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　煤氣在使用過(guò)程中容易產(chǎn)生管網(wǎng)壓力波動(dòng)，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(dòng)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(gè)危險(xiǎn)性氣體的“歸宿”，煤氣柜的安全運(yùn)行對(duì)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(lái)，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(dòng)、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(jì)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(shí)現(xiàn)了煤化工與精細(xì)化工的科學(xué)整合，做到了資源利用最大化與資源利用價(jià)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(jì)時(shí)不具備硬件的冗余、容錯(cuò)和復(fù)雜邏輯判斷等功能，當(dāng)現(xiàn)場(chǎng)儀表出現(xiàn)顯性故障時(shí)，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(jí)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(dòng)化儀表技術(shù)、自動(dòng)化控制系統(tǒng)、計(jì)算機(jī)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(shí)。新系統(tǒng)的設(shè)計(jì)需要重點(diǎn)解決現(xiàn)有系統(tǒng)面臨的以下三方面問(wèn)題：
　　 故障安全：原有系統(tǒng)配置不能夠排除當(dāng)現(xiàn)場(chǎng)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(dú)立設(shè)置：對(duì)參與聯(lián)鎖的各個(gè)傳感器(如活塞高度、氣柜內(nèi)壓力等值)配置為單臺(tái)測(cè)量，未使用不同的測(cè)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(cuò)：模塊前期設(shè)計(jì)時(shí)，未考慮PLC模塊的冗余、容錯(cuò)設(shè)計(jì)，如發(fā)生儀表的損壞、模塊損壞、電源異常斷電等故障時(shí)，極易造成工藝事故。
　　解決方案
　　針對(duì)金能科技干式煤氣柜實(shí)際情況，基于羅克韋爾自動(dòng)化組態(tài)技術(shù)和人機(jī)界面檢測(cè)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(shí)現(xiàn)了無(wú)縫的融合與兼容。
　　項(xiàng)目總體實(shí)施過(guò)程包括五個(gè)步驟：氣柜監(jiān)控監(jiān)測(cè)系統(tǒng)總體的方案設(shè)計(jì);氣柜監(jiān)測(cè)系統(tǒng)邏輯關(guān)系模型的建立;冗余、容錯(cuò)目的的達(dá)成，及數(shù)學(xué)模型的建立;完成氣柜監(jiān)測(cè)系統(tǒng)軟件部分的組態(tài)設(shè)計(jì)與開(kāi)發(fā);最終系統(tǒng)的聯(lián)調(diào)聯(lián)試以及持續(xù)改進(jìn)。
　　新系統(tǒng)采用由羅克韋爾自動(dòng)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(shí)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(dá)到毫秒級(jí)，保證系統(tǒng)安全可靠運(yùn)行?？梢酝瓿蓪?duì)現(xiàn)場(chǎng)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(jìn)出口閥門(mén)等閥門(mén)的過(guò)程控制。對(duì)于輸入、輸出模擬量信號(hào)通過(guò)加裝防爆安全柵(一入兩出)進(jìn)行現(xiàn)場(chǎng)與控制系統(tǒng)的安全有效隔離，現(xiàn)場(chǎng)檢測(cè)信號(hào)一分為二，一路進(jìn)原有系統(tǒng)顯示報(bào)警，另一路進(jìn)本系統(tǒng)參與聯(lián)鎖控制，雙重保證檢測(cè)信號(hào)的穩(wěn)定性和安全性。系統(tǒng)所有開(kāi)關(guān)量輸入、輸出信號(hào)都通過(guò)隔離繼電器隔離，保證測(cè)點(diǎn)的干接點(diǎn)輸入和輸出。

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