In the heavy floods that have happened in Kolubara basin, many mining machines were damaged. Mikro Kontrol did the refurbishment of complete electrical system for 17 mining machines.

Scope of Work

Mikro Kontrol provided detailed and as-built design, electrical equipment assembling and delivery, site supervision, test and commissioning for the following units: two Mobile Shifting Devices, ten Drive Station for Conveyors, two Belt Wagons, one Bucket Wheel Excavator, one Spreader, and two Dispatching Centers.

Benefits

• Open pit mine put into operation after catastrophic damage
• Done within less than two years
• Electrical equipment refurbished and modernized
• State-of-the-art equipment and solution

Technical Description

The basic concept applied to all machines is as follows:

• Supply voltage 6kV
• 6 kV power cable with integrated optic fibers
• SF6 medium voltage switchgears
• Converter-Duty Power transformers, designed for harsh environment and operation in mine    
• Motor drives with variable speed control on voltage 690V
• Multi Drive VFD configuration for machines and Single Drive VFD configuration for conveyors
• Decentralized PLC configuration
• Control, monitoring and visualization via HMI and SCADA
• Ring structure of the fiber optic network

• PROFIBUS and PROFINET protocols

As a part of the project for Coal Quality Management System (CQMS) for a new Stockyard and Crusher Plant on the OCM Tamnava, Mikro Kontrol as a subcontractor of FAM Magdeburg, did the equipment procurement and installation on field.

Scope of Work

Mikro Kontrol provided basic, detailed and as-built electrical design, delivery and installation of VFDs for a new Crushers, hardware expansion of existing DCS system in existing Crushing Plant, software programming, upgrading and integration of existing DCS system in new CQMS, electrical mounting of new stockyard machines and crushers, as well as the commissioning services.

Benefits

• Coal deposit homogenization
• Increased deposit utilization
• Increased energy efficiency
• Reduced negative effects of environment exploitation
• State-of-the-art equipment and solution
• Maximum level of reliability and availability
• Operation and maintenance convenience

Technical Description

New Stockyard for crushed coal on the OCM Tamnava is used for coal homogenization. It includes 18 belt conveyors, 4 crushers, stacker and 2 reclaimers.

MV & LV switchgears supply the whole equipment.

In order to fully integrate the existing DCS system of Tamnava Crushing Plant into the new CQMS, it was expanded with the new network nodes and upgraded to CEMAT, add-on library for Siemens PCS 7.

Mikro Kontrol delivered complete electrical system for a Portal Bridge Stacker for gold sludge in Hydrometallurgical Plant 3 (GMZ-3) of the Navoi Mining and Metallurgical Plant, Uzbekistan.

Scope of Work

Mikro Kontrol provided detailed and as-built design, electrical equipment assembling and delivery, installation materials delivery, site supervision, test and commissioning.

Benefits

• Turn-Key solution
• State-of-the-art equipment
• Advanced drive and software solutions against bridge misalignment
• Maximum level of reliability and availability
• Operation and maintenance convenience

Technical Description

The main power supply 380V, 50Hz is realized over festoon system. The power supply for movable spreader conveyor and its travel drives are realized as sub-distribution over festoon system as well. The main MCC and PLC are located on the bridge itself.

Bridge Drives and Spreader Conveyor Travel Drives are designed as Variable Frequency Drives. The bridge drives are operating synchronously in load-sharing master-slave operating mode. There is a multi-turn absolute encoder to measure travel and a reference marker on the both sides of the bridge.

PLC software is tracking parameters and making corrections against Bridge misalignment. Operator desk with HMI touch panel, operator joysticks and signaling and control elements is in operator room next to the stockyard. Communication between control elements is realized over Profinet communication.

During sintering process the iron ores are thermally treated; the carbonate, sulfide and oxide molecules are dissociated, with the final goal to provide a “self-melted” sinter material which is smelted easily at the Blast furnace plant. Environmental protection is very important issue, therefor the control of Electric precipitators with dust conveying is realized within the project scope.

