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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、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(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(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。

SCHNEIDER MODICON 140CPU43412A 140 CPU 434 12A TSX Quantum

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

SIEMENS Sinumerik 6FX1136-2BA01 CPU Module

Siemens 505-7354 Communication Module Peer Link

SIEMENS Board 6SN1118-0DG23-0AA0

SIEMENS SINUMERIK PCU 50 6FC5210-0DF20-0AA0

SIEMENS MOORE 39ACM28ADN APACS ACM ADVANCED CONTROL MODULE 24V ROM V.3 28014

AllenBradleyVersaView1000PPanelViewTouchScreen

ALLEN-BRADLEY 1201-DMA HMI DOOR MOUNT BEZEL

ABB Circuit Breaker 300 Amp Sace S5N Shunt & Auxiliary 240/480/600 volt

ADEPT TECH 30846-00020 NSPP 3084600020

(4357) Allen Bradley Contact Kit 40783-802-01 Contactor (4357)

INDRAMAT MAC090C-2-KD-4-C/110-A-I4/DI-520 NSFP MAC090C2KD4C110A

TOSHIBA VFP1-4550UP-B1 USPP VFP14550UPB1

FANUC A06B-6035-H422 USPP A06B6035H422

DANFOSS 175H4423 USPP 175H4423

RELIANCE ELECTRIC 3RA2003 NSFP 3RA2003

MTS SYSTEMS CO MPA-35-460-167 USPP MPA35460167

MACTRON INC MGA-3A USPP MGA3A

Siemens 6ES5 377-0AA41 -FS- 6ES53770AA41

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Siemens I/O Module 6ES5 482-8MA13 working

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MERCURY MR-52 DUAL READER INTERFACE MODULE

XEON 6.4GT/s Turbo6000GB HDD 24GB TRUE 3CH DDR3 RAM

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Reliance 0-51893-2

Schneider Modicon AS-984A-816 PLC

Schneider Modicon AS-B224-001 NSFP ASB224001

Schneider Modicon AS-P530-0MA POWER SUPPLY REPAIRED

Schneider Modicon AS-B804-116 Output Module 115VAC

Schneider Modicon AS-B266

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Siemens 6ES7 322-1FH00-0AA0 -FS- 6ES73221FH000AA0

Siemens Simatic 8 Moble Operator Interface Panel 277 HMI w/ Stop Boxed A

SIEMENS 6DD1611-0AD0 MEMORY MODULE /BOX

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SIEMENS Circuit Board 6FC9310-1MD01 _ 6FC93101MD01

ADLink NuDAQ ACL-6128A Isolated Analog Output Card NIB

ALLEN-BRADLEY 1791-0A32 Block I/O 120V AC 32 Point Module 32 Output

ABB ACS 600 AC AUTOMATION INC MULTIDRIVE 250HP

Active EMC broadband antenna 30MHz to 1GHz BicoLOG 30100 X, , biconical

6ES7316-1AG00-0AB0 6ES7316-2AG10-0AB0 Brand , Factory Sealed,

9 UNIT 1660 MFC, UFC-1660, CF4, H2, Cl2, N2, HBr, SF6, different gas range.

SIEMENS CLD63B600 NSPP CLD63B600

BOSCH 1070071221-102 USPP 1070071221102

BAILEY CONTROLS IEPEP-03 USPP IEPEP03

MODICON AS-P453-641 USPP ASP453641

JOHNSON CONTROLS JNCA NSFP JNCA

CONTROL SYSTEMS 7718-C USPP 7718C

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SIEMENS SIMATIC OP3 6AV3 503-1DB10 Operator Panel

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HP AGILENT 35651C INTERFACE/SIGNAL PROCESSOR MODULE

WS-X6704-10GE Cisco 6500 10 Gigabit EN Interface Module 4 ports

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Siemens LOGO! power 6EP1 331-1SH01 6EP1331-1SH01

Omron C200H-OD211

Schneider Modicon AS-C484-266 ASDC484266 Programmable Controller

Schneider Modicon ANALOG INPUT AS-B875-111 OUT OF BOX

Schneider Modicon AS-J471-600 USPP ASJ471600

Schneider Modicon 24 VDC INPUT AS-B827-032

Schneider Modicon AS-W512-003

Schneider Modicon ZAE-201/AS-BZAE-201 High Speed Counter 1X50/500KHZ ASBZAE201

SM321 16DI 24VDC INPUT MODULE 6ES7-321-1BH02-0AA0

Schneider TELEMECANIQUE XBT-GT-2110 XBTGT2110 with cable

Siemens TI 500-5016 Analog Output Module

Siemens 6AV3 525-1EA01-0AX0 6AV35251EA010AX0 Panel

SIEMENS Sinumerik 6FX1130-6BA00 Module 130. E Stand A.

ECDL Syllabus 5.0 Module 7b Communication Using Ou.....

