With the continuous development of computer technology, DCS control technology has been rapidly developed and improved. Its control strategy covers various control strategies such as traditional PID control, logic control, and sequence control. At the same time, the PC-based human-machine interface is used to simplify the engineering of DCS and improve engineering efficiency. The CENTUM CS3000 series DCS system of Henghe Company was used in the 800,000 t PTA reconstruction and expansion project in Liaohua to complete the control of the production process of the plant and lay a foundation for the smooth operation of the plant.
The CENTUM-CS3000 system is a large DCS system based on WINDOWS-XP launched by Yokogawa Corporation of Japan. This model inherits the advantages of the previous Yokogawa system and enhances network and information processing functions. The operation station adopts a general-purpose PC, and the control station adopts a fully redundant hot backup structure, which makes it cost-optimized. It is one of the most advanced large-scale DCS systems in the world.
Characteristics1 Monitoring points can be operated simultaneously by multiple HIS (Human Interface StaTIon). Each HIS can also operate multiple monitoring points at the same time (can be multiple monitoring points in different positions).
2 The CS3000 system is very powerful, it can process 100,000tags (station number), 4,000 screens (including various monitoring screens), and can display up to 400 data per screen.
3 Human-machine interface is better. Windows NT is selected as the operating system, and X-Windows (multi-screen) technology is adopted, which is similar to a general PC. A variety of friendly control monitoring screens can be implemented according to the requirements of the process. For example, it can dynamically display the change of liquid/boundary position with bar graph; use color, flicker, sound and other means to remind the operator to generate process alarm and high and low level; single point operation uses Faceplate (panel) similar to the columnar liquid crystal display of conventional instrument. Monitoring and operation are more intuitive.
4 CS3000 system has powerful data processing capability, which is enough to complete the data calculation and statistical requirements required for general production, and can print and output the production data in real time.
5 In the normal production, the configuration can be modified online according to the requirements to better serve the production.
6 Easy to integrate with information system (ERP, MES) In the excellent network function of Windows 2000 and Windows XP, by installing the OPC upper interface, it is convenient to access the process from the upper level, thus achieving the overall optimization of the management level. In addition, it can be connected not only to the PC connected to the OPC, but also to the host computer that was originally built by UNIX.
7 Connectivity to the FA system In the production equipment, the post-production packaging and inventory management are the first, and the system needs to be synchronized with the FA system, especially the PLC (Programmable Logic Controller)-based subsystem. A rich and varied software package for system connection. Ability to implement optimizations including subsystems.
1 overall designPTA is purified terephthalic acid, which is obtained by reacting p-xylene as a raw material and acetic acid as a solvent, and then hydrogenating it. Therefore, the device is divided into three units: oxidation, refinement, and auxiliary. DCS is to control the normal operation, driving and parking of the device. Control functions are performed by the Control Station (FCS), which mainly includes indicator loops, conventional PID control, interlocking, sequence control, etc. In addition, due to the complexity of the PTA production process, a large number of complex control schemes are also included. The operator station (HIS) functions as a human-machine interface to perform the following functions, indicating controlled and uncontrolled variables; operating control loops, including setpoints, operating modes, and output signals; recording real-time trends and historical trends; alarm signals and displays; system status And diagnostic report; alarm accumulation; process dynamic graphic display; information to the operator; report display.
In order to complete the above control and operation of the PTA device, the oxidation unit is equipped with 2 sets of control stations (FCS), 3 sets of operation stations (HIS), 1 set of exquisite unit setting control station (FSS) and 3 sets of operation stations (HIS). Unit set control station (FCS) 1 set, operation station (HIS) 2 sets, and engineer station 1 set. A schematic diagram of the system structure is shown in Figure 1.
hardware designNetwork structure
From the system configuration diagram, you can see that the CENTUM CS 3000 network application has a V-net network, an Ethernet network, an ESB bus, and an ER bus.
The V-net network is a real-time control network used to connect system components such as control stations and operator stations. Each domain can connect up to 64 stations per V-net network. The communication modes are read/write communication, information communication, link delivery, and access control is token transmission. The transmission path is redundant bus, and the transmission rate is 10 MB / s, coaxial cable and fiber optic cable can be used for communication cable, and coaxial cable is used in the system.
