2009-11 The tests on the largest automation system GEA Wiegand has ever realized up to now could be successfully completed.
For this purpose, the complete process control system for the bio-ethanol factory KoronAgro in the Ukraine was installed in its original configuration with Siemens in Karlsruhe.
The process control system PCS7 comprises seven operator stations, two redundant servers, one archive sever, one engineering station and
3 PLCs 416.
This system operates and monitors hundreds of motors, frequency converters up to 1000 kW, several hundred pneumatic valves and control valves as well as more than thousand analogue and binary measuring points. Step chain controls allow a fully automatic operation of mill, fermentation system, molecular sieve, evaporation plant, dryer and pelletizing system.
For the complete plant, a simulation of the measuring points and actuators with the
WinMOD system, installed on 3 workstations, was prepared for the software test.
In this way, the process engineer could check the behaviour of the plant and of the process control system in his "usual P&I environment. This did not only allow the detection of mere software errors, but a plausibility check of the program description could be performed.
For the fully automatically operated GEA Wiegand technologies fermentation, molecular sieve and evaporation plant, GEA Wiegand prepared a process technological simulation.
This allowed a functional check of the step chains of the bio-ethanol plant already prior to the actual commissioning of the plant.