„Tamnava - East Field“, Kalenic - Crusher plant control system reconstruction

Mikro Kontrol, Belgrade, in consortium with Siemens Belgrade, has successfully completed reconstruction all lines in crusher plant. The entire work included the development of the main electrical design, detailed design and as built design, delivery and installation of equipment and commisioning.


"Crusher plant" is supplied with coal from open pit mine "Tamnava-West Field". There, coal is ground and loaded into wagons for the power plant "Nikola Tesla" in Obrenovac. Transport of coal through "Crusher plant" is done through 24 belt conveyors. As part of the transport, there is the combined machine RS1 which is used for temporary storage of coal. Coal and coal dust is transferred by belt conveyor feeders in 8 bunkers which is used for temporary storage. Spilt coal near wagons is sent back to the bunkers by elevator. Four belt weighing scales measure transported coal. The choice of technology line, i.e. the redirection of coal transportation is carried out using five foundries and three mobile cars. Coal is grinded in the four crushers. As protection, in front of each crusher, the device for metal materials recognition is set. For the purposes of the consumer, through the cribble the raw coal screening (dedusting) is made. Sampling of coal for  testing is performed using 4 units, sampler.

Coal transporting from coal bunkers to the conveyor belt is carried out using five extraction units.

Coal wagons are fed with coal using four feeders, and are transported by rail to the Termal power plant „Nikola Tesla”.


The entire process is done in three shifts, 24 hours, without interruption. It was necessary to install the control system that has a high level of reliability and security, that can process a large number of signals, that is connectable with other control systems in Crusher plant and can provide the availability for future expansion.

For this reason, we chose the Simatic PCS7 (Process Control System), which is basically, a DCS a decentralized control system.

The control system handles over 2000 signal. Signals from individual devices are collected in the distributed units in 12 locations. Signal processing and user program execution is performed in AS (Automation Station). Distributed units and AS are connected by optical cables, PROFIBUS DP protocol in a redundant ring. The monitoring system consists of two redundant OS (Operator Station), SCADA server (SCADA operator stations), an ES (Engineering Station), five OS clients and one archive server. As the process does not suffer delays in production, there is a level of redundancy derived in AS stations (PLC), also in PROFIBUS DP network processor and network, and in OS SCADA station. In case of failure of the main unit (AS, OP, or network), auxiliary (backup) device, automatically and without delay takes over the control. To meet the needs of the individual devices, locally, on each of the control cabinet in which peripheral units are placed, there is touch panel, where you can see all the data related to the work Crusher plant.

The scope of work

Crusher plant control system revitalization included the following phases:
  • Development of main electrical design.
  • Development of detailed electrical design.
  • Installation, delivery, installation and connection of 14 electrical cabinets with control equipment, two rack cabinets with computer and networking equipment, LCD TV 70''.
  • Development of user program and generation of reports (shift, daily, ...).
  • Commissioning.
  • Development of electrical as built design.
  • Training.


The new control system is built to increase the level of reliability of all parts in Crusher plant. It provides a safer and more accurate monitoring of Crusher plant, which quickly recognizes the warning and alarm state of all parts. In this way, the problem is quickly detected and can be solved very fast. The duration of the production delay is significantly shortened.

The control system automatically generates necessary reports (daily, shift, month, ...). All necessary data during the process are stored in the archive station. Analysis of these reports helps to identify critical points in production, which allows the application of appropriate measures for their removal, as well as to improve and enhance the overall production.


Vase Pelagica 30
11000 Belgrade, Serbia
+381 (0)11 3699 080
+381 (0)11 3699 939
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