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　煤氣在使用過程中容易產(chǎn)生管網(wǎng)壓力波動，存在不安全因素。煤氣柜作為調劑煤氣供應、減緩管道波動的有效方法，在冶金和化工等行業(yè)得到了廣泛的應用。煤氣柜可以有效回收放散煤氣，充分合理利用企業(yè)內(nèi)部的附產(chǎn)煤氣，調節(jié)管網(wǎng)壓力。作為煤氣這個危險性氣體的“歸宿”，煤氣柜的安全運行對于全廠的生產(chǎn)安全具有重要意義。
　　山東金能科技股份有限公司是一家綜合性化工企業(yè)。多年來，公司秉承 “資源高效、綠色低碳”的循環(huán)發(fā)展理念，以技術創(chuàng)新為驅動、以資源高效利用為導向，打造了區(qū)別業(yè)內(nèi)其他企業(yè)的循環(huán)經(jīng)濟產(chǎn)業(yè)鏈，構建了資源利用、產(chǎn)品結構、技術裝備、環(huán)保模式四大差異化的盈利模式，實現(xiàn)了煤化工與精細化工的科學整合，做到了資源利用最大化與資源利用價值最大化。
　　由于金能科技現(xiàn)有的30000m2煤氣柜控制系統(tǒng)在設計時不具備硬件的冗余、容錯和復雜邏輯判斷等功能，當現(xiàn)場儀表出現(xiàn)顯性故障時，極易造成工藝事故。為提高全廠的安全水平，金能科技決定利用冗余控制技術，升級現(xiàn)有的煤氣柜監(jiān)控系統(tǒng)。
　　挑戰(zhàn)
　　煤氣柜監(jiān)控系統(tǒng)是智能自動化儀表技術、自動化控制系統(tǒng)、計算機技術和網(wǎng)絡技術等多種技術的結合，涉及到多方面的知識。新系統(tǒng)的設計需要重點解決現(xiàn)有系統(tǒng)面臨的以下三方面問題：
　　 故障安全：原有系統(tǒng)配置不能夠排除當現(xiàn)場儀表出現(xiàn)故障或假液位造成的顯性故障，易造成工藝事故。
　　 傳感器的獨立設置：對參與聯(lián)鎖的各個傳感器(如活塞高度、氣柜內(nèi)壓力等值)配置為單臺測量，未使用不同的測量方式，不符合傳感器冗余設置三選二的原則。
　　 硬件的冗余、容錯：模塊前期設計時，未考慮PLC模塊的冗余、容錯設計，如發(fā)生儀表的損壞、模塊損壞、電源異常斷電等故障時，極易造成工藝事故。
　　解決方案
　　針對金能科技干式煤氣柜實際情況，基于羅克韋爾自動化組態(tài)技術和人機界面檢測技術，金能科技構建了現(xiàn)代化的煤氣柜監(jiān)控系統(tǒng)，并與原有控制系統(tǒng)實現(xiàn)了無縫的融合與兼容。
　　項目總體實施過程包括五個步驟：氣柜監(jiān)控監(jiān)測系統(tǒng)總體的方案設計;氣柜監(jiān)測系統(tǒng)邏輯關系模型的建立;冗余、容錯目的的達成，及數(shù)學模型的建立;完成氣柜監(jiān)測系統(tǒng)軟件部分的組態(tài)設計與開發(fā);最終系統(tǒng)的聯(lián)調聯(lián)試以及持續(xù)改進。
　　新系統(tǒng)采用由羅克韋爾自動化PLC冗余控制系統(tǒng)結構，基于ContrlNet協(xié)議、工業(yè)以太網(wǎng)協(xié)議等通信方式，實現(xiàn)了傳感器、電源、控制單元以及通信的冗余設置，控制精度達到毫秒級，保證系統(tǒng)安全可靠運行?？梢酝瓿蓪ΜF(xiàn)場活塞高度、氣柜內(nèi)部壓力、油槽液位、頂部泄漏量的數(shù)據(jù)的采集和進出口閥門等閥門的過程控制。對于輸入、輸出模擬量信號通過加裝防爆安全柵(一入兩出)進行現(xiàn)場與控制系統(tǒng)的安全有效隔離，現(xiàn)場檢測信號一分為二，一路進原有系統(tǒng)顯示報警，另一路進本系統(tǒng)參與聯(lián)鎖控制，雙重保證檢測信號的穩(wěn)定性和安全性。系統(tǒng)所有開關量輸入、輸出信號都通過隔離繼電器隔離，保證測點的干接點輸入和輸出。

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