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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(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。

Schneider TCCX1730LW Operator Interface Module

WOODWARD NETCON 5000 5466-258 REV E DISCRETE I/O MODULE

Siemens 6ES7315-1AF01-0AB0 CPU315 6ES73151AF010AB0

Siemens S7-200 EM231 6ES7 231-0HC22-0XA0 NIB FreeShip

Reliance 0-51811-1

Schneider Modicon AS-W801-002 ASW801002 Extender Cable

Schneider Modicon AS-BVIC-205 4 Channel Counter In ASBVIC205

Schneider Modicon AS-B579-001 USPP ASB579001

Schneider Modicon DIVISION AS-M485-004 MEMORY BOARD 4K W/BATTERIES FOR C484 ASM485004

Schneider Modicon AS-HDTA-202 USPP ASHDTA202

Schneider Modicon AS-B872-002 Output Module B16

MODICON - EATON - IDT - PANELMATE - BOARD P/N 42-14360

Siemens 6ES7-321-1BH02-0AA0 Input Module

SCHNEIDER DISCRETE I/O MODULE TSXEMF16DT2

Siemens HMI Operator Panel 6AV6 641-0CA01-0AX1 "FS"

SIEMENS Sinumerik 6FX1122-1AC02. Coupling PLC/NC .

Siemens Communication Module 6ES5535-3LB12

SIEMENS 6SN1123-1AB00-0AA1 SIMODRIVE LT-MODUL INT. 2X15A WORKING VERY CLEAN

SIEMENS 6SN1123-1AA00-0CA1 Simodrive LT-Module INT.50A Version A

SIEMENS 6FC5203-0AF03-0AA0 OP015 Membrane Keypad 6FC5 203-0AF03-0AA0 0P015

Allen-BradleyPro-Set700ReplacementTouchscreenTouchpanelInterface

Allen-Bradley - 1794-TBNF

ABB CONTROLLER,RF533 SUBRACK,BB510,SC520,CS513,SC510,CI545V01,TC520,SB510,SR511,

ADEPT TECHNOLOGIES ROBOT CONTROL PANEL 15 AMPS 50/60HZ 120/240VOLTS

(5244) Honeywell RTD Logic Board 51301259-100 (5244)

INDRAMAT MDD065A-N-040-N2M-095PBO NSPP MDD065AN040N2M09

TYCOR PTY-H-277/480-PD-4XTS NSPP PTYH277480PD4XTS

FANUC A06B-6050-H103 NSFP A06B6050H103

DOLAN JENNER SS950-48020 USPP SS95048000

RELIANCE ELECTRIC 57552-1 USPP 575521

NACHI UM837A USPP UM837A

MITSUBISHI AD51 USPP AD51

Siemens 6ES5 395-0UA11 6ES53950UA11

Siemens 6ES5-777-1BC01 USPP 6ES57771BC01

SIEMENS 6ES5-377-0AA21 USPP 6ES53770AA21

Siemens 6ES5 421-8MA12 Digital Input Module NIB

Siemens S5 115U CPU 942B 6ES5 942-7UB11

Siemens 6SE7024-7ED61

Siemens USB/PPI 6ES7 901-3DB30-0XA0 PLC Cable NIB

Siemens 6SE7016-1TA10

Mini USB Bluetooth Interface GPS Module Demo Board

WS-X6816-GBIC CISCO CAT 6500 16-PORT GIGE MODULE

Siemens 6ES7 323-1BH01-0AA0 6ES7323-1BH01-0AA0 FreeShip

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

Reliance 0-52875-1

Schneider Modicon AS-853-5000 PLC

Schneider Modicon AS-B231-500 USPP ASB231500

Schneider Modicon AS-P840-000 USPP ASP840000

Schneider Modicon AS-B807-132

Schneider Modicon AS-B355

Modicon PanelMate Plus 92-01125-01 Interface No Monitor

SIEMENS SIMATIC DIGITAL INPUT MODULE 6ES5 431-8MD11

Siemens 6ES7 321-1BL00-0AA0 -- 6ES73211BL000AA0

SIEMENS SIMATIC 6AG70111BA000AD0 PANEL PC TOUCH PANEL NIBBD

SIEMENS 6DD1-642-0BC0 NSPP 6DD16420BC0

SIEMENS 6DD1600-0AF0Processor 16M PM16

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SIEMENS 840D NCU BOX 6FC5247-0AA00-0AA3 --

