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Industrial cyber physical systems

Engineering of process automation and control systems, including development of specialized software

WHAT ARE CYBER PHYSICAL SYSTEMS?

The most common classical definition says that a cyber physical system stands for interacting networks of physical and computing elements that were developed together. The computing element of a cyber physical system gathers and analyzes information and enables control over physical processes. It typically includes feedback loops so that physical processes could influence computations and vice versa

Viewing cyber physical systems as critical for protecting their national interests, the governments of the developed countries put them on their innovation agendas as priority items

WHAT LED TO THE CREATION OF CYBER PHYSICAL SYSTEMS

A rising number of devices with onboard processors and data storage capacity – sensor networks that are used in all extensive technical platform; medical equipment; smart homes, etc.

Integration of separate components to form bigger systems, such as Internet of Things (IoT), World Wide Sensor Net, Smart Building Environment, defence systems of the future

Limited cognitive abilities of the humans, which are lagging behind machines in their evolution. There comes the time when humans are no longer capable to handle the amount of information that is necessary for making decisions, and they are forced to involve cyber physical systems to take care of certain actions. In this case, a human being is out of the loop

At the same time, there are cases when cyber physical systems can contribute to the analytical capabilities of humans. Therefore, advanced interactive systems are needed, in which a human being remains in the loop

Computers influenced all aspects of human life that are related to information, and cyber physical systems will change everything else

TOOLS THAT ARE USED FOR PROJECT IMPLEMENTATION

VENDOR'S PRODUCTS AND SOLUTIONS

Wonderware: (System Platform)

Siemens: (Step7, WinCC, PCS7, TIA Portal, WinCC OA, SIMATIC IT R&D)

Парадокс: Парадигма, Proflink SG, SVG mnemo, Charts constructor

SERVICES

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Inspections (process control system audits)

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Statements of work

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Research & development work

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Development of software for various levels

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As-built documentation

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Supervision

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Implementation of innovative Industry 4.0 solutions

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Support of the developed products and solutions

KEY FEATURES TYPICAL OF INDUSTRIAL CYBER PHYSICAL SYSTEMS

HYBRID STRUCTURE

Such systems have a hybrid structure. Thus, they encompass information components responsible for process control and physical components performing the process. At the same time, there can be quite a difference between cyber physical systems designed for different industries

COMMUNICATION ENVIRONMENT

These systems have their communication environment that enables a continuous exchange of information internally and with the external environment. Such information exchange is not always controllable by the user

CONTROL CENTRE

The systems have their control centre that typically encompasses a few feedback loops and is designed to maintain the process parameters within the given ranges/limits under external impacts

DEPENDENCE ON EXTERNAL EFFECTS

Cyber physical systems are influenced by external information effects that are directed at the control subsystem or the human-machine interface or the constituting devices or the communication and network protocols

CONTROL

Such systems can be controlled both by changing their parameters and by changing their structure and redistributing the functionality between the system components

VENDORS

MAJOR PROJECTS

Automation & Integration Package for Mill 5000, Rolling Facility No.9

Inspection

Preparation of a Statement of Work

Engineering

Development of applied software

Delivery and installation

Commissioning

Warranty and service

Training

Automation & Integration Package for Mill 2000, Rolling Facility No.11

Monitoring of shipping yard cranes and control of coil movement

Main and auxiliary equipment and process status monitoring

Lubricant yard status and lubricant consumption monitoring

Utility consumption monitoring

Electric power consumption monitoring

Utility (electric power) consumption monitoring and analysis

Network infrastructure control system

Production planning and control system

Product quality and process flow control system

Production monitoring and shipping yard control system

Inspection & design work, construction & erection, commissioning

Automation & Integration Package for Mill 2500, Rolling Facility No.4

Monitoring of shipping yard cranes and control of coil movement

Main and auxiliary equipment and process status monitoring

Lubricant yard status and lubricant consumption monitoring

Utility consumption monitoring

Electric power consumption monitoring

Utility (electric power) consumption monitoring and analysis

Network infrastructure control system

Inspection & design work, construction & erection, commissioning

Automation & Integration Package for Mill 2000, Rolling Facility No.11

Monitoring of shipping yard cranes and control of coil movement

Main and auxiliary equipment and process status monitoring

Lubricant yard status and lubricant consumption monitoring

Utility consumption monitoring

Electric power consumption monitoring

Utility (electric power) consumption monitoring and analysis

Network infrastructure control system

Production planning and control system

Product quality and process flow control system

roduction monitoring and shipping yard control system

Inspection & design work, construction & erection, commissioning

Automation & Integration Package for Sinter Plant No. 5. Commissioning of a process control system

Preparation of a Statement of work

Engineering

Modelling and development of applied software

Commissioning of the system

Automation & Integration Package for the Ferronickel Plant in El Estor, Izabal, Guatemala

Delivery of equipment

Basic engineering and implementation of a process parameter visualization, archiving and graphic representation system

