新型干法水泥生产线混合控制系统设计与研究
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摘要
以预分解窑为代表的新型干法水泥生产技术是国际公认的代表当代技术发展水平的水泥生产方法。它具有生产能力大、自动化程度高、产品质量高、能耗低、有害物质排放低、工业废物利用量大等一系列的优点,成为当今世界水泥工业生产的主要技术。90年代中后期以来,DCS伴随着新型干法水泥工艺在国内得到广泛应用,DCS实现实时监控、工艺参数集中调整,保证热工制度的动态平衡,统一协调整个生产过程,功能完善、使用方便。DCS提升了水泥工业的技术水平,使管理科学化,为企业带来显著的综合效益。随着信息技术和控制技术的进一步发展,现代水泥生产线的控制系统已经超越了传统的DCS控制的功能,实现了过程控制、逻辑控制、批处理控制、ERP、MIS和专家系统等的综合,实现了企业控制、管理和决策一体化,使得控制系统真正实现全集成自动化(TIA)。作为全集成自动化体系的过程控制,西门子SIMATIC PCS7采用了TIA系列甄选的标准硬件和软件部件,其统一的数据管理、通讯和组态功能,为用于过程工业、制造业以及综合工业领域的先进和经济的自动化解决方案,提供了一种开放式的平台。
本文以中国承建的沙特阿拉伯某5000TPD水泥生产线为研究和设计对象,分析了新型干法水泥生产技术和设备,研究了各种工业过程控制系统相关技术和最新的成果,比较了国内外同行业控制系统的现状,结合实际工艺流程和客户要求,研究和设计了一个基于西门子SIMATIC PCS7为基础的水泥生产线过程控制系统。
本文重点进行了以下几个方面的研究和设计:①研究了水泥生产的新工艺和新设备;②研究了水泥生产线控制系统的相关技术,并进行了比较和分析;③设计了系统的现场电气系统;④设计整个系统控制网络结构;⑤应用西门子SIMATICPCS7+CEMAT软件实现了整个控制系统,并对软件设计中注意的问题和难点进行了分析。整个系统与2007年8月设计完成并进行现场调试,系统运行稳定,达到了设计的目标。本系统是一个典型的连续过程控制系统案例,经产品化设计后,可方便的移植到类似系统中,具有良好的推广应用前景。
Taking pre-decomposed kiln as representative's new drying cement production craft is internationally recognized representative of cement production method in advance. Because it has the productivity in a big way, the automatist high, the product quality high, the energy consumption low, the deleterious substance discharges, the industry lowly makes use of waste the quantity to be big and so on a series of merits, becomes now cement industry production main technology in the world. In since the 90's the later period, DCS has followed new drying cements production craft in domestically to obtain the widespread application, it realized the real-time monitoring and the craft parameter's centralism adjustment, guaranteed dynamical equilibrium of the hot working system, coordinated entire production process, and consummates of the function, operated easily. DCS has promoted the cement industry technical level, cause the scientific management, and brings the remarkable comprehensive benefit for the enterprise. Along with the information technology and the control technology further development, the modern cement production line control system had already surmounted the traditional DCS control function, has realized synthesis of the process control, the logical control, the batch run control, ERP, MIS and the expert system, realized the enterprise of integration of control, the management and the policy-making integration, caused the control system truly to realize the totally integrated automation (TIA). As process control in the totally integrated automation system, Siemens SIMATIC PCS7 has used the standard hardware and the software part which the TIA series selects. Its unified data management, the communication and the configuration function, provides open platform for advanced and economical automation solution in the process industry, the manufacturing industry as well as the synthesis industry.
This article takes Saudi Arabian some 5000TPD cement production line which to build by China as research and design object, analyzes new drying cements production technology and the equipment, studies correlation technology and the newest achievement in all kinds of c industry process control system, compares with the domestic and foreign colleagues industry control system present situation, considers of actual technical process and the customer request, studies and designes cement production line process control system based on Siemens SIMATIC PCS7.