Scope of Work

Mikro Kontrol provided detailed and as-built design, application software, MCC and control panel manufacturing and install, electrical works at the site (dismantling the old control system - panels and cabling, mounting of electric equipment as well as sensors and actuators), testing and commissioning.

Benefits

• State-of-the Art Control System equipment and solution
• well-tuned process parameters
• operation and maintenance convenience
• done within 6 months

Technical Description

The control and monitoring scope involves manufacturing, installing and connection of 11 MCC / control panels, 2 operator pulpits and 70 local control cabinets; replacing of 6 DC motor drives (drum feeder, sinter machine and line cooler) with AC motors (frequency control drives); design, delivery and mounting of two weigh scales 200t/h, 80 process sensors (pressure, flow, temperature and moisture); control of MV fan (two speed, 6kV / 1000kW, DC drive); electrical erection – more than 25km of cable trays and cables – signal and power.

Control system is realized with decentralized architecture where master PLC communicates over fieldbus with 8 decentralized I/O nodes, including decentralized periphery at electric precipitation location as intelligent slave (autonomous PLC).

To increase the safety transport of agglomerates of HBIS ironworks in Smederevo, Mikro Kontrol delivered a turnkey project of mobile conveyors, which includes complete electrical engineering for mobile conveyors.

Scope of Work

Mikro Kontrol provided detailed design, assembly and delivery of electrical cabinets, FATs, complete electrical works, site supervision, as well as commissioning.

Benefits

• State-of-the-art equipment and solution
• Done within 6 months
• Maximum level of reliability and availability
• Operation and maintenance convenience

Technical Description

The 400V power supply to the low voltage conveyor cabinets is derived from the local H3 and H4 conveyor cabinets and is located on the platform below the conveyor.

The whole electrical equipment is placed in electrical cabinets and is made in relay technology. The local control cabinets are located on a platform near the conveyor to allow the operator a detailed overview and information about the state of the conveyor and the material flow.

The belt conveyor motor and the transport conveyor are controlled by a direct online method with protection functions via the protection relays and sensors on the conveyors.

• Pressure and temperature
• Flue gas oxygen ratio (O2)
• Water flow at return pipeline

Mikro Kontrol has developed and implemented control system for Herbicide Compounds Production. This project is one in succession in a series of successful projects done for this client, in addition to fungicide and insecticide production control systems.

Scope of Work

• PLC, HMI and SCADA application development
• Commissioning and testing
• End user training

Benefits

• Ensured reliable operation with implemented technological blocks
• Prevention of unforeseen actions
• The synoptic view clearly indicates the states of the devices, individual tanks and dissolvers
• Improved production by production flow analysis

Technical Description

The production facility consists of several underground and surface tanks, reactors, storage tanks for the finished product and bottlers. The operator through the SCADA application chooses a recipe according to which the raw materials from the tanks to the reactor are automatically dosed and mixed. The finished product is then transported to the reservoirs from where the bottlers are fed to get the final product.

The recipes are downloaded directly from the factory information system and transferred through the SCADA application to the PLC controller. After each dosing, mixing or transport operation, detailed information on the operation performed is recorded in the factory database via the PLC controller and the SCADA application.

A new information system for management and surveillance of productoin process is implemented in Zorka Color. The system enables production management according to manufacturing orders, starting from raw materials separtions, through technological steps implementation, all the way to the packiging of end products.

Scope of Work

Mikro Kontrol did the basic electrical design, PLC, HMI and SCADA software programming, as well as the start-up and commissioning of the whole system. The delivered equipment includes:

•  2 SCADA workstations
• 5 PLCs (programmable logical controlers)
• 12 touch operating panels (HMI)

Benefits

• Significantly improved product stanadardisation quality
• Unification of manufacturing process
• Significant decrease in human factor errors
• Decrease of production unit resource consumption (raw materials, time, etc.)

