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TPP Tuzla [BiH]: Automation of stacker-reclaimer

Automation of stacker-reclaimer


Customer: JP Elektroprivreda BiH, Thermo Power Plant Tuzla, B&H, 2011


Process description
Bucket-wheel Stacker/Reclaimers travel on a rail track alongside the piles of material, offering the potential to selectively stack and reclaim materials in different stockpile sections. This is carried out in two quadrants (directions) on both sides of the track. Four-quadrant reclaiming is possible with units featuring tripper-trailers that can be uncoupled. Active stockpiles may be stacked and reclaimed within the traveling limits and operating radius - up to the boundary zone of the storage area on the boom side of the machine. On the trailer side, a clear space, or box cut, is provided, which permits the bucket-wheel to cut into a free end face of the pile.


Implementation of a cost efficient and user friendly process control system with as less as possible classical cabling which have to result in a very fast and
easier cabling, engineering and commissioning of a very high level. Very detailed diagnostics and intuitive representation of current step for fast fault analysis and low deadlock times. Robust solution to endure harsh environmental conditions and 24h 7 days a week work.


The solution is a totally integrated automation architecture with PROFIBUS based topology. Distributed ET200M stations with PROFIBUS interface are connected to the central 315-2PN/DP processor. Two PC stations are connected via industrial Ethernet to the controller. Robust monitoring of machine position is achieved trough redundant BERO limit switches and SIMODRIVE absolute value encoders. Control of motors is improved by introducing micromaster 4 frequency drives. For remote monitoring a video surveillance system with Siemens SISTORE is installed.


Project overview

  •  50 motors
  •  15 analogue instruments
  •  500 digital signals
  •  Control system with 315-2PN/DP
  •  2 OS stations with WinCC v7.0
  •  5 ET 200M
  •  Industrial Ethernet and Profibus DP
  •  Based on network topologies
  •  Micromaster 4 frequency drives
  •  Absolute value encoders
  •  5 IP cameras
  •  SISTORE camera monitoring system
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