Control System References & Projects

ISYSTEMS AUTOMATION has delivered control, protection and optimisation systems since 2007. The list below covers projects carried out by the company. Where a client requires confidentiality, the site is described by type rather than by name.

Since 2007: Company founded in Ploiești, Romania
ISO 9001: Certified since 2009
260 t/h at 100 bar: Largest CFB boiler under our control system
6 DCS platforms: Ovation, ABB 800xA, ABB Symphony, PCS7, TIA Portal, Centum VP
SIL 2 / SIL 3: Certification support for safety applications under IEC 61511

What we do on site

Engineering and design

DCS conceptual architecture, I/O databases, control logic and control narratives, HMI design and alarm schemes
ESD and Burner Management System architecture, test and FAT procedures
SIL 2 / SIL 3 — certification support for safety applications under IEC 61511
I&C design verification against local and international standards
P&ID, cable schedules, panel design, hook-up and as-built documentation
Procurement of control and instrumentation equipment

Commissioning and operation

Factory and site acceptance testing, loop checks, functional testing, loop tuning
Autonomous plant operation with remote control over four redundant IEC 60870-5-104 channels
Turbine acceptance testing: quality of primary and secondary frequency regulation, rate of load change, generator disconnection from the grid, emergency stops
Boiler efficiency by direct and indirect method for gas and petroleum coke fired CFB boilers; steam turbine efficiency and losses; thermal and electrical energy balances
Process data collection from control systems and commercial metering, long-term archiving and calculation
DCS backup, lifecycle updates, and protection of control system assets against internal and external cyber threats
Operator training on new control schemes

The plant we know best

Most of the work below was carried out at one industrial CHP plant supplying a refinery in Ploiești, continuously from 2007 to 2018 and again from 2022.

The plant: three steam boilers of 120 t/h and one circulating fluidized bed boiler of 260 t/h at 100 bar; three steam turbines of 12 MW and one of 30 MW; steam headers at 100, 35, 16, 6 and 1.2 bar with reducing stations between them. Fuels are natural gas, refinery gas and petroleum coke. The refinery takes steam from four headers and electricity from the plant. A photovoltaic park and a wind farm are dispatched together with it.

Knowing a plant for eleven years is a different kind of engineering from delivering a project to it. Nothing below was handed over and forgotten.

Project list

Newest first. Years are as recorded by the client.

