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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(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(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。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(jī)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(dá)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(jìn)。
　　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(dá)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(jìn)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(jìn)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(jìn)原有系統(tǒng)顯示報警，另一路進(jìn)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。

Siemens 6GK1-543-0AA02/6GK15430AA02

Siemens 6ES7132-4BD01-0AA0 w/ 6ES7193-4CA40-0AA0

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Keyence KV-L20 Serial Interface Module PLC sn 05165

Tripp Lite B055001PS2 PS2 Server Interface Module B055-001-PS2

WS-C2960-48TC-S CISCO CATALYST 2960-48TC SWITCH-1YEAR - GRADE A Fast Shi

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SIEMENS SINUMERIK 6FC5203-0AF02-0AA0 Membrane Keypad

Saftronics CIMR-G3U42P2

Schneider Modicon ASP120000 AS-P120-000Compact supply

Schneider Modicon AS-B552-000 USPP ASB552000

Schneider Modicon AS-W801-002 USPP ASW801002

Schneider Modicon AS-BDEP-218 DISCRETE INPUT MODULE

Schneider Modicon AS-B827-032 32 point Input Module

MODICON AEG PANELMATE PLUS OPERATOR INTERFACE MM-PMC2-200 PARTS OR REPAIR

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SFP-GE-Z CISCO GENUINE 1000BASE-ZX GIGABIT ETHERNET SFP DOM

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Advantech SOM-2353 SOM-2353F

ALLEN-BRADLEY 160-P1 PROGRAMMING TERMINAL KEYPAD ""

ABB BAILEY SYMPHONY CONTROLS DIGITAL IMASI23 ANALOG INPUT SLAVE MODULE 88239

ADEPT TECH 10332-12350 REP

(12) AB Allen Bradley 1606-XL480E-3W Power Supply 460/480V 24VDC, 20A

INDRAMAT DDS02.2-W100-B USPP DDS022W100B

TELEMECANIQUE TSX-P574823AM USPP TSXP574823AM

ENERDYNE DEC2000R2 USPP DEC2000R2

CUTLER HAMMER CPS160480YAX USPP CPS160480YAX

RANSBURG 78789-02 USPP 7878902

MODICON AS-P453-632 USPP ASP453632

INDRAMAT PLCB03-02 USPP PLCB0302

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Lot 2 Network General NGC-T1 / NGC-RS/V Interface Module 5V / Warranty

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Schneider Modicon AS-884A-211 Control Module 3.5K W/MBUS PORT AND RIO

Modicon Stand Alone Modem Part J478

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ABB AC DRIVE 40 HP ACS550-U1-059A-4 ACS550U1059A4

Acterna JDSU SmartClass OLT-55 Optical Loss Test Set Power Meter Light Source

6ES7134-0KH01-0XB0 Brand , Factory Sealed,

85640A HP/Agilent RF Tracking Generator, 2.9 GHz, cal valid through 8/10/2012

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BAILEY CONTROLS NCOM-03 NSFP NCOM03

ATLAS COPCO 4240-0367-82 USPP 4240036782

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BALDOR CDP3585 NSFP CDP3585

WESTINGHOUSE A200M4CAC USPP A200M4CAC

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Schneider Modicon AS-J810-000/ASJ810000 RIO Interface

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Ford Communication System Module OEM

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AB,ALLEN-BRADLEY PLC 1756-PA72/B,1756-DHRIO,1756-CNB/D,1756-M02AE,1756-0F6VI

AC TECH Q14075B 75HP VARIABLE SPEED AC MOTOR DRIVE

A06B-1567-B123#0021 FANUC AC SERVO SPINDLE REMANUFACTURED

78093-1R

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ALLEN BRADLEY 6180-AEEBECABACZ USPP 6180AEEBECABACZ

ALLEN BRADLEY 2711-K9C1 USPP 2711K9C1

INDRAMAT TDM1.2-100-300-W1/2 USPP TDM12100300W12

YOKOGAWA 436104-2/A2/C7/F1 NSPP 4361042A2C7F1

XYCOM 3515-02S314103901T USPP 351502S314103901

KOLLMORGEN IND B-204-C-21 USPP B204C21

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Texas Instruments 530C-1104

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Schneider Telemecanique Inverter ATV11HU09M2A

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PWR-ME3750-DC CONFIGURABLE ME-C3750 DC POWER SUPPLY

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OMRON F400-C10E NSFP F400C10E