This article includes:
(1) Researches the cement production new craft and the new equipment;
(2) Researches the cement production line control system related technology, and carries on the comparison and the analysis;
(3) Designs field electrical system;
(4) Designs the entire system control network architecture;
(5)Realizes the entire control system used Siemens SIMATIC PCS7+CEMAT, and analyses the question and the difficulty which pays attention to the software design.
The entire system design and commissioning completes in August, 2007, and the system runs stably, achieves the design goal. This system is a typical continuous process control system case. After the product-design, it may facilitate to transplant the similar system, has the good promoted application prospect.
本文以中国承建的沙特阿拉伯某5000TPD水泥生产线为研究和设计对象,分析了新型干法水泥生产技术和设备,研究了各种工业过程控制系统相关技术和最新的成果,比较了国内外同行业控制系统的现状,结合实际工艺流程和客户要求,研究和设计了一个基于西门子SIMATIC PCS7为基础的水泥生产线过程控制系统。
本文重点进行了以下几个方面的研究和设计:①研究了水泥生产的新工艺和新设备;②研究了水泥生产线控制系统的相关技术,并进行了比较和分析;③设计了系统的现场电气系统;④设计整个系统控制网络结构;⑤应用西门子SIMATICPCS7+CEMAT软件实现了整个控制系统,并对软件设计中注意的问题和难点进行了分析。整个系统与2007年8月设计完成并进行现场调试,系统运行稳定,达到了设计的目标。本系统是一个典型的连续过程控制系统案例,经产品化设计后,可方便的移植到类似系统中,具有良好的推广应用前景。
Taking pre-decomposed kiln as representative's new drying cement production craft is internationally recognized representative of cement production method in advance. Because it has the productivity in a big way, the automatist high, the product quality high, the energy consumption low, the deleterious substance discharges, the industry lowly makes use of waste the quantity to be big and so on a series of merits, becomes now cement industry production main technology in the world. In since the 90's the later period, DCS has followed new drying cements production craft in domestically to obtain the widespread application, it realized the real-time monitoring and the craft parameter's centralism adjustment, guaranteed dynamical equilibrium of the hot working system, coordinated entire production process, and consummates of the function, operated easily. DCS has promoted the cement industry technical level, cause the scientific management, and brings the remarkable comprehensive benefit for the enterprise. Along with the information technology and the control technology further development, the modern cement production line control system had already surmounted the traditional DCS control function, has realized synthesis of the process control, the logical control, the batch run control, ERP, MIS and the expert system, realized the enterprise of integration of control, the management and the policy-making integration, caused the control system truly to realize the totally integrated automation (TIA). As process control in the totally integrated automation system, Siemens SIMATIC PCS7 has used the standard hardware and the software part which the TIA series selects. Its unified data management, the communication and the configuration function, provides open platform for advanced and economical automation solution in the process industry, the manufacturing industry as well as the synthesis industry.
This article takes Saudi Arabian some 5000TPD cement production line which to build by China as research and design object, analyzes new drying cements production technology and the equipment, studies correlation technology and the newest achievement in all kinds of c industry process control system, compares with the domestic and foreign colleagues industry control system present situation, considers of actual technical process and the customer request, studies and designes cement production line process control system based on Siemens SIMATIC PCS7.
This article includes:
(1) Researches the cement production new craft and the new equipment;
(2) Researches the cement production line control system related technology, and carries on the comparison and the analysis;
(3) Designs field electrical system;
(4) Designs the entire system control network architecture;
(5)Realizes the entire control system used Siemens SIMATIC PCS7+CEMAT, and analyses the question and the difficulty which pays attention to the software design.
The entire system design and commissioning completes in August, 2007, and the system runs stably, achieves the design goal. This system is a typical continuous process control system case. After the product-design, it may facilitate to transplant the similar system, has the good promoted application prospect.
