Mihai Dunareanu PFA

Engineer - Control specialist - Hacker (taking it back)



I am a lover of life, avid learner and a passionate engineer. I like to think of myself as a stoic, trying to enjoy the basics of life to the fullest: the quality of a homecooked meal with good ingredients, a glass of excellent wine and a good book, or a hike through nature, a gentile reminder of the vastness of life compared to the smallness of human thought.

I am lucky to be able to say that engineering is both a profession as well as a passion. I began this passion in my youth, at first trying to create the weapons of medieval knights, bow and arrow, to then tinkering with my linux box and with maths and physics as a highschooler, and then, after graduating electrical engineering, working in industrial automation as a control specialist.

Now i control an apparently different, albeit similar kind of beast, in the form of RPA development, which aims to automate repeatable tasks in found in all computer related tasks, as well as less routine tasks using machine learning capabilities!

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Business sector: metal industry/copper laminator.

Employer: S.C. SIND Process Control S.R.L

Beneficiary: S.C. Laromet S.A.

My job was to program a copper laminating factory which included a big oil pressure driven press, induction furnaces for heating the copper billet, thermal treatment furnaces and all the auxiliary equipment of the factory.

The physical Input/Output count of the project was about 2000. I used Modbus RTU communication networks (with the operator panels, frequency drives and network analyzers). The factory was driven by a central Honeywell Masterlogic (ML) PLC that was connected to many remote islands using redundant ring Fiber optics. The process is fully automated and supervised by a Honeywell Experion PKS SCADA system.

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Business sector: petroleum refining and distribution.

Employer: S.C. SIND Process Control S.R.L

Beneficiary: Rompetrol Grup S.A.

The refinery was undergoing schedueled maintenance and we had a number of contracts there. The refinery runs on an Emerson DeltaV DCS system with multiple controllers. Most of the auxiliary equipment are controlled by Allen Bradley ControlLogix PLCs. My company's first contract was implementing regulators (PIDs) on the DCS.

Although the total number was high (around 1000), the highly customizable export functions of the DeltaV system meant that we were creating classes (like the scaling of an analogical input), exporting them into Excel, multiplying them, modifying just the desired properties (like the Analog Input address, scale min/max) and then importing. The second part was then calling the objects in the controllers and making the HMI pages along with the faceplates (a popup window with all the object's data).

The second Contract involved work on the nitrogen compressors. All the compressors were running on two Allen Bradley ControlLogix systems. Both had redundancy in processing -2 CPUs-, I/O redundancy, Power redundancy and communication redundancy. The object was to split up the two systems into 4 systems that would maintain all the redundancy principles mentioned above. The PLC programming was kept. I dismembered the redundant systems, reconfigured and adjusted the code and reassembled them. The work was critical and had to be done fast as the refinery still stored gasoline.

The third was implementing Profibus DP communication between two Siemens S7-300 PLCs and transferring some data.

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Business sector: energy production, energy distribution.

Employer: S.C. SIND Process Control S.R.L

Beneficiary: Energie de France

The project was a part of the Brennilis (France) Nuclear Power Plant decommissioning works. It comprised fully functional prototypes of the tools (similar to a crane) that lifted the radioactive tubes from the core of the reactor. One equipment was used to pull the vertical tubes out, another the horizontal ones. They tubes were then taken to a cutting cell to be cut into measured pieces for the purpose of containment in led boxes. The system runs on Siemens S7-300 CPU with a distributed Profinet network of I/O islands -Siemens ET200s-. Since the crane had to move after it had detached the tubes, part of the Profinet network was wireless.

The most interesting part of the project by far was the programming of the Cutting Cell. Because radioactivity was high, no electronics were allowed inside the cell. Everything was driven from outside by servo motor controllers. The interface to the controllers was serial ASCII built on RS485.

The motors drove the gate, saw, sliding table of the saw, clamps etc. of the cutting cell. The difficulty of the project lay in the error free, fast communication and data interpretation of the motor controllers. The system had to work in a step by step, human operator guided procedure as well as in a semiautomatic one. The safety of the operators was crucial.

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Business sector: energy production, hydroelectric power plant.

Employer: S.C. SIND Process Control S.R.L

Beneficiary: Turkish state

I worked as a contractor for a romanian company which was building the electrical system of Kilavuzlu Electrical Power Plant near Kahramanmaras, Turkey. I was brought in to take over the development of the SCADA system of the power plant, because it was running late. I was not involved in the PLC programming jobs. The SCADA system employed was Schneider Citect and the main communication protocol was Modbus TCP/IP. Most of the work was done onsite. The interesting part for me was learning more about the way the plant worked.

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Industry: Wood processing.

Employer: SYSCOM Water Technology S.R.L

Beneficiary: Kronospan Belarus

My job was to supervise from an electrical standpoint the relocation of a Kronospan factory from Germany to Belarus. I was responsible with the Emergency Shutdown system of the Boiler. The system was running on two redundant Siemens S5 PLCs.

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Industry: Water management.

Employer: S.C. SYSCOM Water Technology S.R.L

Beneficiary: Braila, Romania city council

My job was to implement software for three fountains with the purpose of having their water jets move in the same rhythm as the ambient music playing in the park. The biggest fountain had 17 pumps driven by frequency converters pumping water through different nozzles.

The fountain was driven by a Unitronics V570 PLC, connected through a CAN network to remote Input/Output islands. An additional Modbus TCP network connected the PLCs of the three fountains. Time was synchronized between them so they would all start at the same moment.

During summer, the fountains were started and stopped automatically at programmable hours. The dance was created using a data structure of steps that contained information about step duration, commands for which pumps to run on each step and frequency reference of the pumps. Some of the nozzles on the bigger fountain were mounted on moving stainless steel structures that rotate. The other two fountains are, from a functional standpoint, the same as the bigger fountain described above.

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