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PGZ STOCZNIA WOJENNA – control and visualization of a steam boiler room with a capacity of 24 MW

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K&W Expert odpylanie filtracja chłodzenie sterowanie i wizualizacja kotlowni parowej SCADA


PGZ Stocznia Wojenna was established in 2017. It is part of the Polish Armaments Group, one of the largest arms companies in Europe. It began its operational activity on January 3, 2018, after taking over the assets of the Naval Shipyard (SMW), which from 1922 was associated with the Polish Navy. They offer services in the field of design, repair, reconstruction, construction, modernization and maintenance of both warships and civilian ships and other floating structures.

Offered solution:

The scope of work included the reconstruction of the documentation of control switchgears, control and visualization of a steam boiler room with a capacity of 24 MW (Three Danstoker steam boilers with Weishaupt burners powered by GZ50 gas and light fuel oil). As part of the work, the condition of the existing elements of the I&C installation was verified, an algorithm was written to control the operation of the boiler room, industrial visualization was created and the boiler room was launched in automatic operation mode.

The control was carried out using the existing Siemens PLC and 4 distributed I/O sets (ET200 islands). PLC performs all functions of technological algorithms functionally divided into control of the ZZ supply tank, ZK condensate tanks and ZU supplementary tanks, ko1, KO2, KO3 boiler control.

The operator has the ability to choose the control of pumps by selecting the mode switch on the cabinets:

-Automatic – the pumps are switched on/off via the PLC, which automatically changes the lead pump ensuring uniform consumption of individual pumps in the set. The operator has the option of tasking the time after which the primary pump will be changed. In this mode of operation, it is also possible to attach manually from the visualization.

-Manual – the pumps are on/off from the cabinet or locally with start/stop buttons outside the control of the control system.

Control of valve and flap actuators is carried out from the PLC in the following modes:

-Automatic – the adjustment is performed by a PID regulator with fixed parameters (gain, integration and differential time).

Manual – the operator, after switching to this mode of operation, has the ability to manually close and open valves and flaps.

In addition to controlling the standard equipment of the boiler room, a signal from the PLUM gas converter regarding the impending exceeding of hourly gas consumption (Modbus RTU) and the ability to control the power regulators of the burners via the PROFINET-DP protocol were introduced into the system. The availability of the above signals made it possible to introduce the function of a guardian of the value of the ordered gas.

Failure alarm, directly from the PLC level, is carried out through a buczek and a telephone connection. The program also offers counting signals from impulse meters installed in the boiler room.

The visualization was created using the PROMOTIC software, which acts as a monitoring system over the entire boiler room control process. The Profinet protocol (MPI/Profinet converter) was used to communicate with the controller. The application uses three levels of access with different permissions: operator, administrator and service.

The application registers events (switching the operating mode, changing settings, etc.) and alarms, and also allows you to view their history. It is also possible to trend variables and display them on a chart. The administrator has the ability to change the values of alarm thresholds and freely add trends of individual variables.

The solution allows remote access within the local company network, secured by logging in. To ensure the reliability of continuous operation, the Watchdog program was used.

Technical data:

Communication protocolProfinet, Modbus RTU, MPI
Remote connectionUsing a Web page
Operator stationPC, 22′ monitor
Sterownik PLCSiemens S7-300

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