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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(diào)劑煤氣供應(yīng)、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(yīng)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(diào)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(shù)創(chuàng)新為驅(qū)動、以資源高效利用為導(dǎo)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(gòu)建了資源利用、產(chǎn)品結(jié)構(gòu)、技術(shù)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(xué)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(shè)計時不具備硬件的冗余、容錯和復(fù)雜邏輯判斷等功能，當(dāng)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(shù)，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(shù)、自動化控制系統(tǒng)、計算機技術(shù)和網(wǎng)絡(luò)技術(shù)等多種技術(shù)的結(jié)合，涉及到多方面的知識。新系統(tǒng)的設(shè)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(dāng)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(shè)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(shè)置三選二的原則。
　　 硬件的冗余、容錯：模塊前期設(shè)計時，未考慮PLC模塊的冗余、容錯設(shè)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(shù)和人機界面檢測技術(shù)，金能科技構(gòu)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(shè)計;氣柜監(jiān)測系統(tǒng)邏輯關(guān)系模型的建立;冗余、容錯目的的達成，及數(shù)學(xué)模型的建立;完成氣柜監(jiān)測系統(tǒng)軟件部分的組態(tài)設(shè)計與開發(fā);最終系統(tǒng)的聯(lián)調(diào)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(jié)構(gòu)，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(shè)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(guān)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。

Allen Bradley SLC 500 1746-OX8 -0X8 Output Module Sealed Box NIFSB

ACBE17FPU 17" FLAT PANEL MONITOR UPGRADE KIT

Adtech AX4000 LOADED WITH CARDS

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MEASUREX 053669-01 USPP 05366901

ALLEN BRADLEY 1352-143678 USPP 1352143678

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Schneider Modicon GOULD REMOTE I/O DRIVER MODEL AS-J820-001

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SIEMENS 6FC5510-0BA00-0AA0 USPP 6FC55100BA000AA0

Advantech PCA-6186VE PCA-6186 Rev.A1 NIB

Allen-Bradley 1771-OA AC OUTPUT MODULE

ABB ASEA BROWN BOVERI POWER ITE AIR CIRCUIT BREAKER 800A 800 AMP KDON K-DON 800S

ADEPT 90400-60131 AMPLIFIER MODULE MEGATORQUE 300 WATT CONTROLLER

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SYMAX 8020-SCP-424 NSPP 8020SCP424

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CLEVELAND MOTION CONTROL BNR5110GPA00CS0002 NSPP BNR5110GPAOOCS00

NEMATRON CORP IWS-4824 USPP IWS4824

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GE FANUC 44A719348-102 USPP 44A719348102

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Jova Solutions TIMS-0102 USB 12C/SPI Interface Module

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Patriot WA0750

Schneider Modicon AS-B872-002/ASB872002 Output Module OFFERS ACCEPTED

Schneider Modicon AS-5540-006 NSFP AS5540006

Schneider Modicon AS-M680-108 Memory Module

Schneider Modicon AS-9490-004 USPP AS9490004

Schneider Modicon 800 SERIES 11 SLOT RACK AS-H827-103

Schneider Modicon TSX COMPACT DISCRETE INPUT DEP 216 AS-BDEP-216 LOT OF 5

Siemens TI 505-4108 Low VDC Input Module

Telemecanique ATV11HU09M3A 0.37kW Inverter in Box

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Allen-Bradley 2711-T6C15L1 Panelview 600

ABB 3HNE00313-1

ACCURAY AIC8 086155-001 SCANNER MODULE CARD CONTROLLER B211850

A2LA 17025 Accredited Calibration with full Data Report

82-1/2" OVER ALL LENGTH 2-1/4" DIAMETER BALLSCREW 55" TRAVEL 5-1/2" FLANGE

SIEMENS 6ES7-623-1DE01-0AE3 USPP 6ES76231DE010AE3

ASEA BROWN BOVERI 750191-001B NSFP 750191001B

ALSTOM ALSPA-MV-1013 USPP ALSPAMV1013

MICRO MOTION DL065-S242SU NSPP DL065S242SU

HUB CITY 88 NSFP 88

ALLEN BRADLEY 1774-KA USPP 1774KA

SIEMENS 6ES5-925-3SA11 USPP 6ES59253SA11

Siemens 6ES5-391-5AA13 USPP 6ES53915AA13

SIEMENS 6ES5 454-7LA11 6ES54547LA11

SIEMENS 6ES5 465-7LA13 Module

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Siemens PLC 6ES7 338-4BC01-0AB0 6ES73384BC010AB0 NIB