Advantech ADAM-5060

Allen-Bradley 1771-OYL Reed Relay Contact Output Module - ATS 365 Warranty

ABB ACS500 30HP AC Drive ACS501-030-4-00P2 Ser B

ACTUS POWER NPSA-103MU-EIBS/1680336B USPP NPSA103MUEIBS168

6ES7414-4HJ04-0AB0 Brand , Factory Sealed,

90 DAYS PARTS AND LABOR , SEE VIDEO 400HRS

SPRECHER & SCHUH PNS-0180-480V USPP PNS0180480V

CABLETRON ESX-1320-F600 NSFP ESX1320F600

BALDOR SD23H4A15-ER USPP SD23H4A15ER

MODICON MM-PMC1-110 NSFP MMPMC1110

KOLLMORGEN IND ME9-203-B-AQ9-254 NSFP ME9203BAQ9254

CUTLER HAMMER 92-01858-01 USPP 920185801

Siemens 6ES5 095-8MB04 6ES50958MB04

Siemens 6ES5-460-7LA13 USPP 6ES54607LA13

SIEMENS 6ES5 930-8MD11 6ES59308MD11

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HP ProCurve Switch 1-Port 10 GBE LR Interface Expansion Module J8733A

XpressKIT Interface and Bypass Modules from Directed Electronics 1101T

SIEMENS 6ES5 947-3UA22 6ES5947-3UA22

Siemens Micromaster 430 BOP 6SE6400-0BE00-0AA0 FreeShip

Omron C500-OC221

Schneider Modicon AS-BDEP-217 PLC

Schneider Modicon AS-212P-020 NSFP AS212P020

Schneider Modicon AS-J812-000 ASJ812000 Remote I/O Adapter

Schneider Modicon AS-4750-000 NSFP AS4750000

Schneider Modicon DAU202/AS-BDAU-202

Schneider Modicon /AS-P190-212 PLC Programmer NR/AIPO

Sixnet ST-AI-INS-08 SixTRAK IPm Controller Instrumentation Analog Input Module

Schneider TSX Premium TSXETY410 Interface Module ETY410

Siemens TERMINAL BLOCK TB16SC 6ES7120-0AH01-0AA0

Siemens 505-4908 Output Relay Module 5054908 ++

SIEMENS SINUMERIK 6FZ1125-1AA01 ENCODER CONTROL

DIGITRACE TRACER 2000 ALARM COMMUNICATION MODULE AC2000

SIEMENS Simodrive HSA Module 6SC6116-0HA00_6SC61160HA00_6SC 6116-OHAOO

SIEMENS SIMODRIVE 6SN1145-1BA01-0BA1SINUMETIK 840D NCU-BOX 6FC52476FC5356 DK

Advantech ADAM-5018 Thermocouple Input Module 7 T/C PLC

ALLEN-BRADLEY 77131-107-02 Lamp Base Real Part

ABB 3BSE010535R1 SE0103B302 PM645B (3BSF 010 535 R1 )