ALLEN BRADLEY 1756-L72 FNFP 1756L72

ALLEN BRADLEY 1336F-CWF100-AA-EN-HAS2-L6-LA4 USPP 1336FCWF100AAENH

GENERAL ELECTRIC DS200IIBDG1AAA USPP DS200IIBDG1AAA

SYMAX 8884-SPR-25 USPP 8884SPR25

SMC CLS200-UA NSPP CLS200UA

CHROMALOX TMO-6065 USPP TMO6065

Siemens 6ES5 948-3UA23 6ES59483UA23

Siemens Simatic S5 CPU 6ES5 943-7UA22

SIEMENS 6ES5-731-1BD20 NSFP 6ES57311BD20

Siemens 6ES5 497-4UB11 NSFP 6ES54974UB11

SIEMENS 6AV6545-0AA15-2AX0 TP070 TOUCH PANEL

Siemens LOGO 230RCo 6ED1052-2FB00-0BA5

RTD Model EFM104HR PC/104 Data/Fax Modem Peripheral Module

Telemecanique LR F160

Siemens Simatic 6ES5 Interface Module 315-8MA11

Wago 750-842 ETHERNET TCP/IP PROGRAMMABLE FIELDBUS CONTROLLER

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Modicon AS-P180-011

Schneider Modicon 984 series of Switch b modules AS-B809-016 WARRANTY

Schneider Modicon ASB82501624VDC 16point Input Module AS-B827-016

Schneider Modicon AS-B872-200 ANALOG OUTPUT MODULE

Schneider Modicon AS-J890-101 Remote I/O Processor Module

Schneider Modicon DEP 217 I/O MODULE AS-BDEP-217 ASBDEP217

Schneider Modicon AS-J810-000 J810 REMOTE I/O ADAPTER

Schneider Electric PLC Output Module TSXDST1635 2972

SIEMENS 6ES5 422-8MA11 16Point Input Module

REXROTH 0-608-830-166 NSPP 0608830166

Siemens 9600 9600DC-1156-BFZA Power Meter Display ION Ethernet Access

SIEMENS Sinumerik MachiControl Panel 3T 548 025 9004

ProSoft Technology MVI56-ADM Communications Module Pro Soft MVI56ADM

SIEMENS E-Stand 6SN1118-0AE11-0AA0 CONTROL BOARD SERVO

SIEMENS SINUMERIK 840C/840CE 6FC5112-0CA03-0AA0 NIB

SIEMENS 6FC3-984-3RA USPP 6FC39843RA

AllenBradley2711C-T10C/B2711CT10CPanelviewC1000

ALLEN BRADLEY TERMINAL LUG KIT 199-LF1

ABB Irb 6400 Axis 1 motor; part# 3HAB4039-1

Advanced Micro Controls 1944

(Q5-4) 1 ALLEN BRADLEY 803-F812 ROTARY CAM LIMIT SWITCH Q5-4

METRONICS ALPHAJET-C-HS NSFP ALPHAJETCHS

ALLEN BRADLEY 1336R-VB078-AA-HAP USPP 1336RVB078AAHAP

GENERAL ELECTRIC 0786E201P1G0001 NSFP 0786E201P1G0001

FANUC A20B-0004-0171-10D USPP A20B0004017110D

SIEMENS 6ES5-247-4UA41 USPP 6ES52474UA41

RELIANCE ELECTRIC 86466-60S NSPP 8646660S

SQUARE D HU366 USPP HU366

Siemens 6ES5 470-8MC12 -FS- 6ES54708MC12

Siemens 6ES5-951-7ND41

SIEMENS 6ES5-445-3AA11 USPP 6ES54453AA11

Siemens 6ES5 300-3AB11 /6ES53003AB11

Siemens S5 BUS MODULE 6ES5 700-8MA11 6ES57008MA11

Siemens C98043-A1663-L C98043-A1663-L11-48

Siemens 6ES5 451-8MR12 -FS- 6ES54518MR12

Square D 8030 CRK-300

RV LP INTERFACE MODULE PN 38030057

WS-C2950G-48-EI CISCO CAT. SWITCH 2950 48 10/100 WITH 2 GBIC SLOTS

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Siemens Soft Starter 3RK1903-0BA00 3RK19030BA00 FreShip

Schleicher USA 8/1 D/2.1 31511134 880 075

Schneider Modicon ASJ14600 Multi-Node Panel AS-J146-000

Schneider Modicon AS-B557-001 NSPP ASB557001

Schneider Modicon AS-W808-008 NSFP ASW808008

Schneider Modicon AS-C384-204 Programmable Mainframe Controller

Schneider Modicon AS-B829-116 Input Module 5VOLT TTL Fast Respon16POINT

Modicon 992 019 1002 Robot Teach Pendant HHTP

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SEALEDASA5540-AIP20-K9 CISCO 5540 W/AIP-SSM-20 SW HA 4GE1FE 3DES/AES

Siemens MS300 Circuit Board MS3OO 6FX1113-4AD01 6FX11134AD01 6FX1113-4ADO1

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Spectrum Industires Power Communication Module parts

SIEMENS 6SN1123-1AA00-0CA0 Version D Simodrive LT-Modul Int 50A 6SN11231AA000CA0

SIEMENS 6SN1146-1AB00-0BA1 SIMODRIVE 611 GOOD TAKEOUT

SIEMENS 6FC5-247-0AA00-0AA2 USPP 6FC52470AA000AA2

Alllen Bradley Panelview 300 Micro Panel View 2711-M3A18L1 w/ AB 1761-CBL-HM02

ALLEN-BRADLEY 160-BA01NPS1P1 0.5HP 460VAC Control. in good condition

ABB BAILEY SYMPHONY CONTROLS DIGITAL IMASI23 ANALOG INPUT SLAVE MODULE 88304