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　煤氣在使用過程中容易產生管網壓力波動，存在不安全因素。煤氣柜作為調劑煤氣供應、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，充分合理利用企業內部的附產煤氣，調節管網壓力。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。多年來，公司秉承 “資源高效、綠色低碳”的循環發展理念，以技術創新為驅動、以資源高效利用為導向，打造了區別業內其他企業的循環經濟產業鏈，構建了資源利用、產品結構、技術裝備、環保模式四大差異化的盈利模式，實現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。
　　由于金能科技現有的30000m2煤氣柜控制系統在設計時不具備硬件的冗余、容錯和復雜邏輯判斷等功能，當現場儀表出現顯性故障時，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，升級現有的煤氣柜監控系統。
　　挑戰
　　煤氣柜監控系統是智能自動化儀表技術、自動化控制系統、計算機技術和網絡技術等多種技術的結合，涉及到多方面的知識。新系統的設計需要重點解決現有系統面臨的以下三方面問題：
　　 故障安全：原有系統配置不能夠排除當現場儀表出現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：對參與聯鎖的各個傳感器(如活塞高度、氣柜內壓力等值)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技術和人機界面檢測技術，金能科技構建了現代化的煤氣柜監控系統，并與原有控制系統實現了無縫的融合與兼容。
　　項目總體實施過程包括五個步驟：氣柜監控監測系統總體的方案設計;氣柜監測系統邏輯關系模型的建立;冗余、容錯目的的達成，及數學模型的建立;完成氣柜監測系統軟件部分的組態設計與開發;最終系統的聯調聯試以及持續改進。
　　新系統采用由羅克韋爾自動化PLC冗余控制系統結構，基于ContrlNet協議、工業以太網協議等通信方式，實現了傳感器、電源、控制單元以及通信的冗余設置，控制精度達到毫秒級，保證系統安全可靠運行�？梢酝瓿蓪ΜF場活塞高度、氣柜內部壓力、油槽液位、頂部泄漏量的數據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)進行現場與控制系統的安全有效隔離，現場檢測信號一分為二，一路進原有系統顯示報警，另一路進本系統參與聯鎖控制，雙重保證檢測信號的穩定性和安全性。系統所有開關量輸入、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。

SIEMENS 6ES7 331-7NF00-0AB0 INPUT MODULE 6ES73317NF000AB0

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SIEMENSTEXASINSTRUMENTSOUTPUTMODULE500-5012

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ABB IRB 2400 SER 24-29338 ROBOT S4C PLUS CNTRLR TEACH PENDANT W/ MATCHED SET

Advanced Fiber Solutions TBX61-SM-SC, SM source and Meter 1310/1550 SC W/Toolbo

(Q4-2) 1 BALDOR BC20H220-CL DC CONTROL DRIVE Q4-2

MEASUREX 51402797-100 USPP 51402797100

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GENERAL ELECTRIC 04019J47G0001 NSFP 04019J47G0001

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SKF 64010000 NSPP 64010000

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Schleicher UKE B 31806981 284 085

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MODICON AEG AS-B356-001 24VDC Output Module

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SEL-2505 SCHWEITZER REMOTE I/O MODULE L@@K

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(2) Systems Available Click for Pics Both Tested

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Advantest Hand Held Programmer

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ATLAS COPCO LTD27SR005-RE USPP LTD27SR005RE

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Siemens S5 PLC 6ES5 420-8MA11 Digital Input Module.

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Omron C200H-BC081-V1

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Schneider Modicon AS-HDTA-201 SECONDARY SUBRACK

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