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集散控制系統(tǒng)(Distributed Control System-DCS)集計(jì)算機(jī)技術(shù)、控制技術(shù)、通信技術(shù)、CRT技術(shù)于一體,廣泛應(yīng)用于生產(chǎn)過程控制系統(tǒng)。隨著計(jì)算機(jī)和網(wǎng)絡(luò)技術(shù)的飛速發(fā)展,產(chǎn)生了一種新型的控制系統(tǒng)———現(xiàn)場總線控制系統(tǒng)(Fieldbus Control System-FCS)。但國內(nèi)生產(chǎn)企業(yè)的情況是:大多數(shù)企業(yè)還處于模擬儀表和人工控制的階段,采用DCS控制系統(tǒng)的企業(yè)仍是少數(shù)。由于DCS應(yīng)用廣泛、技術(shù)成熟,在現(xiàn)有的技術(shù)條件和市場條件下,F(xiàn)CS還不能完全取代DCS,而且目前現(xiàn)場總線設(shè)備和系統(tǒng)還十分昂貴。因此,除了新建企業(yè)外,國內(nèi)企業(yè)在較長時(shí)間不可能全面采用現(xiàn)場總線技術(shù),而必須走逐步發(fā)展、過渡的道路。 我們在上海石化股份公司環(huán)保部水質(zhì)凈化廠監(jiān)控系統(tǒng)的改造項(xiàng)目中,對3個(gè)生產(chǎn)單元已有的DCS和PLC進(jìn)行改造,增加通信功能,實(shí)現(xiàn)總調(diào)度室對各生產(chǎn)裝置的集中監(jiān)控。 2 系統(tǒng)改造方案 根據(jù)水質(zhì)凈化廠各生產(chǎn)單元的功能和建設(shè)階段,分為廠外調(diào)節(jié)池、污水一段、氧化溝、四期污水處理、污泥脫水、污泥干化6個(gè)生產(chǎn)單元。另外,在廠部設(shè)有總調(diào)度室,但是總調(diào)度室的監(jiān)控水平較為落后,改造之前基本上不能對各個(gè)生產(chǎn)單元進(jìn)行監(jiān)控。為了適應(yīng)生產(chǎn)需要,提高生產(chǎn)效率,改善操作條件,加強(qiáng)監(jiān)控手段,確保各生產(chǎn)裝置的正常運(yùn)行,急需對各生產(chǎn)單元和總調(diào)度室進(jìn)行技術(shù)和設(shè)備的更新改造,從而能在總調(diào)度室對各裝置進(jìn)行監(jiān)視管理,及時(shí)了解各裝置的運(yùn)行情況,達(dá)到指揮及時(shí)和調(diào)度準(zhǔn)確的目的。 2.1 現(xiàn)場監(jiān)控系統(tǒng)的改造 現(xiàn)場監(jiān)控系統(tǒng)的改造要充分利用原有儀表和設(shè)備,主要考慮可靠性和實(shí)時(shí)性。首先對自控程度較高的3個(gè)單元進(jìn)行改造(系統(tǒng)結(jié)構(gòu)見圖2—1): 四期污水處理生產(chǎn)單元控制設(shè)備配置了兩套ALLEN-BRADELY公司PLC設(shè)備。25塊開關(guān)量輸入信號卡,可采集384點(diǎn)信號;7塊開關(guān)量輸出信號卡,可輸出112點(diǎn)信號;3塊模擬量輸入信號卡,可采集24點(diǎn)信號。兩套AB—PLC通過DH+(數(shù)據(jù)高速通道)實(shí)現(xiàn)數(shù)據(jù)共享。在原有的現(xiàn)場控制計(jì)算機(jī)上分別增加以太網(wǎng)卡,通過以太網(wǎng)將實(shí)時(shí)數(shù)據(jù)送到總調(diào)度室處理。 輸出192點(diǎn)信號;1塊模擬量輸入信號卡,可采集8點(diǎn)信號。系統(tǒng)運(yùn)行采用遙控開關(guān)操作與全模擬流程盤顯示。在原有的Siemens S5-115UPLC上增加RS-232通訊模塊(CP524)和1臺現(xiàn)場操作站,用點(diǎn)對點(diǎn)方法連接,使PLC的數(shù)據(jù)通過現(xiàn)場操作站送到以太網(wǎng)上,與總調(diào)度室監(jiān)控計(jì)算機(jī)通信。但RS-232傳輸速率只有9600bps,操作站僅對現(xiàn)場起到監(jiān)視作用。Siemens 3VL9300-3MN00
Applied Materials AMAT Transducer Meter, 1040-01218
Applied Materials AMAT 1270-00485
AMAT Applied Materials 0090-09145
Applied Materials ASSY 0100-14015, SCH 0130-14015
APPLIED MATERIALS AMAT 0010-00201elay, 0680-01738
APPLIED MATERIALS 19676 APPLIED MATERIALS HOSE, ASSY, CNDCTV, 3/8TFE/TBG,72LG, 1.8M 0010-37171
15027 PANALYTICAL XRD GLASS TUBE X-RAY,FINE FOCUS MO,2000W PW2215/20
