Best Project Competition Automatic Control System for shale oil particle separation process EKTACO AS Akadeemia tee 21E Tallinn, ESTONIA Phone

Automation As a result of the work performed and as a sign of partnership Schneider Electric granted us Modicon's quality and training certificates for control engineering and technology in Schneider Electric Eesti AS granted us the certificate of control system integrators

Automation Application overview Infrastructure Infrastructure Shale oil production Shale oil production Application main task Application main task Produce from heavy shale oil lighter high quality oil Produce from heavy shale oil lighter high quality oil ACS main tasks ACS main tasks Provide faultless and economical as possible automatic control of application processes Provide faultless and economical as possible automatic control of application processes Fast and accurate reaction to possible emergency situations in processes Fast and accurate reaction to possible emergency situations in processes Displaying and saving process data for better quality and later analyze Displaying and saving process data for better quality and later analyze Main difficulties Main difficulties Ex environment Ex environment Preserve maximal capability to work of system while faults appear in system or devices related to system Preserve maximal capability to work of system while faults appear in system or devices related to system

Automation Process overview Heavy oil and petrol will be pumped to blending tank Heavy oil and petrol will be pumped to blending tank Particles separation module (centrifuge) will be started with light oil Particles separation module (centrifuge) will be started with light oil Heavy oil blended with petrol will be pumped to centrifuge while centrifuge is ready for production Heavy oil blended with petrol will be pumped to centrifuge while centrifuge is ready for production Light (clean) oil goes from centrifuge to light oil tank, heavy fraction (sludge ) to sludge tank Light (clean) oil goes from centrifuge to light oil tank, heavy fraction (sludge ) to sludge tank Most of separated heavy oil (sludge) will be transported to factory for reprocessing, little part will be mixed with blended heavy oil for separating process (back to centrifuge) Most of separated heavy oil (sludge) will be transported to factory for reprocessing, little part will be mixed with blended heavy oil for separating process (back to centrifuge)

Automation Process architecture Heavy oil Mix no 1 Light oil Start tank Centrifuge Sludge Light oil Sludge Light oil to storage Sludge to reprocessing Petrol

Automation ACS implementation methodology For its high work capability and good efficiency Unity Quantum CPU65150 was used to guarantee realization of system requirements. Configuration of PLC includes backplane expansion For its high work capability and good efficiency Unity Quantum CPU65150 was used to guarantee realization of system requirements. Configuration of PLC includes backplane expansion For satisfying system high safety requirements Preventa XMF3502 was used For satisfying system high safety requirements Preventa XMF3502 was used For displaying process data, notifying about emergency situations and saving meter’s data Monitor Pro was used For displaying process data, notifying about emergency situations and saving meter’s data Monitor Pro was used For displaying process in operators computer was used one picture over 4 monitors For displaying process in operators computer was used one picture over 4 monitors New Workstation with 2 monitors was added for supervisor of main control room New Workstation with 2 monitors was added for supervisor of main control room

Automation ACS architecture Operator workstation Monitor Pro client MonitorPro server 140DAI DDO DAI CPS XBE DDI DAI DDI DAI CPS CPU ACI ACO XBE ACI ACO ACI ACO ACI04000 UPS 230 VAC/ 24 VDC Switch 499NES25100 XPS MF MF2DO1601 Safety PLC Preventa TWDLCAE40DRF Switch MOXA x e x e x e MODBUS E+H flowmeters Supervisor workstation Monitor Pro client Process control room Main control room TWDLCAE40DRF x e x e MODBUS E+H flowmeters Process Sensors and actuators

Automation Realization Main services provided Main services provided ACS design ACS design ACS control cabinets’ design and implementation ACS control cabinets’ design and implementation Meters supply and mounting Meters supply and mounting PLC and SCADA algorithms design and coding PLC and SCADA algorithms design and coding System tests, employees training and start–up System tests, employees training and start–up Main products used Main products used Unity Quantum CPU65150 with backplane expansion Unity Quantum CPU65150 with backplane expansion Unity Pro XL V3.0 Unity Pro XL V3.0 Safety PLC Preventa XPS MF3502 with MF2DO1601 Safety PLC Preventa XPS MF3502 with MF2DO1601 ELOP II Factory ELOP II Factory OPC Factory Server V3.2 OPC Factory Server V3.2 Monitor Pro 7.6 server and 2 clients Monitor Pro 7.6 server and 2 clients Microsoft Server 2003 for system server and XP Pro for clients Microsoft Server 2003 for system server and XP Pro for clients

Automation Gallery Control cabinet 1 with Quantum Backplane no1 and Twido Control cabinet 2 with Quantum Backplane no2 and Preventa Operator’s workstation Block of heavy oil particle separation

Automation Customer benefits Automatic control over process improves product quality Automatic control over process improves product quality Automated monitoring and control of process increases safety of employees, environment and process related devices Automated monitoring and control of process increases safety of employees, environment and process related devices Continues saving of process data allow later analysis and through analysis results enhance the system Continues saving of process data allow later analysis and through analysis results enhance the system System is scalable if necessary System is scalable if necessary Competent support is phone call and if really necessary few hours drive away Competent support is phone call and if really necessary few hours drive away

Automation Our Partners We thank all our partners in this project, especially: Schneider Electric – our long time partner and supplier of automation products and support Schneider Electric – our long time partner and supplier of automation products and support EE Tehnoloogiatööstus AS – mounting of meters and actuators EE Tehnoloogiatööstus AS – mounting of meters and actuators EE Elektrotehnika ja automaatika AS – in field cable works, electrical connections of meters and actuators EE Elektrotehnika ja automaatika AS – in field cable works, electrical connections of meters and actuators Thank You!