基于PLC的连续重整装置ITCC和ESD系统的改造

发布时间：2018-03-16 13:03

本文选题：控制系统　切入点：改造　出处：《兰州理工大学》2017年硕士论文　论文类型：学位论文

【摘要】：在石油化工装置的生产过程中,自动化程度越来越高,过程控制系统的作用也越来越重要。仪表是工艺操作的“眼睛”,而自动控制系统就是“大脑”。由于生产过程趋于复杂,原料和工艺介质不断变化,在要满足企业低成本、高质量的追求,又要保障装置规模以及设备、人身、环境的安全情况下,配置合理的过程控制系统以及安全系统显得尤为必要和重要。因此,中国石油兰州石化连续重整装置在升级改造的过程中,迫切需要改善系统的安全功能和稳定性能,以保证人员安全的最佳可靠性、生产设备的寿命、环境保护、有关利润和持续性的可应用性。针对此问题,在充分调研连续重整装置工艺流程、控制系统运行状态和仪表常见故障的基础上,结合逻辑控制器的模块化、灵活型、快速响应及通信技术,设计了一套基于PLC的机组ITCC和装置ESD的综合系统,来实现机组控制和紧急停车。设计采用当前先进的TMR(三重化冗余)微处理器硬件技术,利用功能强大的专用编程软件,在原有机组ITCC系统的基础上构建冗余容错的控制系统,不影响生产装置或设备正常运行的同时去修复系统潜在故障,来提高系统的稳定性和可靠性。通过硬件改造和软件版本的升级,提升系统的控制精度和可扩展能力。通过状态监测系统的改造,优化控制网络。新型转速卡的采用,减少了硬件连接的故障点,提高了响应速度。温度误判逻辑的实现,降低了因机组轴承温度测量原件受润滑油冲刷、磨损的故障停车概率;联锁旁路的软设计和操作权限,避免了设备的老化和人为误操作。SOE(第一事件记录)系统的投用,有助于对停车首要故障进行跟踪和分析。整个综合系统的设计和改造,以实用、可靠、安全为首要目标,经施工、调试投入运行后,将大大提高装置的安全性和控制系统的高可用性和高维护性,减少误停车,从而保障装置的长周期运行。通过对现场仪表设备的排查和联锁逻辑的分析,结合当前在用控制系统的特性,综合考虑实用性和性价比,选用北京康吉森自动化设备技术有限公司的TRICON硬件及TRISTATION 1131软件平台,配置相应的工程师站和操作站,构建ITCC和ESD的综合控制系统。系统硬件的主处理器和I/O模件完全三重化,没有单点故障会造成系统失效。I/O模件上每一个通道中的采样器、信号放大器、A/D转换器(D/A转换器)、通讯单元全部独立,32位芯片保证了系统的快速运行。高度的系统诊断覆盖率,诊断功能皆为系统内置,不需编写应用程序。各卡件可在线更换。TRISTATION 1131软件开发平台,能够提供给用户多种编程语言,并具有在线修改程序和在线下装功能,较大的方便了用户。所有卡件,软件及浮点协处理器经过TUV六级认证,整套系统工作性能稳定,完全能够满足连续重整装置长时间安全稳定运行的需要。
[Abstract]:In the production process of petrochemical plant, the degree of automation becomes higher and higher, and the function of process control system becomes more and more important. The instrument is the "eye" of the process operation, and the automatic control system is the "brain". Raw materials and process media are constantly changing, in order to meet the enterprise's low cost, high quality pursuit, but also to ensure the size of the device and equipment, human, environmental safety conditions, It is necessary and important to configure reasonable process control system and safety system. Therefore, it is urgent to improve the safety function and stability performance of the system in the process of upgrading and reforming of PetroChina Lanzhou Petrochemical continuous reforming Unit. In order to ensure the best reliability of personnel safety, the life of production equipment, environmental protection, related profits and sustainability of the application. In view of this problem, in full investigation of the continuous reforming plant process, On the basis of the operation state of the control system and the common faults of the instrument, combined with the modularization, flexibility, fast response and communication technology of the logic controller, a comprehensive system of the unit ITCC and the device ESD based on PLC is designed. The design adopts the current advanced TMR (triple redundancy) microprocessor hardware technology, uses the powerful special programming software, constructs the redundant fault-tolerant control system on the basis of the original unit ITCC system. To improve the stability and reliability of the system by repairing the potential faults of the system while not affecting the normal operation of the production device or equipment. Improve the control precision and expandability of the system. Through the transformation of the condition monitoring system, optimize the control network. The adoption of the new speed card reduces the fault point of the hardware connection, improves the response speed, and realizes the logic of temperature misjudgment. The failure stopping probability of wear and tear due to the original bearing temperature measurement of the unit is reduced, the soft design and operation authority of the interlocking bypass are reduced, and the aging of the equipment and the operation of the .SOE (first event record) system are avoided. It is helpful to track and analyze the main fault of parking. The design and transformation of the whole integrated system is aimed at practicality, reliability and safety. After construction and commissioning, the system is put into operation. The safety of the device and the high availability and maintainability of the control system will be greatly improved, and the false stop will be reduced, thus ensuring the long period operation of the device. According to the characteristics of the current active control system and considering the practicability and the ratio of performance to price, the TRICON hardware and TRISTATION 1131 software platform of Beijing Congison Automation equipment Technology Co., Ltd are selected to configure the corresponding engineer station and operation station. The main processor and I / O module of the hardware of the system are completely trimmed, and no single point failure will cause the system to fail. The sampler in every channel on the I / O module. The A / D converter has a D / A converter, and all the communication units are independent 32-bit chips to ensure the rapid operation of the system. The high diagnostic coverage of the system and the diagnostic function are all built into the system. There is no need to write an application program. Each card can be replaced on line. TRISTATION 1131 software development platform, can provide users with a variety of programming languages, and has online program modification and online download function, more convenient for the user. All cards, The software and floating-point coprocessor are certified by TUV and the whole system is stable and can meet the need of the continuous reforming unit running safely and stably for a long time.
【学位授予单位】：兰州理工大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TE96;TP273

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