Process Automation

Powder Plant - Drying - Calcining and Combustion Systems Automation :

Process Control which is automatically performed by considering  set values (parameters), material feeding, temperature and pressure control which are limited by Safety Parameters.


Performed Process Control is provided with Top Level Safety. Hardware Architecture which is created for ideal material calcination and applied Software are inseperable whole of each other.Instruments used in calcination / combustion process is optimized instruments. The implemented software has sophisticated structure


General Features :

  • Temperatures and pressure values can be monitored in real time
  • Suitable for  PID Control with Parameters (Temperature and Pressure ) defined by Operator
  • Operator controlled  “manual” work with the condition to stay inside “Top Level Defined Safety Parameters”  (System would not allow operator’s interventions if the conditions are out of SafetyPrameters)
  • With the contidion to stay inside “Top Level Defined Safety Parameters” , Safety Alarm Set Values and Safety Stop Set Values could be set by Operator. (If the values are out of  Safety conditions, System will not accept  )
  • System material feeding procedure is performed by operator defined PID control
  • Whole Process Values, System Set Values, Alarm and Safety Values can be recorded to Graphical Trend part and retroactive reporting and output can be taken
  • Machine running hours, capacity amounts (fuel and material) is kept its own Database.  Daily- Monthly-Annualy and retroactive reporting can be done
  • It has strong and robust database for Process Reporting / Alarm Reporting / Trend outputs


Dry Mixing and Dosing Plant’s Automation :

It is the control structure of solid material dosing and mixing facilities which are performed prescription-based production.


General Features :

  • SIWAREX (weighing electronics moduls) for sensitive weighing and control
  • Class – C3 with Y=1/10.000 coefficient Load Cell
  • Operator control for continuous or discontinuous work
  • Establishable prescription structure with menu based graphical interfaces
  • Production prescription database that is available to group the different kinds of production for specific categories
  • Capability to record material amount which is taken from silos, their times, total amount of material inside the scale, tolerance and the amount of errorsforeverybatch
  • Strong database structure for Production reporting / Alarm Reporting / Trend outputs
  • PLC program structure which is unaffected by power failures (continuous)


Dry Mixing Reporting Software:

Dbf based Production Reporting software is running independently of SCADA. It is prepared by considering the requirements of production reporting of facilities and need for creation of prescription records. Whole reporting parameters  are presented to the user wtih flexible graphical interface.


Features:

  • Reporting based on production charge period
  • Reporting based on produced raw material
  • Reporting based on Scale and Silo
  • Reporting based on production date period
  • Reporting based on number of charges
  • Reporting based on charge units
  • Reporting based on daily charges
  • Reporting based on monthly charges
  • Reporting based on annually charges
  • Reporting based on prescription that is entered to Automation System
  • Reporting based on total charges
  • Recording those reports as a excel file
  • Recording those reports as a pdf file
  • Printing out the listed report by print tab


Automation of Packing Machines :

Central Control Unit :

  • Cabinet with IP-65 Protection Class
  • PLC controlled Siemens S7-300 Series
  • Programmable and can be Calibrated by using “Siemens - Operator panel”
  • Different ON - OFF Switch for every unit
  • Emergency Stop Button For Safety Stop
  • Whole field connections are Pluggable Type (Industrial Type)
  • Communication feature with external systems by Profibus or Profinet


Machine Components :

  • IP - 65 protection class motor and valve cabinet for every unit
  • Class - C3 Y=1/10.000 (minimum) Load Cell
  • Operator Display with Box (IP-54) for monitoring Filling Amount in Every Unit
  • With Start-Stop Button, Also Filling Starts in connection with Limit Switch
  • Whole connections are Pluggable Type (Industrial Type)
  • Pressure Switch for Air Pressure Control
  • Bunker Level Sensor is ready to connect for Control of Filling Bunker


Operational Features :

  • Adjustable filling capacity between 5-50 kg
  • %0,5 filling precision
  • Stop working, if the actual value of System Air Pressure is under set value
  • Stop filling, if the Packing Bunker Level is under certain value
  • “Filling Capacity” Counter with Reset option for every unit
  • “Number of Bags” Counter with Reset option for every unit


Automation of Scale Belt :

Central Control Unit :

  • Cabinet with IP-65 Protection Class
  • PLC controlled Siemens S7-300 Series
  • Programmable and can be Calibrated by using “Siemens - Operator panel”
  • Class – C3 Y=1/10.000 (minimum) Load Cell
  • SIEMENS – SIWAREX CS series , with high precision , weighing electronics modul
  • SIEMENS – ET200S seriesHSC Encoder modul
  • 1024 pulse incremantal encoder for speed measurement
  • Communication feature with external systems by Profibus or Profinet

Operational Features :

  • Applicable for every type of conveyor belt
  • Software to reduce the effect of vibrations
  • Continuous Monitoring feature for Speed of Belt, Weighing Amount and Flow
  • Self-Calibrating Speed Measurement System
  • Password protected - Resettable – Counter
Composite Material Processing Autoclave Automation :

Features:

  • Multiple point temperature, pressure and vacuum reading feature
  • Control of high pressure and hig temperature with safety
  • Prescription based process control
  • Independent graphical view for every point measurement
  • Database record feature for every signal
  • Continuous fault check for Autoclave instruments
  • Cabinet with IP65 class
  • PLC control : SIEMENS S7 300
  • Optimized SCADA software for process control
  • Database management software for reporting, preparations of test documentations and component documentations


Automation of Gypsum Board Plant :

Features:

  • Liquid and solid dosing with %0,5 precision
  • Sophisticated PID control ( the ability to reach set value even with instantaneous flickering )
  • Optimized liquid and solid mixing system
  • Stabilization on freeze control
  • All units synchronous operation feature
  • Intagrated multiple area drying
  • Optimized use of sensors
  • Serial - Gradual feeding in the entrance of Kiln
  • Depending on the nature of the programming to achieve perfect surface
  • Impeccable stacking
  • Whole Process Values, System Set Values, Alarm and Safety Values can be recorded to Graphical Trend part and retroactive reporting and output can be taken
  • Machine running hours, capacity amounts (fuel and liquid/solid raw materials) is kept its own Database.   Daily- Monthly-Annualy and retroactive reporting can be done
  • It has strong and robust database for Process Reporting / Alarm Reporting / Trend outputs



Gersan Sanayi Sitesi 2310 Sok. No: 22 Ergazi - Yenimahalle Ankara -Turkiye
Phone.:+90(312) 256 91 11-12  Fax:+90(312) 256 91 50