Years	Site and scope	Platform	Detail
2022–present	Refinery CHP plant, Ploiești · control system maintenance	Emerson Ovation, ABB Industrial IT 800xA, HIMA HIQuad, Honeywell PHD	Continuous safe operation of DCS, ESD, BMS and MES on an operating plant
2019–2021	Combined cycle power plant, Pančevo · investor's representative for the automatic process control system	Emerson Ovation, ABB Symphony Plus, Foxboro Triconex, ABB AC800 at SIL 3	Two gas turbines and one steam turbine. Verification of design for execution documentation; review of control algorithms and signal databases; mnemonic scheme approval; schedule development and monitoring; equipment inspection at the manufacturers under their quality control programmes; site entrance control; quality control of erection and commissioning; review of test and commissioning programmes; participation in the performance test; training of operating personnel
2019–2021	Combined cycle power plant, Pančevo · HMI architecture	ABB Symphony Plus	Unit overview; gas turbine 1 and 2 including fuel gas systems; steam systems across pressure levels; unit load control; SIL 3 status integrated into the operator picture; DCS grounding scheme
2020–2021	Hydroelectric power plant, Krasnaya Polyana · hydro turbine control	Siemens S7-300 / S7-1500 / S7-1200, TIA Portal
2019	Hydroelectric power plant, Belorechensk · hydro turbine control	Yokogawa Centum VP
2018–2019	Refinery CHP plant · sludge dosing on the CFB boiler	Emerson Ovation 3.5.1 with HIMA	Pump, variable speed drive, valves, sequences, historian, integration into MES
2017–2018	Refinery CHP plant · automatic boiler start-up, boiler No. 3	Emerson Ovation with HIMA HIQuad BMS	100 kgf/cm² at 540 °C, nine burners. Purge, light-off through the burner management system, ramp against drum thermal stress limits, hand-over to load control. To SR EN 12952
2017	Refinery CHP plant · flue gas desulphurisation and dedusting, CFB boiler	Emerson Ovation 3.2	Dedusting and lime blower algorithms
2017	Refinery flare · electrical retrofit for DCS interfacing		Motor feeder cells, oil pump, protection relays, 4–20 mA interfacing
2016–2017	Refinery CHP plant · manufacturing execution system	Honeywell PHD	Approximately 9,150 tags over OPC from the CHP plant, the photovoltaic park and commercial metering. Central archive of production data; boiler, turbine and auxiliary equipment efficiency; plant balance and losses; plant fuel efficiency
2015	Refinery CHP plant · central control room, design and construction
2015	Refinery CHP plant · island mode operation	Emerson Ovation	Algorithm implemented in the DCS and proven on the running plant in two trials, holding 13–14 MW in the island. Agreed with the transmission and distribution system operators
2015	Refinery CHP plant · advanced control on four boilers	Emerson Ovation	Performance monitoring system, combustion optimiser, steam temperature and pressure optimiser, fuel optimiser, SOx and NOx emission optimiser, running against a real-time optimisation target
2014	Photovoltaic park · SCADA	GE D400, National Instruments CompactRIO	Inverter communication over Modbus; P and Q setpoint control; reporting to the transmission system operator over IEC 60870-5-101 and to the market operator over IEC 60870-5-104; cabinets and HMI. Delivered in 32 days
2014	Refinery CHP plant · plant-wide protection algorithms	Emerson Ovation, ABB Industrial IT	Four turbines, four boilers and auxiliary equipment, so that a trip on one item takes the correct action on the rest
2013–2016	Refinery CHP plant · plant coordinated control	Emerson Ovation, ABB Industrial IT	Four turbines, four boilers and auxiliaries controlled as one unit against a load target, with real-time optimisation above the loops
2013–2015	Refinery CHP plant · turbine 4	Emerson Ovation	Primary frequency control, secondary load control, island mode algorithms
2011–2018	Multi-plant coordinated control · CHP plant, photovoltaic station and wind farm	Emerson Ovation with SCADA links	Three sites dispatched as a single balancing group (virtual power plant), with the steam turbine as the regulating machine. Seven years of operation
2013	Refinery CHP plant · fifth electrostatic precipitator		Design, P&ID, cabling, panels, specifications
2013	Refinery CHP plant · baghouse filter		Documentation, schematics, specifications
2012	Refinery CHP plant · boiler hall HVAC and smoke extraction, 260 t/h CFB boiler		With the plant designer, the equipment supplier and the boiler manufacturer
2012	Dalkia CHP plant, Ploiești · turbine TA5, I&C and DCS		P&ID, panels, cable schedules, turbine interfaces, HMI
2011	Dalkia CHP plant, Ploiești · steam turbine control	Siemens PCS7, S7-400 / S7-300
2011	Refinery CHP plant · control room, design and construction
2010–2012	Refinery CHP plant · boiler 4	Emerson Ovation	DCS hardware and software, design, project management, engineering for power-up, commissioning, testing, tuning and training
2010	CHP plant, Teleajen · boiler 3 instrumentation and control		Schematics, signal databases, ISA drawings, as-built documentation
2010	Operator console panels for control rooms
2010	Plant automation	Allen-Bradley ControlLogix
2008–2009	Refinery CHP plant · boiler 3	Emerson Ovation	DCS hardware and software, design, project management, engineering for power-up, commissioning, testing, tuning and training
2008–2009	Gas distribution station, Atyrau	ABB SCADA
2007–2008	Refinery CHP plant · turbine 4	Emerson Ovation	DCS hardware and software, design, project management, engineering for start-up, commissioning, testing, tuning and training
2007–2018	Refinery CHP plant · control system maintenance	Emerson Ovation, ABB Industrial IT 800xA, HIMA HIQuad, Honeywell PHD	Eleven continuous years on one plant

Client names and a signed client recommendation are available on request under NDA.

Featured projects

Advanced load control, CFB boiler

Emissions monitoring display showing dust, NOx and SO2 readings

Energy boiler, 260 t/h steam at 100 bar, circulating fluidized bed, firing petroleum coke, coal, gas and fuel oil, on DCS Emerson Ovation.

Virtual power plant dispatch schematic — Open full size

Four photovoltaic plants, one wind farm and one conventional gas/coal plant combined into a single dispatch unit balanced by the steam turbine.

Combustion efficiency monitoring display

Real-time efficiency of boilers, turbines and heat exchangers against design values, with loss costs and deviations calculated continuously from DCS and metering data.

Design, manufacture and supply of control room equipment and operator furniture, covering acoustics, layout, lighting, microclimate, backup power and operator interface, specified for 24/7 operation.