SIEMENS Simodrive LT-Modul INT. 15A 6SN1123-1AA00-0AA1

SIEMENS SIMODRIVE 6SN1145-1BA01-0BA1SINUMETIK 840D NCU-BOX 6FC52476FC5357 BBE

Adb CPCI-R6780

ALLEN-BRADLEY 800MB-CPB16RAS PUSH BUTTON

ABB 1MRS090416-AAA REA 101 ARC PROTECTION RELAY SYSTEM MAIN MODULE 57976

ACCU SORT 22E8SL NSFP 22E8SL

A06B-6066-H003 FANUC SERVO AMPLIFIER REMANUFACTURED

800' Hollins 3/0 3/0 1/0 Triplex Aluminum URD RHH RHW 600 volt

SIEMENS 3SF7834-6PB00 NSFP 3SF78346PB00

ALLEN BRADLEY 8520-3S10A-BAT-EX4-T1-Y-4-5-7 USPP 85203S10ABATEX4T

ALLEN BRADLEY 5370-CVIM USPP 5370CVIM

JAGUAR VXSM220-1 USPP VXSM2201

GENERAL ELECTRIC DS3800NFCD1Q1H USPP DS3800NFCD1Q1H

YASKAWA ELECTRIC CACR-SR10SZ1SSY86 USPP CACRSR10SZ1SSY86

MITSUBISHI HCSFS1524BK NSFP HCSFS1524BK

Siemens 6ES5-308-3UC21 NSPP 6ES53083UC21

SIEMENS 6ES5 430-7LA12 DIGITAL INPUT

SIEMENS S5 6ES5 453-7LA11 Digital Output Module

Siemens Digital Output Module 6ES5 454-7LA11 6ES54547LA11

Siemens 6ES7 221-1BH22-0XA0 6ES72211BH220XA0 FreeShip

SIEMENS OP270-6 6AV6542-0CA10-0AX0 Membrane Keypad

Redback CM-M-512MB Connection Manager BAC8GMBEAA

Texas Instruments 5TI5-5020

TERAWAVE 10096-01 M2-0-ALL/2C/10/ATM/ED INTERFACE MODULE FREE SHIP

TSXCUSBMBP Modicon Premium Modbus Plus Converter TSX-CUS-BMBP

Siemens EM 222 6ES7 222-1BF20-0XA0 EM222 PLC

Modicon MMS22351C1A

Schneider Modicon AS-P120-000 Power Supply Module - 1 YEAR RETURN POLICY

Schneider Modicon AS-BDAP-204 SEALED Compact Out ASBDAP204

Schneider Modicon AS-C184-004 USPP ASC184004

Schneider Modicon ASHDTA201 Compact Subrack AS-HDTA-201

Schneider Modicon /Modicon/Input Module AS-BDEO-216/DEO

Schneider Modicon Input Module AS-B825-016

Schneider Telemecanique TSX P57303AM TSXP57303AM

SCHNEIDER AEG DEP215 AS-BDEP-215 MODICON INPUT MODULE 65

PVDM3-64 CISCO 64 -Channel Voice and Video DSP Module

Siemens 6ES5441-4UA14 Simatic Output Module Repaired

SIEMENS 6DD1661-0AB0 COMMUNICATION MODULE

Johnson Controls NU-NCM201-1 NUNCM2011 Network Communication Module -

SIEMENS Simodrive 6SN1135-1BA12-0CA0

SIEMENS Sinumerik 840C Interface 6FC5103-0AD13-0AA0 GWE 570080924900 Ver C

SIEMENS MOORE PRODUCTS 16353-52 I/O EXPANDER BOARDNIB

Allen-Bradley RediPanel Push Button Module2705-P21J1

52002 YOKOGAWA shading pipes type colorimeter

ABB SAFT 110 POW 57411414, , 57411414,

A06B-0148-B177#7076 FANUC SERVO MOTORS REMANUFACTURED

700' Hollins 3/0 3/0 1/0 Aluminum URD Wire RHH RHW Triplex

PERCEPTRON 911-0025 USPP 9110025

ALLEN BRADLEY 1775-MR8 NSFP 1775MR8

ALLEN BRADLEY 1336S-B020-AE-ES5 USPP 1336SB020AEES5

GENERAL ELECTRIC DS3800HPBC USPP DS3800HPBC

TELEMOTIVE 18027 NSPP 18027

SST 5136-DNP-MUL USPP 5136DNPMUL

DAYKIN GPFS-01TBA627 USPP GPFS01TBA627

Siemens 6ES5 955-3LC14 6ES59553LC14

SIEMENS 6ES5 100-8MA02 6ES51008MA02

SIEMENS 6ES5-777-0BB00 USPP 6ES57770BB00

Siemens 6ES5 525-3UA21/6ES55253UA21

Siemens 6AV8 100-0BC00-1AA1 Membrane Keypad FreShip

Siemens LOGO! 12/24RC 6ED1052-1MD00-0BA2

roland prelude 61 key keyboard in VG CONDITION

Telemecanique TSXDET3242

SIEMENS SIMATIC S5 INTERFACE MODULE 6ES5 316-8MA12

Wago 750-461/003-000 2-CHANNEL ANALOG INPUT MODULE

Siemens 7MF4033-1DA00-1AA6-Z Pressure Transmitter

Modicon AS-S491-000

Schneider Modicon DEP216/AS-BDEP-216 Discrete Input WOW

Schneider Modicon AEG/GOULD// DEP-218/AS-BDEP-218 16POINT INPUT MODULE NNB

Schneider Modicon AS-B875-102 INPUT MODULE ANALOG HI SPEED 8POINT 800 SERIES ASB875102