PVDM3-32 CISCO 32-CHANNEL HIGH-DENSITY VOICE AND VIDEO DSP MODULE

GSM/GPRS Modem Pool 8 Ports USB interface Wavecom Module AT Commands Q2406

Unico 314-739 314739 Interface Module No Box

Siemens 6AV6 640-0DA11-0AX0 Touch Panel NIB

Siemens Logo 230RC 6ED1 052-1FB00-0BA3

MTT ms2304

Schneider Modicon Connector/Cable AS-W801-002/ASW801002

Schneider Modicon 800 SERIES AS-H827-103 11 PORT RACK ASH827103

Schneider Modicon AS-E685-904 USPP ASE685904

Schneider Modicon Gould AS-B804-016 PLC I/O Module

Schneider Modicon AS-B804-116

Schneider Modicon Output Module True High AS-B824-016

Schneider XBTGT5230 Touchscreen Glass

Schneider Modicon TSXPCX3030+ Optical Isolated Cable

SiemensSimatic6AV6641-0CA01-0AX16AV66410CA01

Siemens 6AV6642-0BC01-1AX0 6AV6 642-0BC01-1AX0 SIMATIC TP 177B 6" Touch Panel

SIEMENS SE47.1 6DD1681-0EH1 OPTICAL COUPLER MODULE

GE Fanuc IC697RCM711C 90-70 Redundancy Communication Module IC697RCM711-C

SIEMENS Simodrive Posmo A 1FK6032-2AF1 s/n 22253202 6SN2155-2BD10-1BAO

SIEMENS SINUMERIK 6FC5203-0AF01-0AA0 Membrane Keypad

SIEMENS Moore 63SD Differential Type Flow Controller

Allen-Bradley Panel View 600 Plus

AB 1336S-A030-AN-EN 30HP 240VAC VFD QUANTITY TESTED

ABB/ACS 500 150 HP Drive 440-500 VAC Cat# H502125400P2BBB200 3000

A06B-0332-B069#7000 FANUC SERVO MOTORS REMANUFACTURED

75 HP ELECTRIC MOTOR 1200 RPM 405T FRAME NEMA PREMIUM EFFICIENT SEVERE DUTY

RELIANCE ELECTRIC 6V41-096TA NSPP 6V41096TA

ALLEN BRADLEY 2711-K14C1 USPP 2711K14C1

ALLEN BRADLEY 1771-IF05 USPP 1771IF05

HONEYWELL 30731737-006 NSFP 30731737006

WESTINGHOUSE DBL-25-1200 USPP DBL251200

TEXAS INSTRUMENTS PLC VPU500-3104 USPP VPU5003104

GENERAL ELECTRIC DS3800DMEC1D1D USPP DS3800DMEC1D1D

Siemens 6ES5-188-3UA12 PLC Rack 21 Slot

SIEMENS 6ES5 375-0LC31 6ES53750LC31

SIEMENS 6ES5-988-3NA11 USPP 6ES59883NA11

Siemens 6ES5 930-8MD11/6ES5930-8MD11 POWER SUPPLY XLNT

Siemens 6ES5 944-7UB11 in Sealed Box

Siemens Micromaster 430 6SE6430-2UD31-8DA0 18.5KW

RELIANCE ELECTRIC 61C-350 USPP 61C350

Texas Instruments 500-2151

Spirent Adtech AX/4000 401381 L3 Gigabit MM Interface

VIA Artigo A2000 Barebones Storage Server 1.5 GHz VIA C7-D Brand

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Modicon AS-W510-002

Schneider Modicon Automation AS-BDEP-216 Discrete Input -

Schneider Modicon AS-H819-209 CHASSIES ASH819209

Schneider Modicon AS-BDAP-112 USPP ASBDAP112

Schneider Modicon ASB872002 Excellent Analog OUT Module AS-B872-002

Schneider Modicon Automation Output Module DAP 210/AS-BDAP-210

Schneider Modicon AS-W801-006 ASW801006 Extender Cable NIB

Schneider Modicon 140CRA93100 / 140CRA 931 00

SCXI Accelerometer Input Modules NI SCXI-1531

RELEASE SuperMicro X9DRT-F MB ※Check W/ Us for Availability FIRST※

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SIEMENS SINUMERIK 840D/DE NCU 572.3 6FC5357-0BB22-0AE0