引文
[1]阳宪惠.现场总线技术及应用.北京:清华大学出版社,1999
[2]刘三山.以太网与现场总线的混合网络设计.自动化与仪表,16(6),2001
[3]魏彬彬.现场总线控制系统的现状与未来.交通与计算机,2001(19)
[4]赵天烘.现场总线与控制系统.电力系统自动化,24(13),2000
[5]张凤刚等.CEMAT系统在大型水泥企业中的应用.水泥,2004.10:62-63
[6]李嘉等.引入以太网技术是现场总线技术发展的一个必然趋势.自动化仪表,2001,22(5):1-4
[7]SIMATIC S7-300 可编程序控制器.西门子(中国)有限公司出版社,2000
[8]袁任光.可编程序控制器(PC)应用技术与实例.广州:华南理工大学出版社,1992
[9]郑震宇.监控平台软件的功能及设计实例.自动化仪表,2000.6:5-7
[10]高鸿斌,孔美静,赫孟合.西门子PLC与工业控制网络应用.北京:电子工业出版社,2006.3
[11]袁南儿,王万良.计算机新型控制策略及应用.北京:清华大学出版社,1998
[12]黄海峰,孙小苗.多媒体工业监控网络中信号实时传输机制的研究.工业仪表与自动化装置,2000.5:8-11
[13]李晓枫.在分散控制系统上实现的PID参数模糊自整定控制.工业仪表与自动化装置,2000.5:31-33
[14]汪晓平.PLC可编程控制器系统开发实例导航.北京:人民邮电出版社,2004
[15]车忠鹂.SIMATIC PCS7 在净水厂中的应用.航天制造技术,2002.12(6):38-39
[16]王常力,罗安.分布式控制系统(DCS)设计与应用实例.北京:电子工业出版社,2004
[17]刘继光.西门子工业控制软件CEMAT在水泥生产线的应用.工业控制计算机,V.19.6,2006
[18]樊世民.现场总线和集散控制系统.工业仪表与自动化装置,2000.2:61-63
[19]F.G.欣斯基.过程控制系统.北京:化学工业出版社,1982
[20]刘磅.TCP/IP Ethernet自控设备的新选择.世界仪表与自动化,2002.1:5253
[21]俞金寿.工业过程先进控制.世界仪表与自动化,2002.3:12-14
[22]张志学等.以太网与现场总线.工业控制计算机,14(7),2001
[23]廖常初.大中型PLC应用教程.北京:机械工业出版社,2005
[24]自动化技术的骤变,全集成自动化:TIA SIEMENS.
[25]何吕伟.如何提高DCS的可靠性,减少维护嫩.自动化仪表,2000.3
[26]金以慧,郭仲伟.过程系统控制与管理.北京:中国石化出版社.1998
[27]西门子自动化与驱动集团.深入浅出WinCC V6[M].北京:北京航空航天大学出版社,2004.11
[28]许志军.工业控制组态软件及应用.北京:机械工业出版社,2005.7
[29]王慧锋,何衍庆.现场总线控制系统原理与应用.北京:化学工业出版社,2006.1
[30]斯可克,王尊华,伍锦荣.基金会现场总线功能块原理及应用.北京:化学工业出版社,2003
[30]肖争鸣,李坚利.水泥工艺技术.北京:化学工业出版社,2006.6
[31]李海涛主编.新型干法水泥生产技术与设备.北京:化学工业出版社,2006.1
[32]陈全德主编.新型干法水泥技术原理及应用.北京:中国建材工业出版社,2004
[33]韩梅祥主编.水泥工业热工设备及热工测量.武汉:武汉理工大学出版社,1990
[34]胡夏波,卢军.用西门子SIMOCODE-DP组建的电厂电动机控制系统[J].低压电器,2005.5:55-56
[35]杨汝清.工程系统设计与运作.上海:上海交通大学出版社,2004
[36]孙洪程,翁唯勤.过程控制工程设计.北京:化学工业出版社,2001
[37]熊会思.新型干法烧成水泥熟料设备设计、制造、安装与使用.北京:中国建材工业出版社,2004
[38]杨公源.机电控制技术及应用.北京:电子工业出版社,2005.5
[39]Steve Schoenberg.An Ethernet World Bus Tour.ISA:In Tech,August 2000
[40]Anon.Lonestar Plant changes from DCS to PLC control.CementAmericas.1999(9):24-2
[41]Paul G Ranky,Modular field bus designs and application,Assembly Automation,2000(20),40-46
[42]Hiroshi U.Cement and Concrete Industry orienting Toward Environmental load Reduction and Waste Recycling.Chichibu onoda Cement Corporation.1997.48(133):1-33
[43]Chris web Field bus sparring.Control& Instrumentation 1998(3)
[44]David Harrold.New 'Soft DCS' REACHES the Market.Control Engineering.1998(7)
[45]Software Review DCS Runs on PC Hard ware.Control Engineering 1997(10)