Tenchnical Description

Manufacturing orders from the Oracle database are being forwarded to the SCADA system according to a specifiic execution schedule. Active manufacturing orders are available online on touch operating panels on production line. Their primary function is to guide the operators and to be their interface in technological steps implementation.

Data are primarily being entered on barcode readers, decreasing the required entering time as well as mistakes. Barcode operators log in on the system, making a manufacturing order selection, raw materials, available processing equipment for the implementation of technological steps.

The PLCs installed in technological parts of manufacturing plants automatically control and manage implementation of individual technological operations defined by manufacturing orders. This is enabled by information obtained from the SCADA system and data entered by operators.

The data collected during production process is being stored in the Oracle database. It is used for generating tecnical and technological reports for different organizational segments of the company (production, sales, maintenance etc.).

As part of the project for the re-instrumentation of the ethylene factory, HIP Petrohemija, Mikro Kontrol, as a subcontractor of the company Yokogawa, did electrical design, cabinets assembly and implementation of equipment in the field.

Scope of Work

Mikro Kontrol provided the basic, detailed and As-built electrical design, assembly, delivery and installation of equipment.

The scope of work is divided into the following segments:

• Production, delivery, installation and connecting of RIOS cabinets, Energy cabinets and JB local control cabinets
• Delivery and installation (assembly) of cable routes (PNK 50 - 400), production of brackets as well as installation of pipe protection
• Laying and connecting power cables for power supply of RIOs cabinets, electric heating and other electrical equipment, signal and communication cables, optical cables

Benefits

• Safer and better process management with minimization of production interruption
• High reliability of the new control system
• Quick response of the control system (electronic transmission instead of pneumatic)
• More efficient use of process equipment
• Optimization of process fluid and energy consumption
• Redundancy of the alarm locking and control system
• Full transparency of management, with the possibility of analyzing past events
• Significantly lower maintenance costs
• Greater availability of plant and equipment

Technical description

The ethylene factory re-instrumentation project included the delivery of control-locking systems and instruments in the field with accompanying materials and equipment. The project includes the following units:

• Pyrolytic furnaces section
• Boiler section
• Superheater section
• Steam and condensate system
• Natural gas distribution system
• Primary fractionation section
• Main control room and local boiler control room
• Room for storage of DCS and ESD equipment
• Power installations
• Optimization and saving of raw materials and energy

The Japanese government approved the donation to upgrade the supervisory control and data acquisition system (SCADA) for the Belgrade Water Supply System.

The scope of the project was to establish a SCADA system for control and monitoring of all wells, distribution pumping stations and reservoirs, reconstruction of the 7 main distributive pump stations and renewal of the equipment for water quality analysis.

Scope of Work

Mikro Kontrol provided detailed and As-built electrical designs, delivery and installation of the whole equipment, PLC and HMI software programming, electrical mounting on all sites, as well as commissioning.

The delivered equipment included:

•  14 server racks with belonging SCADA workstations
• 126 new PLCs as well as around 80 existing on which applicative adaptations were made in order to connect them to the system
• 25 touch operator panels
• 20 chlorine analyzers
• 26 L3 switches, 32 SHDSL routers and 149 GPRS routers

 Benefits

• Maximum level of reliability and availability
• Increased energy efficiency
• State-of-the-art equipment and solution
• Operation and maintenance convenience

 Technical Description

SCADA system covered 155 totally location:

•  MCC - Main Control Center at 1 location
• LCC - Local Control Center at 4 locations
• Pumping stations of type A (with a local SCADA server) 14 locations
• Pumping stations of type B (without a local SCADA server) 14 locations
• Wells at 102 locations
• Reservoirs at 20 locations

 The main functional tasks placed in front of the SCADA system included data acquisition, monitoring and real-time data archiving from all facilities connected to the system (around 10.000 tags), real-time control and monitoring of 102 wells and 7 main pump stations, as well as the real-time monitoring of all distributive pumping stations and reservoirs.