MODULE COMMUNICATION ALLEN BRADLEY 1203-GD1

SIEMENS SIMODRIVE 611 BOARD 6SN1118-0DJ21-0AA1NIB

SIEMENS SINUMERIK OP 010S 6FC5203-0AF04-0AA0 NIB

SIEMENS Caterpillar D6H / D6H Series II Tractors Service Manual 8KB 4RC 6FC

ALLEN-BRADLEY1756-OFCI/AOUTPUTMODULE1756-0FCI

Allen Bradley SLC 500 Output Module 1746-OX8 Ser. A

ABB ROBOT DSQC345B - RECTIFIER DC1 - 3HAB8101-2

A06B-0128-B575#7076 FANUC SERVO MOTORS REMANUFACTURED

0.1-1250 μm LPA-9Z Desktop Inbligent Laser Particle Size Analyzer Sizer

MODICON AS-M909-001 USPP ASM909001

ALLEN BRADLEY 1398-PDM-150B USPP 1398PDM150B

ADEPT TECH 10332-00500 USPP 1033200500

GE FANUC IC640WMI910 NSFP IC640WMI910

SIEMENS LMXD63B700 NSPP LMXD63B700

SIEMENS 6ES5-928-3UB12 USPP 6ES59283UB12

ALLEN BRADLEY 2755-DD1A-R1 NSFP 2755DD1AR1

Siemens 6ES5 928-3UB21 6ES59283UB21

Siemens SIMATIC 6ES5 926-3SA12

SIEMENS 6ES5-512-5BC12/6ES5512-5BC12 INTERFACE MODULE XLNT

Siemens 6ES5 441-4UA14/6ES54414UA14 Digital Input SEALED OFFERS ACCEPTED

SIEMENS 1FT6105-8SB71-1AA0 3-phase Brushless Servomotor

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Schneider Digital Input Block Fuse 140CFB03200 3436

Square D 9006-PBF121

Siemens 6ES7460-0AA01-0AB0 SIMATIC S7-400 IM460-0 Transmitter Interface Module

WE SHIP SAME CISCO SLM2024T SG200-26 SLM2024T-NA 26PORT GIGABIT SMART

Siemens 6RA7018-6DV62-0-Z 6RA7018-6DV62-0 DC DRIVE

Siemens TP27-10 6AV3 627-1QL00-0AX0 Touch Glass, Bergquist Touch Products

Schneider Modicon TSX COMPACT DISCRETE OUTPUT AS-BDAP-210 4

Schneider Modicon ASBDAP210 AS-BDAP-210Compact output

Schneider Modicon AS-B825-016 NSFP ASB825016

Schneider Modicon MODULE AS-E908-131 S35D

Schneider Modicon AS-W192-015

Schneider Modicon AS-BZAE-204 HIGH SPEED COUNTER IN BOX FACTORY SEALED

SCHNEIDER TC2000 OPERATOR INTERFACE 3515 KPM PARTS/REPAIR BROKEN NOB

Siemens 6ES7 131-4BB00-0AA0 Digital Input Module 24 VDC /Un

RSP720-3CXL-GE Cisco Route Switch Processor 720-3CXL Router

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SIEMENS Sinumerik 840C 6FC5110-0BA01-1AA0 NC-CPU .

RTI CM-232 Serial Communication Module

SIEMENS 6SN1162-0EB00-0AA0 SIMODRIVE SHIELD CONNECTION PLATE 50MM

SIEMENS 6SC 6101-4A Simodrive Case -NO BOX

SIEMENS 6FC5-111-0CA02-0AA2 USPP 6FC51110CA020AA2

AllenBradley6182H-10TLH4DVersaViewCE1000HWorkstationPanel

Allen Bradley VersaView Display 17" to 19" Repair Service $169.99

ABB E3N-A20 600V 2000A PR112/P-A L/S/I/G INSULATED CASE CIRCUIT BREAKER

Adtech Spirent AX-4000 ATM Testing Solution AX4000

(H2-1) 1 EATON 92-00944-02 POWER SUPPLY H2-1

KENT TAYLOR 6202NZ10000B-1342 USPP 6202NZ10000B1342

ACUITY IMAGING 010-PV9040 USPP 010PV9040

FLUID POWER DIVISION PMC-20T NSFP PMC20T

FANUC A06B-0146-B675 USPP A06B0146B675

SEIKO INSTRUMENTS & ELECS LTD OFL-760A-26 USPP OFL760A26

RAPID POWER TECH SPSAA100012 USPP SPSAA100012

RELIANCE ELECTRIC 86466-47T NSFP 8646647T

Siemens 6ES5 460-4UA13 -FS- 6ES54604UA13

Siemens 6ES5-928-3UA11 USPP 6ES59283UA11

SIEMENS 6ES5-430-7LA11 USPP 6ES54307LA11

Siemens 6ES5 490-7LB21 CONNECTOR IN BOX

Siemens S5 6ES5 464-8MC11

SIEMENS 802Dsl Membrane Keypad

SIEMENS 6ES7 223-1BL22-0XA8 EM 223 CN I/O MODULE

Square D 8005 MP-1

Nokia NIF4303FRU 2-Port X.21 PMC Interface Card Module

WS-F6K-DFC3A DIST FWD CARD-3A FOR 65XX 6816 MODULES WITH SUP720

SIEMENS 6ES7-151-1AA03-0AB0

Siemens SCD 1597-ET 6AV8100-1BB00-0AA0

Reliance 45C940

Schneider Modicon GOULD B805 AS-B805-016 INPUT MODULE 115 V AC

Schneider Modicon AS-B352-001 USPP ASB352001

Schneider Modicon AS-S908-021 USPP ASS908021

Schneider Modicon AS-B883-101