The system for acceptance, storage and transportation of grain at an alcohol factory (Alcohol factory in Kalsnava Town)

Used controller: Siemens Simatic S7-313 un Siemens Simatic TP177A.

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This automation system is intended for controlling grain charging and discharging at the grain elevator of an alcohol-producing enterprise. The grain elevator comprises 3 storage hoppers, a trestle for grain acceptance from railway cars and motor vehicles, a separator and a receiving hopper of the main production facility. Note: there do not exist any substantial restrictions for the number of hoppers, and the types of such devices in use; for the purpose of controlling any other similar production facilities, only adaptation of the system to configuration of particular object will be required. Operator's interface is graphical, intuitively understandable doe to similarity of mnemonic diagram with technologic diagram of the object. The used touch-panel makes it possible for operator to easily monitor condition of devices and control them by pressing virtual buttons on the screen.

From the operator's panel, the following operation modes can be set and the following processes ensured:

  1. Manual control mode. Checking the serviceability of individual devices, and controlling them from the operator's panel.
  2. Automated control mode. The required control program is selected. It is started and ended by an operator. In case of necessity, operator may stop execution of the program.

For operator's convenience, all processes are divided into three types:

  1. Grain loading. Grain is received from the trestle, and directed (through a separator or by-pass) to one of the storage hoppers or directly into the receiving hopper of the main production facility.
  2. Operation. This is understood as replenishment of the receiving hopper of the main production facility from one of the storage hoppers. An operator may either fill the receiving hopper manually or use automated filling mode, which is started and ended by signals from the upper and lower level sensors in the receiving hopper.
  3. Grain reloading. Grain can be relocated from one storage hopper to another.

Control of ventilation of hoppers is performed separately. Ventilators are switched in and off by an operator, taking into consideration the ambient temperature and humidity of grain.

In both manual and automated control modes, the diagnostic system is accessible for operator and technical personnel, which generates graphical (in the form of pictograms, showing a current status of a device) and textual messages (notifications of alarms). Besides, a skilled personnel can use expanded diagnostics, which textually shows condition of all sensors and control outputs to the devices.

This system provides for outputting alarm signals and blocking all further operations in the following cases:

  1. Lack of voltage on the power lead-in;
  2. Lack of power supply voltage +24V;
  3. Operation of emergency stop button;
  4. Motor 's starter failed to operate (or "sticked on");
  5. Overload of the motor;
  6. The conveyor fails to rotate;
  7. Operation of over-fill sensors;
  8. Exceeding of time for gate valve switching.


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