The Polimark company transfered most of its production line to a new location, in Zemun suburb of Belgrade. New factory is one of the most modern factories in this part of Europe, and it was necessary to automate the entire new production plant.

Scope of work

As a long-term partner of Polimark in the field of automation and control, Mikro Kontrol performed in this project the following:

• Delivery of electrical cabinets for monitoring and control (PLC, "touch" panels, SCADA, frequency and temperature controllers, signal processors)
• Detailed and As-built design
• Monitoring and Control application (PLC, "touch" panels, SCADA)
• Testing, commissioning and proof of capacity

Benefits

• Significantly increased quality and production capacity
• Unified control system, easy to use
• A touch panel without keys
• The most modern solution and equipment

Technical description

The entire system included automation of the following technological plants: ketchup production, mayonnaise production, mustard production, sugar syrup production, transfer of raw materials,  transport control of final products to the packaging machines and management of CIP (Cleaning-In-Place) system.

The system is designed in the way that each of the above technological drives has a corresponding PLC, "touch" operator panel and electrical equipment housed in a stainless electrical cabinet. The use of "touch" operator panels has completely replaced the use of classic control elements (keys, switches, selectors). The operator is enabled to control the process with a system of menus and active touch-sensitive fields. All PLCs in the system are connected to a "peer-to-peer" network for the purpose of fast data exchange (status, permissions, blocking, alarms). The central SCADA system enables monitoring, collection and archiving of data so that all production processes contain their records. When the system was designed, special attention was paid to meet the requirements of HACCP and ISO 9001 standards implemented in the new factory.

• Improved maintenance and adjustment of process parameters
• Maximum level of reliability and availability
• Very fast detection of errors in the system
  
  

For production of high speed/capacity cardboard machines Mikro Kontrol delivered a highly demanding mechatronics application.

Scope of Work

Mikro Kontrol delivered detailed and As-built electric design, electrical cabinets, servo motors and sensors, PLC and HMI application, commissioning and testing.

Benefits

• Upgraded machine capacity and speed
• High precision of band cutting and stamping
• Easy to operate and working parameters setting-up
• Minimum risk for the operator
• Integration into end customer supervising system

Technical Description

The machine consists of several applicator heads for gluing and band stamping the cardboard boxes on the fly. Each band stamping head consists of two servo motors for adding and cutting the silicon tape that is applied over hot melt glue. Hot melt is applied by the previous applicator consisting of high speed nozzle. Position of each cardboard in the machine is tracked by encoder.

High-speed control system was developed using modern motion controller with EtherCAT communication. A speed of 25 000 pcs/hour is achieved. Control system also includes safety controller. Along with safety devices such as emergency stop buttons and light curtians, control system ensures minimum risk for working enviroment and operator.

Supported by the OPC UA, controller is integrated into the end customer supervising system. Using cloud services machine performance, monitoring by the end user is facilitated.

Mikro Kontrol developed an application for automatic dental bib making machine for a new line of machines. The application is one in the long history of successful projects implemented for our long-term partner, 9. Septembar.

Scope of Work

Mikro Kontrol did the full automation project, which firstly included development of PLC and HMI applications, and later commissioning, testing and integration into the customer supervising system. During the trial operation Mikro Kontrol provided full support to our customer in order to achieve high machine performance.

Benefits

• High production capacity while maintaining top product quality
• Various products including printing or self-adhesive bibs
• Easy product changeover
• Maximum level of reliability and availability
• Operation and maintenance convenience
• Safety control system
• Integration into end customer supervising system

Technical Description

Each machine consists of two paper roll unwinders and two foil unwinders. Two unwinders reduce machine stop time due to material changing. Unwinders, lamination and embossing section of the machine are regulated with frequency inverters.

