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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。可以完成對現(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 8520-ETCP NSFP 8520ETCP

FANUC A16B-0180-0260 USPP A16B01800260

COOPER INDUSTRIES 927255 NSPP 927255

MEASUREX 51400669-100 USPP 51400669100

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INDRAMAT KDS-1.1-100-300-W1-220 USPP KDS11100300W1220

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ALLEN-BRADLEY 2706-D21J2 OPERATOR INTERFACE DATALINER

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882I60930 Marposs GUAGE T5

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AVG UTICOR 100G-UT15T3R1 USPP 100GUT15T3R1

MODICON AS-C184-004 USPP ASC184004

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Siemens 505-6208A

Hp 81531A Optical head interface module

Wieland Bamberg WEB-1001 EGM Encoder Interface Module

SIEMENS 6ES5 375-0LC21 6ES53750LC21

Siemens LOGO! PC CABLE 6ED1 057-1AA00-0BA0 PC-LOGO

Omron C200H-ID212

Schneider Modicon AS-H827-103 Gould 11 Slot 800 Series Rack

Schneider Modicon Analog Output Module AS-BDAU-202

Schneider Modicon AS-J200-001 USPP ASJ200001

Schneider Modicon MODICON/ AS-W808-002 CABLE ASSEMBLY REMOTE I/O SIG XLNT

Schneider Modicon AS-M480-004

Schneider Modicon TSX Compact M AS-BDAP-218 ~ SURPLUS~

SMCSI EX250-IE3 DEVICENET INPUT MODULE

Schneider Telemecanique XB4-BL42 Push Button Switch

Siemens TI 505-4916 Relay Output Module

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Ethernet Communication Module ENC28J60 SPI IEEE 802.3

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re A6FC Raid Controller 700-0127-00 A 7006-2 IDE

Allen-Bradley 855PDB24MEH4322 Operator Indicator Light 24VAC/DC Red/Green

ABB 15 KV Advac Panel Cell Vacuum Breaker Medium Voltage SafeGear w/ PT complete

ACBE17FPU 17" FLAT PANEL MONITOR UPGRADE KIT

A06B-6058-H322 FANUC SERVO AMPLIFIER - -

8" LCD 800x600 Video Zoom Microscope 3.3x-147x w/ Track Stand

SEW EURODRIVE MDX60A0220-503-4-00 USPP MDX60A0220503400

ALLEN BRADLEY 803-A12 NSFP 803A12

ALLEN BRADLEY 3500-P10 USPP 3500P10

INTERMEC J2050-A-07102 USPP J2050A07102

GENERAL ELECTRIC DS3800HPMA1E1D USPP DS3800HPMA1E1D

YAMATAKE 82408470-001 USPP 82408470001

MERLIN GERIN NFNF-36225-AAHJ00 NSFP NFNF36225AAHJ00

Siemens 6ES5-305-7LB11 MODULE 6ES53057LB11

SIEMENS 6ES5 430-4UA12 6ES54304UA12

SIEMENS S5 6ES5 420-4UA14 6ES54204UA14 Input Module

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RELEASE SuperMicro X9DBU-IF MB ※Check W/ Us for Availability FIRST※

Texas Instruments 5TI-2459514

Telenex PL-951-158-2 T1 Dual Port Interface Module

TSXETY5102 Modicon Premium TSX57 10/100 FCAST MOD TSX-ETY-5102

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Modicon MM-PMA2-300

Schneider Modicon Gould AS-B875-111 ASB875111 I/O Analog Input PLC Module

Schneider Modicon ASBADU206 TESTED and GUARANTEED Compact Analog Input AS-BADU-206

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Schneider Modicon AS-C484-600

Schneider Modicon AS-BDAP-210 TSX OUTPUT MODULE NIB

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Schneider Automation Inc 140 DDI 841 00 140DDI84100 Input Module Sealed

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SIEMENS 6ES5-441-8MA11 PLC OUTPUT MODULE ""

SIEMENS 6DD1641-0AC0 EB11 DIGITAL I/O MODULE IN BOX

Lenze EMF2102IBCV003 Lecom-LI Communication Module EMF2102IBC-V003

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SIEMENS Moore XTC Transmitter-Controller 340DBBSAAB NN213

