#11 2022

CONTENTS №11

Sosenkov D.Yu., Komissarov P.V., Reshetnikov I.S.  “Ore-dressing factory’s operation analysis” analytical system

The paper reviews the experience of implementing an analytical system at an ore-dressing factory on the basis of a set of subject dashboards. Project prerequisites and key phases are presented, system’s role in the reengineering of business processes and the performance indicators attained are discussed.

Keywords: informational and analytical system, SCADA, production information management system, ore-dressing factory.

Discussing a Topic…

Digitalization and import replacement in power industry

Editor’s introduction

Nemirovich-Skrabatun D.N., Rybakov A.K.  Fault diagnostics of power equipment with the help of SmartDiagnostics software

The paper describes the key features of SmartDiagnostics software intended for the monitoring and diagnostics of power equipment such as turbines, generators, compressors, boilers, transformers, etc. The software suite was developed by Ctrl2Go Solutions (Russia). Key underlying models and algorithms are discussed as well as the approaches to the detection of equipment operation abnormalities.

Keywords: monitoring system, diagnosis, modeling, prediction, condition-based maintenance.

Karas’ V.M., Mikhalev D.L.  Automated monitoring and diagnosis system for a steam boiler

An automated health monitoring and diagnosis system for boiler unit equipment is presented. The paper reviews the system’s hard-/software components and discusses its advantages with the case study of the new TGE-224 boiler from TKZ Krasny Kotelshchik Public JSC.

Keywords: predictive diagnostics, boiler unit, equipment resource, hard-/software system, analytics, condition-based maintenance.

Korolev M.L., Lazarev V.O.  Digital transformation of power companies based on domestic PROSTOR platform

Key digitalization challenges faced by domestic power plants are formulated. The paper reviews the functionality and featured properties of PROSTOR platform aimed at power company’s operations.

Keywords: digital transformation, power companies, data model, microservices.

Semenkov K.V., Poletykin A.G., Promyslov V.G.  LICS system software

Linux based LICS system software is presented. The background of specialized Linux distribution kit are discussed. The paper shows how the general requirements to process control systems are translated into operating system requirements. Development stages of LICS are outlined, key performance data of its current release are included.

Keywords: process control system, operating system, Linux, cybersecurity, nuclear power engineering.

Golubev P.A., Zharko E.F.  Verification and validation of software specifications for upper level control systems of A-plants

Verification and validation of upper level control software for A-plants are discussed. A formalized verification and validation model for digital systems at process control level is presented. Applied software verification and validation tasks are pointed out with reference to working databases; these tasks should be addressed for improving process control system design and, hence, the operation safety of A-plant’s power units.

Keywords: upper level process control systems, A-plant, verification, applied software, databases, video frames.

Promyslov V.G., Zharko E.F.  Approaches to risk assessment in cybersecurity of A-plant process control systems

The paper examines the problem of risk assessment in cybersecurity of process control systems caused by high functional and system complexity of A-plants. Risk assessment methods are overviewed, key challenges are formulated, the methods to overcome them are described. Risk-oriented approach to the synthesis of cybersecurity architecture for A-plant process control systems is discussed. It uses threat modeling and allows for high system complexity of A-plant process controls. Risk assessment is analyzed in the context of A-plant process control system’s lifecycle.

Keywords: process control system, A-plant, cybersecurity, risk assessment, threat modeling, digitalization.

Journal’s Club

Stepanov P.A.  Secret ingredients of success management

Based on his personal experience, the author makes recommendations, which may help project managers in keeping project implementation (schedule, quality, and budget) under control.

Keywords: project management, project manager, design, construction, contracts, procurement, budget

Starikov I.V., Peshko M.S., Khomchenko V.G.  Advanced control of crude oil heating prior to thermochemical dehydration

Crude oil heating process is a nonlinear one and therefore hampers the application of traditional linear control technologies. The paper substantiates the application of advanced process control, presents the developed model structure for real-life unit, the mathematical model, and the Simulink model. The results of base-level and advanced controls simulation under parametric process perturbation show that advance control ensures higher stability of the heating process.

Keywords: crude oil heating process, mathematical model, base-level and advanced control systems, numerical experiments.

Kazantsev A.V.  How to ensure the information security of a process control system without causing damage

An effective information security system at the process control level cannot be developed without applying the comprehensive approach which comprises both security hardware, administrative actions, and physical access control. This approach presumes the implementation of a wide variety of information security hardware, which overlap within a single security domain. Information security devices most popular at the plant floor level are reviewed, basic recommendations on their application are made.

Keywords: information security, process control system, information security hardware.

Mikhailov V.P., Kopylov A.A.  Active vibration isolation platform for MMR-1 metallographic microscope with an automated control system

The paper describes an active vibroinsulation platform for MMR-1 metallographic microscope with an automated control system that includes dampers based on magnetorheological elastomer. The results of experimental research presented enable the evaluation of the platform’s performance in the low-frequency range dangerous for the MMR-1 microscope.

Keywords: equipment vibroprotection, metallographic microscope, active vibration isolation control.

Zakharov N.A.  Additive technologies in import replacement

The application of additive technologies in import replacement conditions is discussed. A 3D scanner from Scanform is described. The features of additive manufacturing organization in ODK-Aviadvigatel JSC are highlighted. The development history of large-lot additive manufacturing operated under 1C control software in RedFab company is described. Product examples are presented.

Keywords: additive manufacturing, 3D printing, 3D scanner, photolithography, casting in silicone molds, lot production, import replacement.

Sergeev A.I., Kornipaev M.A., Shamaev S.Yu. Popov A.N.  Application of non-uniform cellular genetic algorithms for parametric synthesis of flexible production systems

The problem of parameter seek for flexible production systems (FPS) with the help of structured genetic algorithms, in particular, the cellular ones, is discussed. The advantages of non-uniform cellular genetic algorithms are investigated as against the conventional genetic algorithms with the purpose to find FPS design parameters optimal subject to the equipment load criterion. The advantage of a non-uniform cellular genetic algorithm over the continuous one subject to the effectiveness of KFPS maximization is revealed.

Keywords: non-uniform cellular genetic algorithm, mutation probability, parametric synthesis, flexible production system.

Puzanov A.V., Shvetsov A.D., Puzanova K.A.  Integrated adaptive manipulator model

The change of manufacturing focus to custom products requires rapid-adjusting robot systems. For robot systems installed on mobile chassis most of operations look vague. The selection of possible relationships between design factors and the parameters of executable operations is possible by means of simulation-based study with subsequent selection of optimal solutions as well as the formation of corrective values for manipulating robot’s control system.

Keywords: manipulator, flexibility of robot systems, flexibility of robotic systems, adaptive model, rigidity modeling.

Events

Kharazov V.G.  An overview of “Automation 2022” exhibition

“Radio electronics and instrument-making” and “Automation” took place in St. Petersburg EXPOFORUM on September 21-23, 2022. The paper overviews novel products and solutions presented at the exhibitions.

Keywords: automation, electronics, import replacement.

“Constellation PLM” conference summary

The 15th “Constellation PLM 2022” conference took place on October 12-14. The event regularly gathers T-FLEX PLM users. The experience of digitalization and application of present-day approaches and technologies in mechanical engineering, aircraft building, shipbuilding, and warfare applications was shared by the participants from major Russian corporations and holdings.

Keywords: CAE, geometric kernel, unified information space, master data.