12864 MATSUSHITA AC MTR 3W 2P 1.5μF W/ MICRO-EXCHANGE AIR PUMP LVM-IO M41A3S2L1
11052 VAT BUTTERFLY VALVE PRESSURE CONTROL CONTROLLER 61246-JAGC
2522 SPECTRA-PHYSICS PCB, OPTICS CONTROL BOARD, 10/99 00017 LZT-9004
9164 FUJI PXR-4 TEMPERATURE CONTROLLER (LOT OF 3) PXR4TEY1-1Y000
10800 APPLIED MATERIALS UNION COOLING WATER ROTARY 0760-01015
12570 NUPRO HIGH PURITY VALVE 6L-M1D-222P-11
12400 FUJIKIN 3 PORT BLOCK VALVE, TYPE N.C., O.P. 0.4~0.6 MPA 434062
21190 LEYBOLD TURBO MOLECULAR PUMP P/N: 85677 AMAT TURBOVAC 361C
6351 AERA MFC FC-PA786C FC-PA786CT-BF
3729 OMRON INTERACTIVE DISPLAY W/ NT600M-LB122 C200H I/F UNIT NT20M-DT121-V2
14300 APPLIED MATERIALS PEDESTAL,PIB,300MM A101 HEATER ASSY 0010-27432
6407 UNIT MFC ULTRA CLEAN METAL SEAL UFC-1560A
20860 ASML PCB ASSY 4022.437.0126
22577 DELTA TAU UMAC AC POWER SUPPLY, 603269-106, LFVLT130-4102 ACC-E1
1260 LOVE CONTROLS CORP SELF TUNE PLUS TEMPERATURE CONTROLLER 321
1178 TELETRON REGULATED DC POWER SUPPLY TC-2404Q
T264 MKS BARATRON PRESSURE TRANSDUCER, 133.32 PA 626A-22895
1645 TSURUGA ELECTRIC INTERGRATING DIGITAL PANEL METER 461A-04-A-04T-R
10432 PANASONIC CCD W/ NIKON TV LENS TRINOCULAR COUPLER (C-0.45X) GP-KS162HDE
5683 NOVELLUS FORK, CERAMIC, C2SEQ-X 15-277460-00
13224 ADAPTEC ULTRA2-LVD/SE SCSI CONTROLLER CARD AHA-2930U2
20432 APPLIED MATERIALS GASLINE MIXED, LOWER ISOLATOR, HT BESC 0050-75729
21928 APPLIED MATERIALS ASSEMBLY, RTPC MODULE, 0100-01540, 0100-01539 0010-28579
4176 ALLEN-BRADLEY SLC500 10-SLOT CHASSIS W/ POWER SUPPLY 1746-P2 1746-A10
D22 HONEYWELL UV SENSOR C7035A1023
1655 TOKYO ELECTRONIC CCD CAMERA CONTROLLER CS3500
12071 FESTO SWIVEL MODULE DSM-B, FLANGED SHAFT, P/N: 547597 DSM-16-270-FW-A-B
10243 APPLIED MATERIALS ASSY, TI VIEW LID, CVD 0010-38023
10791 NIKON 50X MICROSCOPE OBJECTIVE LENS LEITZ WETZLAR PLAN L50X / 0.60
16472 APPLIED MATERIALS CABLE ASSY JM9 GP PCB TO P4 0140-23338
13745 APPLIED MATERIALS HOSE ASSEMBLY CATHODE TO BLK HD, 1/2 TS 0190-04985
16475 APPLIED MATERIALS CABLE ASSY, PX9 PRESSURE XDCRS CHX, 5.7FT 0140-23334
22134 ETEL MULTIPLE OVERLOAD PROTECTION CONTROLLER DSCDM332-111C-000C
20432 APPLIED MATERIALS GASLINE MIXED, LOWER ISOLATOR, HT BESC 0050-75729
21928 APPLIED MATERIALS ASSEMBLY, RTPC MODULE, 0100-01540, 0100-01539 0010-28579
4176 ALLEN-BRADLEY SLC500 10-SLOT CHASSIS W/ POWER SUPPLY 1746-P2 1746-A10