[46]LutzeV.Reduce Control System Complexing with Field bus Technology.Control Engineering,1995,42(11)
[47]Eric Poulin,Andre Pomerleau etc.Development and evaluation of an automatic and adaptive PID controller.Automatica,1996,32(1):71-82
[48]Johnson D.The Future of Field bus at Milestone.Control Engineering.1994,41(13)
[49]Configuring Hardware and Communications STEP7 V5.0.SIEMENS AG,1999
[50]Richalet J.Industrial application of model based predictive control.Automatic,1993,29(5):1251-1274
[51]Braae M,Rutherford D A.Selection of parameters for a fuzzy logic control.Fuzzy Sets and Systems,1979(2):185-199
[52]Richalet J.Observations on model-based predictive control.Control Engineering,Aug,1992
[53]SIMATIC Windows Logic Controller User Manual.SIEMENS AG,2000
[54]Tot Schei.Automatic tuning of PID controller based on transfer function estimation.Automatic,1994,30(12):1983-1989
[55]Software Redundancy for SMATIC S7-300 and S7-400.SIEMENS AG,2003
[56]Carrow,Robert S.Soft Logic,A guide to Using a PC as a PLC[J].McGraw-Hill,1998
[57]Dunning Gary.Introduction to Programmable Logic Controllers[Z],Delmar Thomson Learning,2002
[58]Honeywell Inc.HC900 Hybrid Control Designer Function Block Reference Guide.March 2002
[59]西门子公司SIMATIC PCS7过程控制系统手册,2000
[2]刘三山.以太网与现场总线的混合网络设计.自动化与仪表,16(6),2001
[3]魏彬彬.现场总线控制系统的现状与未来.交通与计算机,2001(19)
[4]赵天烘.现场总线与控制系统.电力系统自动化,24(13),2000
[5]张凤刚等.CEMAT系统在大型水泥企业中的应用.水泥,2004.10:62-63
[6]李嘉等.引入以太网技术是现场总线技术发展的一个必然趋势.自动化仪表,2001,22(5):1-4
[7]SIMATIC S7-300 可编程序控制器.西门子(中国)有限公司出版社,2000
[8]袁任光.可编程序控制器(PC)应用技术与实例.广州:华南理工大学出版社,1992
[9]郑震宇.监控平台软件的功能及设计实例.自动化仪表,2000.6:5-7
[10]高鸿斌,孔美静,赫孟合.西门子PLC与工业控制网络应用.北京:电子工业出版社,2006.3
[11]袁南儿,王万良.计算机新型控制策略及应用.北京:清华大学出版社,1998
[12]黄海峰,孙小苗.多媒体工业监控网络中信号实时传输机制的研究.工业仪表与自动化装置,2000.5:8-11
[13]李晓枫.在分散控制系统上实现的PID参数模糊自整定控制.工业仪表与自动化装置,2000.5:31-33
[14]汪晓平.PLC可编程控制器系统开发实例导航.北京:人民邮电出版社,2004
[15]车忠鹂.SIMATIC PCS7 在净水厂中的应用.航天制造技术,2002.12(6):38-39
[16]王常力,罗安.分布式控制系统(DCS)设计与应用实例.北京:电子工业出版社,2004
[17]刘继光.西门子工业控制软件CEMAT在水泥生产线的应用.工业控制计算机,V.19.6,2006
[18]樊世民.现场总线和集散控制系统.工业仪表与自动化装置,2000.2:61-63
[19]F.G.欣斯基.过程控制系统.北京:化学工业出版社,1982
[20]刘磅.TCP/IP Ethernet自控设备的新选择.世界仪表与自动化,2002.1:5253
[21]俞金寿.工业过程先进控制.世界仪表与自动化,2002.3:12-14
[22]张志学等.以太网与现场总线.工业控制计算机,14(7),2001
[23]廖常初.大中型PLC应用教程.北京:机械工业出版社,2005
[24]自动化技术的骤变,全集成自动化:TIA SIEMENS.