ACCURAY 061589-002 USPP 061589002

A06B-6078-H211 FANUC DRIVES REMANUFACTURED

8000-SAAT ALLEN BRADLEY POWER SUPPLY AS-IS

SIEMENS 6AV76150AA120BG0 NSFP 6AV76150AA120BG0

ALLEN BRADLEY 8720-MC-RP-S065-VB-M USPP 8720MCRPS065VBM

ALLEN BRADLEY 6180-ENHEIMDTECZ USPP 6180ENHEIMDTECZ

KEYENCE CORP LS-3060 USPP LS3060

GETTYS 110-223 USPP 110223

YASKAWA ELECTRIC SMC-2000-8M NSFP SMC20008M

OKUMA E4809-045-091-E USPP E4809045091E

Siemens 6ES5-312-5CA22 USPP 6ES53125CA22

SIEMENS 6ES5 431-8MD11 -FS- 6ES54318MD11

SIEMENS S5 6ES5 700-2LA12 Central Mounting Rack-CR2

Siemens I/O Module 6ES5 451-7LA11S5 24429

Siemens 6ES7 223-1BL21-0XA0 6ES7223-1BL21-0XA0 FreeShip

Siemens OP37 6AV3637-1LL00-0AX1 Membrane Keypad

QY22 Mitsubishi PLC 16 Point Triac Output Card

General Electric IFM Interface Module w/ Cables Atari Commodore Series 1

Texas Instruments 6MT33 8 Input Output Interface Module

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

Siemens EM235 6ES7235-0KD00-0XA0 6ES72350KD000XA0

Modicon PC-0984-480

Schneider Modicon OUTPUT MODULE RELAY AS-B814-108 SELECTABLE

Schneider Modicon AS-BDAU-252 Compact Analog Out ASBDAU252

Schneider Modicon AS-C484-264 USPP ASC484264

Schneider Modicon AS-J475-000

Schneider Modicon AS-BDAU-202 2 Channel In. Mod.

Schneider Modicon J200 REMOTE EXPANDER AS-J200-001 =

Schneider Telemecanique TWDPTO220DT TWDPT0220DT FreShip

Schneider 140DAI45300 48V Input Module 140-DAI-453-00

pulls AP763A Hp StorageWorks MDS 600 Dual I/O Module Option Kit 498472-001

Siemens 6ES5 982-3UB11 6ES59823UB11 Fast Shipping

SIEMENS 6DD1681-0EH1 SIMADYN D OPTICAL COUPLER MODULE

Indramat Interbus Communication Module RMK 12.2-IBS-BKL

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SIEMENS Sinumerik 840 1P-6FC5103-0AD13-0AA0 1P6FC51030AD130AA0 _ 570-524-9101-00

SIEMENS MOORE PRODUCTS 15770-202-1 EXPANSION MODULE CARD PLC PC BOARD 29416

Allen-Bradley PanelView PV 550 2711-T5A16L1

5370-CVIM2BC SERIES A, REV B, -------- 1

ABB Servo Drive DM0501, GNT2009357R0013 #10913

A06B-0148-B188#7008 FANUC SERVO MOTORS REMANUFACTURED

700HP 3PH 460V VFD TECO WESTINGHOUSE VARIABLE FREQUENCY DRIVE EQ7-4800-C

POWERTEC INDUSTRIAL MOTORS INC F213Y4A1N0A1000 USPP F213Y4A1N0A1000

ALLEN BRADLEY 1784-T50A USPP 1784T50A

ALLEN BRADLEY 1336T-MCB-SP33B USPP 1336TMCBSP33B

GENERAL ELECTRIC DS3800NEPA1C1B USPP DS3800NEPA1C1B

TEXAS INSTRUMENTS PLC 560-2820 NSPP 5602820

STROMAG CHA450.3CE USPP CHA4503CE

ELECTRO FLYTE 12M25-14-50 USPP 12M251450

Siemens 6ES5-090-8MA01 USPP 6ES50908MA01

SIEMENS 6ES5 305-7LA11 -- 6ES53057LA11

SIEMENS 6ES5-815-0UB12 NSFP 6ES58150UB12

Siemens 6ES5 700-8MA11 NSFP 6ES57008MA11

Siemens 6DS1603-8RR 6DS16038RR

Siemens LOGO! 24 PLC 6ED1052-1CA00-0BA0 NIB

ROBOTRON 503-1-0324-07 USPP 5031032407

Telemecanique TSXP67455

Siemens6ES7-964-2AA01-0AB0Interface Module DP Master

Wago 750-341 ETHERNET TCP/IP FIELDBUS COUPLER

Siemens 802S 6FC5 500-0AA00-1AA0 Membrane Keypad

Modicon AS-S911-800

Schneider Modicon Automation TSX Compact Discrete Combi 8IN/8OUT DAP 220/AS-BDAP-220

