矩形电弧炉DCS系统的设计与实现

发布时间：2018-10-14 19:12

【摘要】：电弧炉自发明以来，已经成为冶金行业核心装备，由于其相较灵活的工艺，较好的经济性，以及其高产高质的特点，越来越受到人们的重视。矩形电弧炉的出现，更是这一技术的新发展，矩形电弧炉拥有特殊的优点，炉内温度高波动小，，能有效地去除杂质，钢液稳定品质好，有利于熔炼含氧化物较多的钢种。 DCS（分布式控制系统）应用于电弧炉系统有很长的历史。DCS最早是1975年出现的，30多年来，各个厂家相继研发出拥有自护知识产权的DCS，DCS的技术得到了很大的提高，其应用领域也迅速扩大，食品、冶金、能源、医疗、化工等等都相继引入DCS来提高生产和服务水平，在冶炼行业，DCS更是渐渐成为了不可或缺的系统。DCS一个由过程控制级和过程监控级组成的以通信网络为纽带的多级计算机系统，综合了计算机，通信、显示和控制等4C技术，其基本思想是分散控制、集中操作、分级管理、配置灵活以及组态方便。电弧炉系统结构复杂，设备多样，成本和能耗都很高，还存在着很大的安全风险，对系统的控制精确度要求很高，由于其各个分系统相对分散，比如高压变电站、配料系统站、环保除尘站、电极控制站等均是分散设置的，传统的计算机控制系统已不能满足现代大型电弧炉的工艺要求和生产需求，而DCS的众多优点正是电弧炉控制系统的最佳选择。以本文为例，攀枝花金江钛业30000KVA电弧炉系统是目前亚洲最大的矩形电弧炉，系统庞大，对DCS的设计和实施提出了很高的要求，电弧炉的硬件设备很多，可划分为11个小系统，包括：短网系统、电极系统、包车系统、渣车系统、出渣系统、出铁系统、炉盖系统、炉壁系统、炉体系统、水冷系统、惰性气体系统等。其电气系统也很复杂，包括低压控制柜、操作控制台、电极调节系统、计算机系统、包车控制系统等，其它的各种电气设备更是数量庞大。在设计DCS时，充分考虑了电弧炉系统的设备多样性，信号传输的实时性，控制过程的精确性，以及生产管理的高效性。本次DCS选用的是西门子SIMATICPCS7，PCS7系统为工业自动化和控制提供了很大范围的硬件、软件、组态、配置和诊断工具。PCS7项目是在PCS7工程师站上设计的，工程师站安装有PCS7组态工具，可以和自动化站和操作员站进行通讯。控制系统结构主要分为两级三层，两级为车间级和厂级，三层分为现场控制层、操作监视层、上级管理层，控制层和监视层属于车间级DCS，负责生产过程的监测和控制。作为矩形电弧炉的核心控制部分，电极的调节控制采用PID，DCS的网络通信方案设计为光纤冗余拓扑结构，保证此核心部分能够高速、安全、可靠地传输数据，上位机使用组态王设计的人机界面系统来连接操作人员与控制站，保证控制命令的准确下达和数据监视的实时准确。该DCS系统现已在矩形电弧炉上得到验证，说明了设计的合理性和可靠性。
[Abstract]:Electric arc furnace has become the core equipment of metallurgical industry since its invention. Because of its flexible process, better economy, and its characteristics of high production and high quality, more and more attention has been paid to it. The appearance of rectangular arc furnace is a new development of this technology. Rectangular arc furnace has special advantages, such as low temperature fluctuation, high temperature fluctuation, effective removal of impurities and good stability of molten steel. It has a long history that. DCS (distributed control system is used in arc furnace system. DCS first appeared in 1975, and it has been used for more than 30 years. The technology of DCS,DCS, which has self-protection intellectual property rights, has been developed by various manufacturers one after another, and its application fields have also expanded rapidly. Food, metallurgy, energy, medical treatment, chemical industry and so on have been introduced to improve the production and service level one after another. In the smelting industry, DCS has gradually become an indispensable system. DCS, a multilevel computer system based on communication network, consists of process control level and process monitoring level, which integrates 4C technologies such as computer, communication, display and control, etc. Its basic idea is decentralized control, centralized operation, hierarchical management, flexible configuration and configuration convenience. The electric arc furnace system has complex structure, diverse equipment, high cost and high energy consumption, and there are also great safety risks. The control accuracy of the system is very high. Due to the relative dispersion of its subsystems, such as high-voltage substations and batching system stations, The environmental protection dedusting stations and electrode control stations are all distributed. The traditional computer control system can no longer meet the technological requirements and production requirements of modern large electric arc furnaces, and the many advantages of DCS are the best choice of the electric arc furnace control system. Taking this paper as an example, the 30000KVA arc furnace system of Jinjiang Titanium Industry in Panzhihua is the largest rectangular arc furnace in Asia at present. The system is huge, and the design and implementation of DCS are very high requirements. The electric arc furnace has a lot of hardware equipments and can be divided into 11 small systems. It includes: short net system, electrode system, chartered car system, slag extraction system, iron extraction system, furnace cover system, furnace wall system, furnace body system, water cooling system, inert gas system and so on. Its electrical system is also very complex, including low-voltage control cabinet, operation console, electrode regulating system, computer system, car-chartered control system and so on. In the design of DCS, the diversity of electric arc furnace system, the real time of signal transmission, the accuracy of control process and the efficiency of production management are fully considered. The Siemens SIMATICPCS7,PCS7 system has provided a wide range of hardware, software, configuration, configuration and diagnostic tools for industrial automation and control. The PCS7 project is designed on the PCS7 engineer Station, where PCS7 configuration tools are installed. Can communicate with automation station and operator station. The structure of the control system is divided into two levels and three levels, two levels are workshop level and factory level, three levels are field control layer, operation monitoring layer, superior management layer, control layer and monitoring layer belong to workshop level DCS, responsible for the monitoring and control of production process. As the core control part of rectangular arc furnace, PID,DCS network communication scheme is adopted to control the electrode, which is designed as fiber redundancy topology to ensure that the core part can transmit data at high speed, safely and reliably. The upper computer uses the man-machine interface system designed by Kingview to connect the operator and the control station to ensure the accurate delivery of the control command and the real-time accuracy of the data monitoring. The DCS system has been verified in rectangular arc furnace, which shows the rationality and reliability of the design.
【学位授予单位】：西安工程大学
【学位级别】：硕士
【学位授予年份】：2013
【分类号】：TF806.6;TP273

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