System of monitoring of technological process for determining emergency situations on food enterprises

Abstract

In order to create effective management systems for food production, which make it possible to use the accumulated experience of experts, intelligent control systems have been significantly developed. However, despite the significant number of works in the field of intellectual management, most of them are aimed at solving problems of effective management of only certain areas of production, and not the enterprise as a whole.

The procedure for making management decisions in any field of activity is based on the selection of the necessary data and their processing [1]. Only a generalized analysis of the factors characterizing the area under study makes it possible to make an informed decision. As a result, decisions are implemented in the form of assessments of emergency situations, plans, projects, etc. The decision-making process is based on an analysis using a systematic approach of expert methodology and modern economic-mathematical and statistical data processing methods, acting as a scientifically based methodology.

Currently, the problems of increasing the level of automation of management processes of Electrotechnological complexes are mainly reduced to the search and improvement of rules for making management decisions. At the same time regarding the standard conditions and situations (under which it is assumed that the controlled system must have predictable behavior), the creation of such rules in many cases does not cause any special problems, there are significant obstacles to emergency situations in the way of their formation.

The main idea of the management strategy that is being developed is to ensure timely and reliable detection and recognition of NA in real-life production conditions, assess risk factors and, on this basis, ensure timely elimination of the causes of risks before the appearance of failures and other undesirable consequences.

The goal of the research is to develop a process monitoring system for identifying abnormal situations and decision support, which helped the operator to assess the situation in real time and make the appropriate decision.

An integral part in the process of food production management is the operator who intervenes in the work of the system in case of violations of the technological regime, which the automated control system cannot handle. The effectiveness of the decisions depends on the professionalism of the operator, the ability to quickly identify the cause of the violation and to develop adequate actions for rapid response. It is advisable to supplement the existing systems of food production automation with a process monitoring system to identify abnormal situations and support decision making with a view to localizing them.

We will implement the developed process monitoring system using TIA Portal (Totally Integrated Automation Portal) of Siemens. Simple development at TIA Portal allows full access to a common digital automation system. As part of the Digital Enterprise Software Suite software, the TIA Portal, along with PLM (Product-Lifecycle-Management) and MES (Manufacturing Execution System), complements the entire series of Siemens enterprise software during the transition to industry 4.0.

The following software packages are integrated into TIA Portal:

- Simatic Step 7, for programming the S7-1200, S71500, S7-300, S7-400 and WinAC controllers;

- Simatic WinCC, for developing a human-machine interface (from the simplest keypads to complex SCADA level changes)

- Sinamics StartDrive for the parameterization, programming and diagnostics of Sinamics drives;

- Simatic PLCSIM - PLC simulator;

- Simatic Step 7 Safety;

- Simatic Visualization Architect;

- Simatic Energy Suit;

The main reason for choosing Siemens TIA Portal v14 sp1 software was the ability to simulate the operation of SIMATIC programmable controllers on a computer without real control equipment, as well as the ability to integrate the finished product into any automation system. This allows you to identify software errors in the early stages of project implementation, improve the quality of programs, speed up and reduce the cost of commissioning work.

 We will develop the development of a system for monitoring abnormal situations using the example of a sugar factory, for which it is necessary to analyze the process of making sugar. The main parameters of the technological process were determined and a parametric diagram of the main departments of the sugar factory was developed, where three sections of the sugar factory (diffuse, defining, evaporation station) and the interrelation of the main parameters of these stations were shown.

As a result of expert judgment, it was determined which parameters affect the process flow at a particular station and affect the processes in adjacent stations, as well as the limits of deviations of the basic parameters depending on the type of HC. A table of interactions for each station and for the three main stations as a whole, and the table for the limits of abnormal situations was constructed.

The software-hardware complex of the system of monitoring and decision-support support is developed, which for the normal functioning should receive data SCADA-system of automated production management.

The basic part of the SPPR is the module for analyzing the impressions of process technology sensors, and the main part of the SPPM of the controller should be the ability to predict the risks and consequences of the use of a decision of the controller. The main task of the monitoring complex is to reduce unplanned production stoppages and simple equipment in the event of emergency situations due to the prediction of the operation of the electrotechnological complex and the increase in the speed of the controller's response. To improve the quality and efficiency of decision-making on managing the electrotechnological complex in the food industry, the task of creating a multi-level system of operational dispatch control is presented and phased out, the main objectives of which are:

- Continuous control over technological processes;

- Presentation of technological information in real time;

- operational detection and prevention of emergencies;

- localization of abnormal situations;

- submission of commercial information on quantity and quality

Consequently, the developed system of management of the electrotechnological complex of food production is implemented as a subsystem of the automated control system of technological processes at the level of the central dispatching point of production. For efficient functioning of the developed system it is necessary to fully realize automated workplaces of all specialists of the enterprise. The user program was developed using a comprehensive programming environment from the Siemens TIA Portal v14 and its integrated programming environment for the simatic S7 STEP7 controllers.