ALLEN-BRADLEY SLC 500 1746-OB8 OUTPUT MODULE QUANTITY

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ABB SACE PR231/P W/ BK15494 P4KLAM04006 OUT OF

A06B-0148-B175#0076 FANUC SERVO MOTORS REMANUFACTURED

7 Digiboard DBI A/N30000354 Full size I/O ISA card

PACIFIC SCIENTIFIC SC755A001-01 USPP SC755A00101

ALLEN BRADLEY 1771-NT1 FNFP 1771NT1

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GENERAL ELECTRIC DS215SLCCG2AZZ01B NSPP DS215SLCCG2AZZ0B

TELEMECANIQUE ATV-66D23-N4 USPP ATV66D23N4

SQUARE D LC-26600AC USPP LC26600AC

CUTLER HAMMER AGSCH120N030040 NSFP AGSCH120N030040

Siemens 6ES5 951-7NB21 -- 6ES59517NB21

SIEMENS 6ES5-752-0AA23/6ES5752-0AA23 INTERFACE MODULE NIB

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Siemens LOGO 6ED1 055-1CB00-0BA0 in sealed box

RPS MKS ASTRON AX7685 GENERATOR

Telemecanique TSX1723428

Siemens Simatic 6ES7 151-1AA05-0AB0 6ES71511AA050AB0 Interface Module

Wago 750-478 2-CHANNEL ANALOG INPUT MODULE

SIEMENS 6SL3211-0KB13-7UA0 0.37KW 220V

Modicon AS-P801-001

Schneider Modicon DTA 200/AS-HDTA-200 DTA200ASHDTA200 Primary Subrack

Schneider Modicon ASB232501 Output Module AS-B232-501

Schneider Modicon AS-B875-011 8CH Analog Module ASB875011

Schneider Modicon AS-W922-015 GENERIC OEM CABLE ASW922015

Schneider Modicon Gould AS-C484-266 484 Controller Programmable

Schneider Modicon AS-J892-001 Communication Module ASCII 984/800 RI/O INTERFACE

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SIEMENS 505-4332 MODULE DIGITAL INPUT 505 32IN 14-30VDC 5054332

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Prosoft MVI56-ADM 'C' Communications Module MVI56DAM

SIEMENS Parameter Circuit Board 6SN1114-0AA01-0AA0

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ALLENBRADLEY2706E43J128B1OPERATORINTERFACEDATA

Allen Bradley Terminal Board 9101-1779 Amphenol Connector /Sealed

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ZEBRA Z220-451-00054 USPP Z22045100054

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MITSUBISHI FR-SF-2-15K-BN04U-573 USPP FRSF215KBN04U573

ALLEN BRADLEY 1336VT-B040-EOR-FA2-L3 NSFP 1336VTB040EORFA2

GENERAL ELECTRIC 5K33GN2A USPP 5K33GN2A

FISHER ROSEMOUNT DM6004X1-FA1 NSFP DM6004X1FA1

SIEMENS 6ES5-927-3KA13 NSPP 6ES59273KA13

REXROTH 1070080542-404 USPP 1070080542404

THK GL20N-106-SWQ-B20Q-U-C-X-N-Y-A053846 NSFP GL20N106SWQB20QU

Siemens 6ES5 524-3UA13 6ES55243UA13

Siemens 6FM1470-4AA25 6FM14704AA25 S5 w/ 6ES5 373-1AA61

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Siemens Cable 6ES7 290-6AA20-0XA0 6ES7290-6AA20-0XA0

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Square D 8030 DLM-110

Schneider TCCX1730LW Operator Interface Module with Cable

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Shimaden SR2201-21B

Schneider Modicon ASH819100800 Series Rack AS-H819-100

Schneider Modicon AS-B573-005 USPP ASB573005

Schneider Modicon Controller AS-B890-101

Schneider Modicon AS-H827-100 11-Slot PLC I/O Rack

Schneider Modicon AS-B846-001 Analog Mix Voltage In ASB846001

Modicon 19" Operator Interface 557VCM74210 11141

SIEMENS 6ES7421-1BL01-0AA0 SIMATIC S7 DIGITAL INPUT MODULE 62669

Schneider Modicon 140CRA21110 MB Drop AC Module