The Ethernet network is an information interconnection network between the internal operations stations (HIS) of the system. Up to 16 operating stations (HIS) can be connected, which conforms to the IEEE 802. 3 standard.
The ESB bus (Enhanced Serial Port Backplane Bus) is a redundant input/output communication bus for connecting the Local Control Station (FCS) I/O card to the Node and Control Unit (FCU) at a transfer rate of 128 MB/s.
The ER bus (Enhanced Remote Bus) is a redundant input/output communication bus for connecting remote nodes to the ESB.
The interface card of the local node on the bus has a transmission rate of 10 MB/s. Due to the large amount of signal transmission between the system and the MCC (Motor Control Center), in order to reduce the cable laying, the remote node is set in the MCC and then transmitted through the ER bus. Go to the control room.
Control Station (FCS) structureAccording to the number of input/output points of each process unit and the complexity of the control scheme, the oxidation unit sets 2 sets of control stations (FCS0101, FCS0102), 1 set of refined unit setting control station (FCS0103), and 1 set of auxiliary unit setting control station (FCS0104). . Although the control points of different control stations are different, the control schemes are not the same, but the basic structure and principle of the control station are the same. The main components are the field control unit (FCU), node (NODE) ​​and all levels of bus.
Field Control Unit (FCU)Advanced AFG40D unit, VR5432 (133 MHz) processor, 32 MB main memory, 72 h battery backup, dual redundant V-net communication interface card, dual redundant ESB bus interface card.
Node (NODE)
A node (NODE) ​​consists of a node interface unit and an input/output unit. The node interface unit is the communication interface between the node and the field control unit. The input/output unit, the I/O card, is responsible for collecting the field measurement signals / executing the controller outputs to the field actuators. FCS0101 configures 6 local nodes; FCS0102 configures 6 local nodes and 2 remote nodes; FCS0103 configures 8 local nodes and 2 remote nodes; FCS0104 configures 7 local nodes and 1 remote node. The main types of I/O cards are as follows:
AAI143 current input module (4 ~ 20mA, 16 channels);
AAI543 current output module (4 ~ 20mA, 16 channels);
ALR121 RS - 422/ 485 communication module;
ADV151 digital input module;
ADV551 digital output module;
ADR541 relay output module.
Operator station / engineer station structureThe operation station is the human-machine interface of the DCS control system, which performs functions such as monitoring, operation, and recording. The engineering station completes the configuration of the system. There is no difference between the operation station and the engineering station from the hardware, but the software packages for different functions are different. Therefore, the operation station and the engineering station are discussed together, and they can also be collectively referred to as operation stations. The CENTUM CS3000 R3 operator station features a general-purpose PC as the hardware foundation for the operator station and WINDOWS as the software platform.
In theory, any reliable PC can be used as the operating station of CEN2TUM CS3000 R3, and Yokogawa uses DELL's PC as the operating station. The operator station uses the VF-701 communication interface card to enable the PC to connect to the V-NET network. The card has a redundant communication interface that plugs into the PCI slot of the PC. The operator keyboard uses a Yokogawa-specific USB interface operator keyboard. Other hardware configurations are the same as for a general-purpose PC.
At present, the operational configuration software platform of Yokogawa DCS adopts WINDOWS XP-SP2.
This software and hardware configuration greatly reduces the cost of the operating station, enhances the versatility of the hardware, is user-friendly, easy to operate, reduces engineering and operation and maintenance costs, and improves work efficiency.
Software configurationThe CS3000 configuration mainly includes system COMMON configuration, operation station (HIS) configuration, flow chart configuration, control station (FCS) configuration, and so on.
System COMMON configuration, operator station (HIS) configuration and flow chart configuration
System COMMON configuration mainly includes system configuration configuration, system constant configuration, engineering unit configuration, alarm table configuration, alarm priority configuration and so on. The operation station (HIS) configuration includes the operation station configuration, operation group, connection transmission, trend record, screen name, window name, and so on. The flow chart configuration is a flow chart configuration with control points. With this part of the configuration, the operator station (HIS) has a human-machine interface that allows the operator to operate the production unit via the operator station (HIS). The oxidation reactor feed flow chart is shown in Figure 2.
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