backup panel)
GPA control systems with power distribution, communication, motor, compressor, and valve control units

System components include:

Fastwel MK-150 controllers
Fastwel I/O periphery
Nutrino real-time OS
ISaGRAF 6 development environment
Ethernet/UDP and Modbus RTU communication protocols
Custom OPC server
MasterSCADA for flexible control

Technical specifications:

800 I/O signals, 5 interface channels
7,800 tags
150 alarms
240 archived trends (250 ms period)
Redundant server with 2 workstations and Firebird DBMS

The main screen displays the operating parameters of the Gas Pumping Unit (GPU), specifically the current performance data of the turbine and compressor. For enhanced system awareness, the interface also presents: the current operating mode, unit status messages, real-time parameter trends, and the event log.

The secondary screen displays additional parameters, including the gas temperature upstream of the High-Pressure Turbine (HPT), the gas temperature downstream of the Low-Pressure Turbine (LPT), and the unit's bearing temperatures.

The compressor shop automatic control system provides a graphical representation of valve positions, pipeline statuses, and flow directions. The display presents operational data for each turbine-driven set (T/A), including its status (in operation or stopped), current gas pressure and temperature readings for each unit, as well as information on its startup and shutdown procedures.

To streamline the replication of standardized I/O channels and actuated valves, custom in-house scripts were developed for automated object generation and configuration. To enhance project load times, optimize RAM utilization and project size, as well as to expedite the copy/paste operations of objects between projects, custom Visual Functional Blocks (VFBs) developed in C# were implemented.

Функции системы

ПО MasterSCADA, установленное на автоматизированных рабочих местах, предоставляет следующие функции:

Monitoring of engine, compressor, compressor shop, and auxiliary equipment parameters;

Automatic fuel control and protection systems, including anti-surge control for the compressor;

Automatic and manual control of all actuated devices;

Fault tolerance strategies for sensor channel failures;

Control of the GPU output and calculation of its thermodynamic performance;

Automatic start-up, normal shutdown, and emergency shutdown;

Automatic control of the shop output / throughput;

Unit-replaceable level diagnostics;

Hourly report generation.

Результат

The system operates in continuous mode. It meets all requirements of Gazprom's Corporate Standards (STO) for the Compressor Shop Process Control System (ACS TP KS) and the Gas Pumping Unit Automated Control System (SAU GPA). MasterSCADA IDE training, along with the development of generation scripts, visual functional blocks, and the application project, took one year to complete. Two control systems engineers with experience in industrial automation development were involved in the project. Commissioning took two months, and system refinement is ongoing during the pilot operation phase.

Implemented projects of MPS Software

Назначение системы

Внедрение новой системы также включало ряд других целей:

Решение

Функции системы

ПО MasterSCADA, установленное на автоматизированных рабочих местах, предоставляет следующие функции:

Результат

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