Schneider Modicon AEG/GOULD// AS-C484-265 MAINFRAME CONTROLLER RFB

Schneider Modicon AS-B882-032 USPP ASB882032

Schneider Modicon AS-884A-211

Schneider Modicon Motion Module M AS-B885-110 ~REPAIRED SUR~

Schneider Modicon AS-P120-000 COMPACT PC POWER SUPPLY NIB

Schneider Automation Inc 140 DAO 842 10 140DAO84210 Output Module

SIEMENS 500-5008 INPUT MODULE 5005008

Reliance Electric 45C961 Output Module XLNT

Siemens 6ES7623-1AE01-0AE3 6ES7 623-1AE01-0AE3 SIMATIC C7-623 WARRANTY

SIEMENS Sinumerik Rack Cat# 6FC3761-2FA-Z

OptiMate Communication Module B- OP-9001 24291

SIEMENS Simo 6SN1112-1AC01-0AA1 Drive

SIEMENS Stepdrive C 6FC5548-0AA00-0AA0 Free Ship

SIEMENS 1P 6FC5103-0AB13-0AA2 _ 6FC51030AB130AA2 VER D

ALLENBRADLEY1771-OW16BELECTROMECHANICALCONTACTOUTPUTMODULE

ALLEN BRADLEY SLC500 OUTPUT MODULE NIP

ABB MOTOR WRIST 3HAB9398-1 - 3HAB9439-1 - 3HAC7312-1 - 3HAB5549-1 - 3HAC7101-1

ZINSCO QSF6053 600A 3PH 600V FUSIBLE PANELBOARD SWITCH

(X6-3) 1 NIB ALLEN BRADLEY 810-A11A MAGNETIC OVERLOAD RELAY X6-3

MODICON 140-CPU-651-50 USPP 140CPU65150

ALLEN BRADLEY 1392-B075-RH-MC-B-F2 USPP 1392B075RHMCBF2

GENERAL ELECTRIC EVWHS553CD04 USPP EVWHS553CD04

FOXBORO D0148MS USPP D0148MS

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

SCHWEITZER ENGINEERING 221G05-4256MVNB USPP 221G054256MVNB

YASKAWA ELECTRIC CACR-SR30BY1SF-E USPP CACRSR30BY1SFE

Siemens 6ES5 544-3UB11 -FS- 6ES55443UB11

Siemens PLC 6ES5-308-3UA12 6ES53083UA12 INTERFACE

SIEMENS 6ES5-456-4UA11 USPP 6ES54564UA11

Siemens 6ES5 420-8MA11 6ES5 420 Digital Input module

Siemens S5 Output Module 6ES5 470-7LB12 29881

Siemens CP5613 Card 6GK1561-3AA01 NIB

SHARP ZW-162N USPP ZW162N

Square D 8030 PS-21

SICK ZONE CONTROL INTERFACE MODULE 7029608

WE SHIP SAME SLM2024PT CISCO 26PORT GIGABIT POE SMART SWITCH SG200-2

SIEMENS 6FX1116-8AA00 6FX11168AA00

Siemens TP177 6AV6640-0CA11-0AX1 Touch Glass ping

Schneider Modicon SMALLVILLE 2 AS JONATHAN KENT PIECEWORKS PW6

Schneider Modicon AS-BDEP-256Compact Discreet Input ASBDEP256

Schneider Modicon AS-B804-116 RECONDITIONED

Schneider Modicon Input Module AS-B827-032

Schneider Modicon AS-J820-001 PLC

Schneider Modicon AS-B873001 4-20 MA 1-5 Volt Analog Input

SchneiderTelemecaniqueXBTG4330Panel

SIEMENS 6ES7 331-7PF11-0AB0 SIMATIC ANALOG INPUT MODULE NIB BOX NEVER OPENED

Scalable package: Ask about adding more SB168-ES units

Siemens HMI 6AV6 642-0EA01-3AX0 NIB 6AV66420EA013AX0

SIEMENS SINUMERIK 6FX1138-6BB01 6FX11386BB01

Siemens 6GK7-343-1EX11-0XE0 Communication Module WOW

SIEMENS 6SN1130-1AA11-0BA0

SIEMENS 6SN1118-1NK01-0AA1 6SN1 118-1NK01-0AA1 SIMODRIVE 611-U Control Unit 2-Ax

SIEMENS 6FC5-203-0AB13-0AA2 USPP 6FC52030AB130AA2

AllenBradleyPanelviewPlus12502711P-T12C4A6/A2711PT12C4A6

Allen Veiw MMI Model M1100

ABB DIGITAL LOOP CONTROLLER 53MC5411A25BAXXDXXXX

ADEPT TECHNOLOGY 30340-30000

(6462) Westinghouse Thyristor Breaker 179C368G14 600VAC 50 Amp (6462)

INDRAMAT PPC-RO1.2N-NV2-FW NSFP PPCRO12NNV2FW

WESTINGHOUSE 149D930G01 USPP 149D930G01

FANUC A06B-6058-H333 USPP A06B6058H333