Encoders and photo sensors enable stable flow of material through the machine. High-speed controller and high speed EtherCAT communication enable precise application of adhesive on every dental bib. Perforation of the bibs according to given length as well as roll producing is done by servo motors.

Ethernet/IP communication between controllers coordinates work of the machine. Implemented controllers fully support OPC UA thus enabling the integration into the end customer supervising system.

Mikro Kontrol provided control system for 6 casting machines for solid and hollow profiles of bronze for the Latvian company SIA KMM METALS.   

Scope of Work

Mikro Kontrol provided detailed and As-built electrical design, low voltage and control cabinets delivery, application software, commissioning, trial operation and training.

Benefits

• Technology monitoring with corrections during casting, without stopping the machine
• Knowledge database for specific cast profile with recommended casting parameters (step, pause)
• Enabled data archiving for casting 24/7 (selected profile, casting speed, temperature, quantity of cast profile in kilograms)

Technical Description

This type of casting machines has been using hydraulic mechanism for pulling with traction rollers. Hydraulic unit is replaced with an AC servo motors with a brake. In addition to the motor operation control, the system includes:

• Temperature measurement in the casting pot and the operating control for the burner that warms up the casting pot with fuel flow measurement
• Crystallizer water flow and temperature measurement (input - output)
• Surface temperature measurement of cast profile

The maximum outside diameter of profile being cast is 65 mm, the minimal wall thickness of hollow profiles is 3.5 mm.

Mikro Kontrol developed a complete algorithm for control software based on function blocks, application software for safety controller, motion controller and HMI interface, and commissioning with performance test.

Benefits

• Very reliable, fast and modern control system based on the last generation Omron NJ Motion controller platform
• Safety protection integrated in safety controller and motion controller
• Parallel work of transport cars, controlled by the Omron servo drives, contributing to a very large line capacity
• Complete monitoring and parameter setting of the machine
• Established fast and efficient communication between all parts of production line

Technical Description

Standard parts of napkin production line include: paper unwinder, printing section, emboser section, longitudinal cutting and perforation, counting and packaging head, transporting part and part for transporting to the packaging machine.

To incerease the line capacity, Mikro Kontrol designed  4 production channels. On every channel, there are 2 pairs of transport cars, driven by 4 servo motors. Internal communication of transportation cars provide very fast and efficient transport without any possibility of collision and accidents.

In addition to many drives controlled by frequency converters, production line includes 24 servo axis capable of very quick and efficient task completion.

In order to avoid channel congestion and capacity decrease, the unloading part of the transport system intermittently moves packages from these 4 channels to an exit chanel on the packaging machine.

Mikro Kontrol has developed PLC and HMI applications for two types of toilet towels rolls packaging machines. RCP machine packs rolls in cardboard boxes, while the URB machine packs rolls in plastic bags. Both machines have a high level of complexity and each has more than 10 motion axes.

Scope of Work

Mikro did the full automation, including development of PLC and HMI application, commissioning, testing and integration to user's supervising system. During the trial period, Mikro Kontrol provided full support to the client to achieve the maximum machine performance.

Benefits

• High capacity with stable product quality
• Easy product changeover
• Working with recipes
• Easy operation and maintenance
• Safety control system
• Integration into end customer supervising system

Technical Description

Both machines consist of an entry conveyor and a diverter that arranges the rolls horizontally to form one row of rolls in the packet. The entire row comes to an elevator that goes down to accept a new row of rolls. The package formed on the URB machine is pushed to the plastic bag which is welded and cut, and then passes through a thermal tunnel. Unlike URB machines on the RCP machine package is inserted into a cardboard box that is previously formed on a separate section of the machine. The box then closes with duct tape on both sides.

Multi-axis high speed controller with Ethernet CIP communication is used for the implementation of the control system. All movements are carried out through CAM profiles to achieve the maximum speed of the machine with minimal mechanical load.

Through Ethernet Data Link Communication, the connection to other controllers in the plant has been achieved and the integration to the user's supervising system has been provided.