Centralized Dispatcher Control System for the Angrensk coal strip mine

Preparation of a Statement of Work

Inspection

Engineering

Development of applied software

Delivery and installation

Commissioning

Warranty and service

Training

Automation & Integration Package for Continuous Caster No.6

Preparation of a Statement of Work

Inspection

Engineering

Development of applied software

Delivery and installation

Commissioning

Warranty and service

Training

Engineering of a calciner control system and its integration with the shop systems. Commissioning. Mikhaylovsky GOK, Zheleznogorsk, Kursk Region

Inspection

Preparation of a Statement of Work

Engineering

Development of applied software

Delivery and installation

Commissioning

Warranty and service

Training

АСУ “Экология”. Система автоматизированного контроля промышленных выбросов от источников ПАО “ММК”

Информационные сети

АС интеграции с АСУП

АС визуализации, мониторинга, архивации и формирование отчётных документов

Автоматизированная интеграции с КИС

СМР, ПНР

Automation & Integration Package for the Ground Phosphate Rock Line, Eurochem, Zhanatas, Kazakhstan

Engineering

Development and commissioning of software

SCADA

Delivery, construction & erection, commissioning

User training

Supervision

A pelletizing plant control system, integration with the shop systems. Commissioning. Sangan Pelletizing Plant, Azaran, Iran

Plant system, Main Automation System (AS-01), equipment for the control rooms, fiber optic data buses, Ethernet, Profibus DB

Instrumentation Project 1: Ore delivery and crushing of recirculation material

Instrumentation Project 2: Ore grinding and classification 1

Instrumentation Project 2.1: Ore grinding and classification 2

Instrumentation Project 3: Flotation

Instrumentation Project 4: Thickening

Instrumentation Project 5: Auxiliary equipment, process water supply system

Instrumentation Project 6: Preparation of reagents (incl. a lime dosing unit, conveyor 624.1-2, scale 624.1-2)

Instrumentation Project 7: Automation and instrumentation (incl. compressors, sampling and sample transportation systems)

Instrumentation Project 9: Tailings treatment

MMK. Tracking Systems. Oxygen Converter Facility. Marking

Metal tracking from casting to shipping

Tracking of shipping yard cranes and slab movement control

Marking and identification system

Inspection

Preparation of a Statement of Work

Engineering

Development of applied software

Delivery and installation

Commissioning

Warranty and service

Training

GE Energy Power Conversion GmbH. Commissioning. Electrical equipment of the roughing mill. Hot Mill 2500, Rolling Facility No.4 (incl. PLC, Scada, L2)

Integration of the roughing mill PCS with the furnace area PCS, the finishing mill PCS and the MES of Rolling Facility No.4

Slab tracking system

Visualization L1, L2 RM

Visualization L1, L2 RM

ПНР

HISTORY OF THE DEPARTMENT

The company’s leadership are taking extensive effort to make the company conform with the global Industry 4.0 standards and trends. They realise that an organization’s success depends on precise and well-coordinated performance of each employee. If one department tries to accomplish their tasks with no interacting with the other departments, it actually does the organization more harm than good read more

In this case, team members are striving to accomplish the task set before them without thinking about the common problem or goal. This results in a few poorly finished parts of one whole. To tackle this problem, in 2018 a department of industrial cyber physical systems and solutions was established in the company. Evgeny Khrenov, who joined KONSOM GROUP back in 2008 as an engineer, was appointed the department leader. Throughout his employment, Evgeny proved to be a true expert in the field capable to adapt to swiftly changing world standards, manage the changes and – what is most important – build relationships and work teams. These skills were indispensable as the new department merged with two others: Department for Process Control Systems and Department for System Integration..

The Department for Process Control Systems was established back in 2003, and at that time it was a completely new undertaking for the company. Yury Volshchukov was offered to lead the new department. After 3 years Evgeny Vasiliev took charge and introduced quite a few changes. At the moment Evgeny acts as a chief technical officer of KONSOM GROUP. Back then the department employed just a few staff. Some of the very first and therefore most cherished projects accomplished by the department were implemented at MMK’s Oxygen Converter Facility: a steel degassing system and a vertical bulk material and ferroalloy feed control system. Later the department participated in the revamping project for NLMK and worked for MMK’s Continuous Galvanizing Line, Mill 5000, Rolling Facility No. 11 and other sites. It was from the Department for Process Control Systems that the new merged department took over their first projects.

The new department helped improve communication between the company staff and save some project implementation time. Today, dozens of the staff from different departments are working on a project acting as a single entity. The Department members continue to develop their skills by taking training classes, participating in workshops and going through certifications. The Department covers Level 0 to Level 3, which helps the company on the whole to stay in line with the Industry 4.0 strategy.

AIM OF THE DEPARTMENT

To contribute to the company’s achieving its strategic goals

To ensure the required quality of services

DEPARTMENT of Industrial Cyber Physical Systems & Solutions

19 members:

  • 1 - Manager
  • 2 - Principal Specialists in software design and development
  • 6 - Lead Automation Engineers
  • 3 - Cat. 1 Automation Engineers
  • 3 - Cat. 2 Automation Engineers
  • 4 - Cat. 3 Automation Engineers