In the Slovenian company where synthetic resins are produced, a decision was made to expand production to maintain market competitiveness and ensure sufficient capacity to meet market demands. Consequently, the client requested the construction of a new reactor line.
This thesis presents the process of creating a project for the automated production of synthetic resins. The content pertains to specific practical procedures encountered during similar projects. Initially, we dealt with technological schematics, which are the foundation of any industrial system as they enable visualization and planning of the entire system. These schematics include various elements such as valves, gauges, and other components that subsequently form tables describing the system elements. We then present the differences between pneumatic and control valves, which are essential for precise fluid flow adjustment, crucial in chemical industries. Following this, we discuss different types of gauges that have various measurement ranges and must also have ATEX certificates required for explosive hazardous zones. After presenting the elements and determining their signals, the electrical plan was drawn in the EPLAN software environment. The plan includes drawings of motor assembly with a frequency converter, gauges, and valves, and ultimately the drawings of all power cabinets that are interconnected. Due to the high flammability, we introduce elements such as barriers that allow safe communication between the control section and the production area where the explosive hazardous zone is located. The following are the requirements for the construction and design of electrical cabinets, both power cabinets, which supply power to high-consumption devices, and control cabinets, which are used for control and communication. In the commissioning of control cabinets, we are encountering the hazardous explosive zone for the first time, so proper planning was crucial for the entire system's operation.
In the final section, the functional blocks are presented, reflecting the communication with valves, gauges, and other power consumers in the Honeywell software environment. Additionally, we gain insight into the software environment where we create graphical interfaces and examine a specific project example. Finally, we highlight the planning and creation of a table for conducting I/O tests, which verify correct connections and proper configuration of output and input signals. In conclusion, we present unfinished tasks still in progress and describe the processes that caused the most challenges, along with any changes that occurred during the implementation.
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