一、KULICKE & SOFFA 01483-4029-000-13引言
大慶油田原油生產(chǎn)已進(jìn)入高含水階段，所采用的油水分離方法分為沉降脫水和復(fù)合電脫水兩個階段。主要工藝設(shè)備有游離水脫除器和電脫水器。油水分離的效果與對這些設(shè)備的控制方式有直接關(guān)系。大慶油田采油六廠某聯(lián)合站的原油水分離控制部分均采用手動控制，數(shù)據(jù)采集，填寫報表等都用人工完成，工人勞動強(qiáng)度大，又很難保證控制和采集數(shù)據(jù)的準(zhǔn)確性。為此，該廠提出了對聯(lián)合站的油水分離控制系統(tǒng)進(jìn)行自動化改造，要求系統(tǒng)不僅要實(shí)現(xiàn)油水分離的自動控制，而且能將主控制室內(nèi)的二次儀表用計算機(jī)上的形象直觀畫面來取代，以監(jiān)視和控制現(xiàn)場設(shè)備運(yùn)行狀況。本文根據(jù)這些要求設(shè)計了油水分離自動控制系統(tǒng)。
二、KULICKE & SOFFA 01483-4029-000-13工藝過程及工藝要求
來自各中轉(zhuǎn)站的高含水油，首先進(jìn)入游離水脫除器，脫掉原油中的大部分含水，再經(jīng)加熱爐加熱，然后到電脫水器進(jìn)行油水分離，最后經(jīng)由凈化油緩沖罐向外輸送。聯(lián)合站現(xiàn)場分為游離水脫除區(qū)、加熱爐區(qū)、電脫水區(qū)和成品油外輸區(qū)四個部分。
其中游離水脫除區(qū)有三臺游離水脫除器，它是聯(lián)合站轉(zhuǎn)油脫水過程中的主要裝置。電脫水區(qū)有四臺電脫水器，是原油脫水的核心裝置。游離水脫除器和電脫水器的油水界面高度和罐內(nèi)及輸油管壓力是保證油水分離質(zhì)量的重要參數(shù)。在實(shí)際生產(chǎn)過程中利用放水閥來調(diào)節(jié)油水界面的高度，油出口調(diào)節(jié)閥來調(diào)節(jié)罐內(nèi)和輸油管壓力。這兩個參數(shù)不是獨(dú)立的，無論是調(diào)整放水閥還是油出口調(diào)節(jié)閥，這兩個參數(shù)都同時受到影響，在控制系統(tǒng)中需要綜合考慮這兩個參數(shù)，以使系統(tǒng)能夠安全、穩(wěn)定地運(yùn)行。
經(jīng)過沉降脫水得到的原油再經(jīng)加熱爐升溫后，才進(jìn)入電脫水器。溫度過低會影響生產(chǎn)，溫度過高造成能源的浪費(fèi)。因此，系統(tǒng)中需要根據(jù)原油脫水工藝設(shè)定的溫度值，對加熱爐燃燒情況進(jìn)行自動調(diào)節(jié)。
外輸油區(qū)有一個凈化油罐和凈化油緩沖罐，其中凈化油緩沖罐的出口流量由油出口調(diào)節(jié)閥和變頻器根據(jù)緩沖罐的液位和壓力來自動控制，其中變頻器控制外輸油泵的轉(zhuǎn)速。
根據(jù)工藝要求，控制系統(tǒng)中需要監(jiān)控的參數(shù)主要有：油水界面高度、液位、壓力、溫度和流量。
三、KULICKE & SOFFA 01483-4029-000-13控制系統(tǒng)總體結(jié)構(gòu)
該聯(lián)合站的幾個工作區(qū)相距100米左右，而且要求總控室和外輸段能夠自動監(jiān)控各個工作區(qū)設(shè)備的運(yùn)行狀況，并根據(jù)檢測的參數(shù)對系統(tǒng)進(jìn)行自動控制?？刂葡到y(tǒng)中上位機(jī)采用工控機(jī)，控制器采用羅克韋爾自動化的SLC500可編程序控制器，對于距離較遠(yuǎn)的工作區(qū)采用DeviceNet現(xiàn)場總線通訊。系統(tǒng)硬件組成如圖1 所示。
現(xiàn)場中，總控室位于電脫水區(qū)和加熱爐區(qū)之間，SLC控制器也在總控室中，通過DH+網(wǎng)絡(luò)與工控機(jī)相 連。因此SLC控制器的本地輸入/輸出模塊直接控制電脫水段和加熱爐段。游離水段作為DeviceNet的一個節(jié)點(diǎn)，用FlexI/O與現(xiàn)場的液位、壓力 變送器和調(diào)節(jié)閥相連。凈化油外輸段的FlexI/O、變頻器和人機(jī)接口界面PanelView1400分別是DeviceNet的一個獨(dú)立站點(diǎn)，其中FlexI/O連接現(xiàn)場的液位、壓力變送器和調(diào)節(jié)閥；變頻器控制外輸油的流量；PanelView1400用于在外輸段監(jiān)控整個系統(tǒng)的運(yùn)行狀況。
系統(tǒng)中的界面高度、壓力、溫度等信號都由對應(yīng)的一次儀表傳感器或變送器檢測出來并轉(zhuǎn)變?yōu)?～20mA 電流信號，經(jīng)安全柵送入SLC500控制器的本地輸入模塊或DeviceNet網(wǎng)上的FlexI/O輸入模塊?？刂菩盘栍上鄳?yīng)的輸出模塊以4～20mA電 流形式控制氣動調(diào)解閥。整個系統(tǒng)中輸入信號有8個界面高度傳感器；4個液位傳感器；4個溫度傳感器；10個壓力變送器，輸出信號有8個液位調(diào)解閥，7個壓 力調(diào)解閥。外輸油流量的測量是通過一次儀表把流量信號轉(zhuǎn)換為脈沖信號，經(jīng)屏蔽電纜傳輸?shù)絊LC的高速計數(shù)模塊，從而測得輸送到下個站的凈化油流量。
四、程序設(shè)計
