Zeus Control has developed countless projects in recent years. Here is a description of the most representative.
SUPERVISION SYSTEM OF TEVA IN ALMARAZ NUCLEAR POWER PLANT
Client: Almaraz Nuclear Power Plant
Location: ¬†Almaraz, C√°ceres (Spain)
The Almaraz nuclear power plant is cooled by water from the Arrocampo dam that flows into the Tagus (River). A set of cooling towers has been installed to control the discharge temperature, which must be kept under an established (upper) limit. The project of TEVA (Torres de Enfriamiento del Vertido de Arrocampo, i.e. Arrocampo Discharge Cooling Towers) integrates different units: cooling towers, valves, pumps and electrical equipment, which are controlled and supervised by the control system implemented by Zeus Control.
The TEVA control system is implemented by a fault tolerant system.¬† The system is based on the Siemens redundant controller 417-H that ensures fault tolerance in the main component. Furthermore, the electrical cabinet includes redundant power supplies and other hardware components that ensure anomaly detection and proper functioning in such conditions.
The control system controls and supervises the following equipment:
- Feeding pumps
- Guard and bypass valves
- ¬†Electric system
- Cooling towers
- Cleanliness grid
- ¬†Dam gates
Communication with Nuclear Power Plant main control systems
All information on the different systems that make up the TEVA is received by SAMO, the main power plant monitoring system, and shown to the control room operators. Moreover, the plant’s main DCS sends direct commands to TEVA.
The TEVA system is designed to withstand against possible threats such as malware intrusion or software virus, as is required in any working application in a nuclear power plant.
During the event of a malware attack on the TEVA net, the main priority is to maintain proper functioning of the plant’s control systems.
ZORITA NUCLEAR PLANT MONITORING AND SUPERVISION
Location: Almonacid de Zorita (Spain)
Zeus Control has implemented a transportable control room where all alarms, equipment status and other signals are wirelessly received. This transportable control room will be used in the Zorita nuclear power plant during the dismantling process.
Two redundant base stations were installed in the turbine building. They collect information from different grouping cabinets distributed throughout the plant, transmitting to the redundant controller located in the transportable control room.
The wireless network used to communicate base stations, controller and grouping cabinets is fault tolerant, so it keeps working in case of a single component failure. The wireless network was designed taking into account the different shadow areas between buildings of the facility, the various distances between communication points and different climatic conditions (rain, fog or wind).
Each monitored device is wired to one out of seven grouping cabinets. The electrical signals coming from monitored equipment, either analog or digital, are converted in the grouping cabinets before being transmitted to the control station.
Protection against power outages
All antennas and grouping cabinets have a range of 48 hours of operation on power failure, ensuring fire alarm detection and radiation monitoring are transmitted to plant control staff.
Transportable control room
The control and supervision system is installed in a transportable control room, allowing location changes during dismantling activities in the nuclear plant facilities.
The control room is equipped with a UPS that feeds the control system, redundant controllers and two SCADA servers that display information on four monitors and a large screen, allowing quick monitorization of alarming conditions in the plant.
CO2 CAPTURE AND H2 PURIFICATION PILOT PLANT CONTROL SYSTEM¬†
Location: Puertollano (Spain)
The Zeus Control project focused on the control system of the pilot plant for capturing CO2 and purificating H2. Elcogas facilities in Puertollano are mainly used for coal gasification and subsequent use. Zeus Control technicians’ specific activities were: control engineering design, manufacturing of control cabinets, control equipment supply, control system programming, control system testing and on-site commissioning.
ROYNE ICE CREAM PRODUCTION PLANT CONTROL SYSTEM REPLACEMENT
Location: Getafe, Madrid (Spain)
The Zeus Control project focused on replacing the existing control system in CIP and maturity processes in an ice cream production plant owned by Royne in Getafe. Zeus Control technicians’ specific activities were: study of improvements in production facilities, design of new control architecture, supply of control equipment, new control system programming, control equipment on-site installation, FAT/on-site testing and on-site commissioning.
BIOMASS POWER PLANT CONTROL SYSTEM
Client: Termisa Energ√≠a
Location: Briviesca, Burgos (Spain)
The plant produces up to 20 MW of electricity using straw as a biofuel. Zeus Control technicians’ specific activities were: control logic design, on-site installation of cable trays and control cables, factory acceptance tests of control system for boiler and biomass transportation, on-site commissioning of control system.
CALERIZAS INTERSECTION REMOTE CONTROL SYSTEM
Client: Canal de Isabel II
Location:Torrelaguna, Madrid (Spain)
16 remote points connected by redundant fiber optic and WiFi systems were installed in this project. The information collected at these 16 points is centralized on a PLC and eventually sent to the monitoring center in Madrid. Zeus Control technicians’ specific activities were: manufacturing of control cabinets, supply of components for the remote system, programming of control system, on-site installation, FAT/on-site testing and on-site commissioning.
BREAD PRODUCTION LINE 9 MANAGEMENT¬†
Location: Noblejas, Toledo (Spain)
The project implementation allowed adequate visualization of information for operations, task prioritization, event recording and ingredient traceability on the production line. Zeus Control technicians’ specific activities were: design of new control architecture, communication and information management detailed engineering, supply of control equipment, manufacturing of control cabinets, new control system programming, control equipment on-site installation, FAT/on-site testing and on-site commissioning.
COAL GRINDING PLANTS CONTROL SYSTEM AND MCC
Client: Loesche Latinoamericana
Locations: Beni-Idir and Oudzem (Morocco)
Period: 2005 – 2008
The project focused on the control system and the motor control center for two new coal grinding plants in Morocco. Zeus Control technicians’ specific activities were: design of control architecture, design of control cabinets and motor control centers, control cabinet and motor control cabinet manufacturing, control system programming, FAT tests in Madrid, on-site testing and commissioning technical assistance.
ROBOTIZED PARKING CONTROL SYSTEM
Client: Rob√≥tica y Mecanizados
Location: Legan√©s, Madrid (Spain)
The project focused on the control system that regulates automated allocation of vehicles delivered in the parking reception and, later on, their return upon request. Zeus Control technicians’ specific activities were: design of control architecture, design and manufacturing of control cabinets, control equipment supply, control system programming, control equipment on-site installation, FAT/on-site testing and on-site commissioning.
COAL BOILER CONTROL SYSTEM
Location: Torrelavega, (Spain)
The project focused on the replacement of an outdated regulation and sequential logic system of a boiler with a new Distributed Control System. The boiler produces 100 tn/h steam and uses coal as fuel. The coal grinding process is also controlled by the new control system. The number of variables considered in the new control system is over 800. Zeus Control technicians’ specific activities were: design of control architecture, design and manufacturing of control cabinets, control equipment supply, control system programming, control equipment on-site installation, FAT/on-site testing and on-site commissioning.