Schneider Modicon AS-521P-011

Schneider Modicon Input Module AS-B837-016

Schneider Modicon AS-M680-008 Memory Module 8K -

Schneider Automation Inc AS-BDAP-216N ASBDAP216N Output Module

SIEMENS 505-4232A INPUT MODULE

RELIANCE ELECTRIC 65C-500 USPP 65C500

Siemens 6FX1130-6BA00 Output Module

SIEMENS Sinumerik Operator Control Panel #6FC3808-3EF21

Power Ware AS400 AS/400 Communications Module XLNT

SIEMENS PW-MODUL 1P 6SN1113-1AB01-0BA1

SIEMENS TERMINAL STRIP CONNECTOR BOARD 6FC9302-2AA 6FC93022AA USMT MILL CNC

SIEMENS 6FC3-061-1EA-Z USPP 6FC30611EAZ

AllenBradley1794-OA16/AFlexI/O120VACOutputModuleB01

ALLEN BRADLEY SWING ARM CATALOG NO. 1771-WA / QTY 10

ABB KP-40 KP40 4000 Amp 4000A Air Breaker MPS-C 2000

Ziatech ZT210 15 S Card Cage w ZT 8907 486 Single Board Computer Card

(U1) 1 UNIMATION INC D918W3 REV K PC BOARD. U1.

MIYACHI MM-730A USPP MM730A

ALLEN BRADLEY 1387-AOB145-A73 USPP 1387AOB145A73

GENERAL ELECTRIC DS3800HMPA1A1 USPP DS3800HMPA1A1

FORNEY UAC100 USPP UAC100

SIEMENS 6ES7-413-1XG02-0AB0 NSFP 6ES74131XG020AB0

RONAN ENGINEERING CO 6.8LC-2000 USPP 68LC2000

VIDEO JET 390646 USPP 390646

Siemens 6ES5 530-3LA12 6ES55303LA12

Siemens CONTROLLER CARD 6GK1143-0TA01

SIEMENS 6ES5-454-4UA11/6ES5454-4UA11 OUTPUT MODULE NIB

Siemens 6ES5 376-1AA11 USPP 6ES53761AA11

Siemens S5 Interface Module 6ES5 318-8MB12

Siemens Connector 6ES7392-1AJ00-0AA0 in Sealed Box

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

Square D 8030 HIM-102

SEALED SQUARE D S/MAX I/O INTERFACE MODULE 8030-CRM222

Westinghouse NL-542 NL542 6ES54648ME11 Analog Input

SIEMENS 6FC5203-0AF50-3AA1 6FC5 203-0AF50-3AA1 MCP416C

Siemens TP170B 6AV6545-0BB15-2AX0 6AV6 545-0BB15-2AX0 Seal Opened FreeShip

Siemens 305-22P

Schneider Modicon AS-BVIC-224 TESTED 4 Ch Ctr IN ASBVIC224

Schneider Modicon AS-B579-001 COUNTER MODULE HI-SPEED INCOMPLETE

Schneider Modicon DEP 218 / AS-BDEP-218 DISCRETE INPUT MODULE ASBDEP218

Schneider Modicon AS-HDTA-202 SUB RACK 2 SLOTS FACTORY 1 YEAR WARRANTY - NIB

Schneider Modicon AS-B872-002 ASB872002

MODICON 115VAC OUTPUT MODULE B230 501

SIEMENS 6ES7321-1BH02-0AA0 INPUT MODULE 16POINT 24VDC SM321 6ES73211BH020AA0

SCHNEIDER DISCRETE INPUT 16PT 115V DEP 218/AS-BDEP-218

SIEMENS SINUMERIK 6FX1122-1AA01 COUPLING MODULE

Siemens Communication Processor Module 6GK1543-0AA01 37354

SIEMENS 6SN1123-1AB00-0AA1 6SN1 123-1AB00-0AA1 SIMODRIVE 611 Power Module 15A

SIEMENS 6SN1123-1AA00-0DA0 Power Module Simodrive ~60 DAY WARRANTY~

SIEMENS 6FC5203-0AF05-0AB0 Membrane Keypad 6FC5 203-0AF05-0AB0

Allen-BradleyPro-Set700ReplacementTouchscreenTouchpanelInterface

Allen-Bradley - 1794-TBNF

ABB CONTROLLER CARD DSQC335 / 3HAB6182-1

ADEPT TECHNOLOGIES ROBOT #640 & CONTROLLER UNIT #310

(5243) Honeywell Logic Board PWA T/C Mux 51301874-100 (5243)

INDRAMAT MAC90C-0-G-4C/110-A-1/W1520/S01 NSPP MAC90C0G4C110A1W

TRIDIUM INC WEB-545I-AX USPP WEB545IAX

FANUC A06B-6050-H005 USPP A06B6050H005

DOLAN JENNER SS950-40000 USPP SS95040000

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