控制系統(tǒng)的軟件設(shè)計由顯示操作程序和過程控制程序兩部分組成。顯示操作程序包括上位機(jī)和人機(jī)接口界面兩部分，上位機(jī)顯示操作采用羅克韋爾軟件的RSView32TM組態(tài)軟件，在上位計算機(jī)編制顯示控制程序，完成各種顯示、控制與生產(chǎn)報表等功能。人機(jī)接口界面使用PanelBuilder軟件編制界面顯示和控制程序，由此實(shí)現(xiàn)生產(chǎn)過程的遠(yuǎn)程監(jiān)視和控制。過程控制程序使用羅克韋爾軟件的Rslogix500 軟件編制SLC500控制程序，實(shí)現(xiàn)對生產(chǎn)過程的直接控制和數(shù)據(jù)采集。上位計算機(jī)與SLC500控制器之間是通過DH+網(wǎng)實(shí)現(xiàn)數(shù)據(jù)通信的。一方面將過程控 制中的參數(shù)傳送給上位機(jī)，用于存儲、顯示、制表、打??；另一方面將工作人員通過顯示操作站設(shè)置的控制參數(shù)發(fā)送給SLC500控制器。由控制器按操作員的要 求實(shí)現(xiàn)對生產(chǎn)過程的直接控制。
1.顯示操作程序設(shè)計
sview32TM軟件是羅克韋爾軟件公司提供的上位機(jī)組態(tài)軟件，通過編程可以實(shí)現(xiàn)監(jiān)控系統(tǒng)所需的人機(jī)界面。PLC采集的數(shù)據(jù)可以根據(jù)需要通過數(shù)字、圖 形、動畫、等多種形式顯示出來，該軟件還具有存儲數(shù)據(jù)歷史紀(jì)錄、趨勢圖顯示、報警監(jiān)視和自動生成報表和打印等功能。利用RSView32TM軟件的開放式 設(shè)計還可以很容易地與Microsoft產(chǎn)品共享信息。
在油水分離控制系統(tǒng)中上位機(jī)和人機(jī)接口界面顯示操作程序都有：工藝參數(shù)顯示、各控制回路的ＰＩＤ調(diào)節(jié)、手/自動控制切換、報警監(jiān)視等界面，其中工藝參數(shù)是以工藝流程圖的形式顯示的。另外上位機(jī)控制界面還有參數(shù)匯總、參數(shù)設(shè)置、歷史數(shù)據(jù)紀(jì)錄、趨勢圖、報表打印等界面。在編成時，充分利用RSView32TM軟件圖形處理能力強(qiáng)的優(yōu)點(diǎn)，繪制出形象直觀的工藝流程畫面。圖2是用RSView32TM軟件繪制 的游離水段和加熱爐段工藝流程圖，在工藝流程圖上直接顯示監(jiān)測點(diǎn)和控制點(diǎn)的位置和參數(shù)值。另外還將在RSView32TM軟件上繪制的流程圖導(dǎo)入PanelBuilder的程序中作為PanelView的背景圖，使上位機(jī)和人機(jī)接口界面以相同的畫面顯示，KULICKE & SOFFA 01483-4029-000-13這樣既實(shí)現(xiàn)了工作站與遠(yuǎn)程監(jiān)控界面的一致 性，又充分彌補(bǔ)了PanelBuilder軟件在圖形處理能力不強(qiáng)和漢字顯示不夠靈活方面的不足。在上位機(jī)和人機(jī)接口界面上都能圖文并茂的實(shí)時顯示過程變量和控制變量。
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WESTINGHOUSE PB1AAHAB NSFP PB1AAHAB
Details about STRUTHERS DUNN RELAYS 219-XBX-PM-120VAC NSFP 219XBXPM120VAC
Details about PYROTRONICS 500-033420 NSFP 500033420
Details about Pro-Face Proface Digital GP370-LG11-24V touch screen HMI 27505620131
Details about Nadex Phase 5 SCR spot weld welding controller contactor PH5 nadesco
Details about SQUARE D MHL360006M1625 NSFP MHL360006M1625
Details about ITE SIEMENS 5SY6-206-8 USPP 5SY62068
Details about ITE SIEMENS Q23020 USPP Q23020
WESTINGHOUSE PB1VQR NSFP PB1VQR
SICK OPTIC ELECTRONIC FGSE1050-111 NSFP FGSE1050111
Details about SIEMENS A5E02356504 NSPP A5E02356504
Details about SIEMENS 6FC5-247-0AA17-0AA0 USPP 6FC52470AA170AA0
Details about HOFFMAN ENCLOSURES A8N6P USPP A8N6P
Details about RELIANCE ELECTRIC 411627-02AJ NSFP 41162702AJ
Details about SIEMENS SFH19 NSFP SFH19
WESTINGHOUSE 1541A11G01 USPP 1541A11G01
Allen Bradley 440N-N15027 Guardmaster Sentinel 1 Safety Interlock Switch
Details about POWER ONE NRG3A35B1V5W3 NSFP NRG3A35B1V5W3
Details about DODGE 117167 USPP 117167
Details about KEYENCE CORP LS-5001 USPP LS5001
MITSUBISHI MC-1 USPP MC1
Details about BENDIX DYNAPATH 4200431 USPP 4200431
WESTINGHOUSE LA2600 USPP LA2600
Details about SQUARE D 2510-KG2C FNFP 2510KG2C