12174 SMC AIR SLIDE TBL, CROSS ROLLER GUIDE W/ SENSOR D-A93 MXS8-10AS-A93L
12071 FESTO SWIVEL MODULE DSM-B, FLANGED SHAFT, P/N: 547597 DSM-16-270-FW-A-B
10243 APPLIED MATERIALS ASSY, TI VIEW LID, CVD 0010-38023
10791 NIKON 50X MICROSCOPE OBJECTIVE LENS LEITZ WETZLAR PLAN L50X / 0.60
16472 APPLIED MATERIALS CABLE ASSY JM9 GP PCB TO P4 0140-23338
13745 APPLIED MATERIALS HOSE ASSEMBLY CATHODE TO BLK HD, 1/2 TS 0190-04985
16475 APPLIED MATERIALS CABLE ASSY, PX9 PRESSURE XDCRS CHX, 5.7FT 0140-23334
22134 ETEL MULTIPLE OVERLOAD PROTECTION CONTROLLER DSCDM332-111C-000C
296 APPLIED MATERIALS FLANGE INTEG,DPS CHAMBER POS B,SEIKO 1300/SLIDE 0050-00382
3583 ZEISS 20X EPIPLAN-NEOFLUAR MICROSCOPE OBJECTIVE LENS 20X/0.50 HD 44 23 44
5681 APPLIED MATERIALS HV MODULE CESC 0010-04926
6420 CELERITY MFC UNIT 125 IFC-125C
18100 NM LASER SAFETY INTERLOCK LASER SHUTTER LST400S24B
13573 OMRON INPUT UNIT, 24VDC CJ1W-1D231
16774 APPLIED MATERIALS CABLE ASSY AMPULE HTR POWER INTERCONN 10FT 0150-09678
16745 APPLIED MATERIALS CABLE ASSY, 50FT SMK DETECT MNFRM INTCON 0150-21932
16470 APPLIED MATERIALS CABLE ASSY, PM6 GP PCB, 11FT 0140-23339
7067 ABB ALLSTROM SENSITIV F804B-63/0.3AP-R
2306 FESTO VLV TERMI MANF ASSY 18255 W/CPV10-GE-MP-8 18200 CPV-10VI2747
7388 TREK ELECTROSTATIC CHUCK POWER SUPPLY (191137359-00) 684-1-L-CE
5028 APPLIED MATERIALS HARNESS ASSY PRECLEAN CHAMBER CLEAR LID 0040-70969
10445 EUTECH INSTRUMENTS CYBERSCAN WATERPROOF PORTABLE METER COND600
0021-52192
0225-95381
Applied Materials 0100-76128
322-0103// AMAT APPLIED 0090-70003
116-0303// AMAT APPLIED 0200-09996
341-0203// AMAT APPLIED 0040-03641
AMAT Applied Materials 0041-35519
0100-00304, Applied Materials
AMAT 1350-00250
Applied Materials AMAT 0020-01416
Applied Materials Assy #0100-1401
Applied Materials AMAT 0020-10117
Applied Materials AMAT 0040-36180 KPTXZ-36180
Applied Materials AMAT 3870-01574, Nupro 6LV-D1V333P-AB
323-0302// AMAT APPLIED 0010-30230
323-0302// AMAT APPLIED 0010-30065
Applied materials 0090-05098 / 0190-27910
AMAT 0200-01155
APPLIED MATERIALS 3011-01302
AMAT Applied Materials , 0100-40013
316-0402// AMAT APPLIED 0020-35032
Applied Materials A1412168
AMAT Applied Materials 0200-36544
AMAT Applied-Materials 0100-40031
Applied Materials AMAT 5160-48437-E SE-063106
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