[25]何吕伟.如何提高DCS的可靠性,减少维护嫩.自动化仪表,2000.3
[26]金以慧,郭仲伟.过程系统控制与管理.北京:中国石化出版社.1998
[27]西门子自动化与驱动集团.深入浅出WinCC V6[M].北京:北京航空航天大学出版社,2004.11
[28]许志军.工业控制组态软件及应用.北京:机械工业出版社,2005.7
[29]王慧锋,何衍庆.现场总线控制系统原理与应用.北京:化学工业出版社,2006.1
[30]斯可克,王尊华,伍锦荣.基金会现场总线功能块原理及应用.北京:化学工业出版社,2003
[30]肖争鸣,李坚利.水泥工艺技术.北京:化学工业出版社,2006.6
[31]李海涛主编.新型干法水泥生产技术与设备.北京:化学工业出版社,2006.1
[32]陈全德主编.新型干法水泥技术原理及应用.北京:中国建材工业出版社,2004
[33]韩梅祥主编.水泥工业热工设备及热工测量.武汉:武汉理工大学出版社,1990
[34]胡夏波,卢军.用西门子SIMOCODE-DP组建的电厂电动机控制系统[J].低压电器,2005.5:55-56
[35]杨汝清.工程系统设计与运作.上海:上海交通大学出版社,2004
[36]孙洪程,翁唯勤.过程控制工程设计.北京:化学工业出版社,2001
[37]熊会思.新型干法烧成水泥熟料设备设计、制造、安装与使用.北京:中国建材工业出版社,2004
[38]杨公源.机电控制技术及应用.北京:电子工业出版社,2005.5
[39]Steve Schoenberg.An Ethernet World Bus Tour.ISA:In Tech,August 2000
[40]Anon.Lonestar Plant changes from DCS to PLC control.CementAmericas.1999(9):24-2
[41]Paul G Ranky,Modular field bus designs and application,Assembly Automation,2000(20),40-46
[42]Hiroshi U.Cement and Concrete Industry orienting Toward Environmental load Reduction and Waste Recycling.Chichibu onoda Cement Corporation.1997.48(133):1-33
[43]Chris web Field bus sparring.Control& Instrumentation 1998(3)
[44]David Harrold.New 'Soft DCS' REACHES the Market.Control Engineering.1998(7)
[45]Software Review DCS Runs on PC Hard ware.Control Engineering 1997(10)
[46]LutzeV.Reduce Control System Complexing with Field bus Technology.Control Engineering,1995,42(11)
[47]Eric Poulin,Andre Pomerleau etc.Development and evaluation of an automatic and adaptive PID controller.Automatica,1996,32(1):71-82
[48]Johnson D.The Future of Field bus at Milestone.Control Engineering.1994,41(13)
[49]Configuring Hardware and Communications STEP7 V5.0.SIEMENS AG,1999
[50]Richalet J.Industrial application of model based predictive control.Automatic,1993,29(5):1251-1274
[51]Braae M,Rutherford D A.Selection of parameters for a fuzzy logic control.Fuzzy Sets and Systems,1979(2):185-199
[52]Richalet J.Observations on model-based predictive control.Control Engineering,Aug,1992
[53]SIMATIC Windows Logic Controller User Manual.SIEMENS AG,2000
[54]Tot Schei.Automatic tuning of PID controller based on transfer function estimation.Automatic,1994,30(12):1983-1989
[55]Software Redundancy for SMATIC S7-300 and S7-400.SIEMENS AG,2003
[56]Carrow,Robert S.Soft Logic,A guide to Using a PC as a PLC[J].McGraw-Hill,1998
[57]Dunning Gary.Introduction to Programmable Logic Controllers[Z],Delmar Thomson Learning,2002
[58]Honeywell Inc.HC900 Hybrid Control Designer Function Block Reference Guide.March 2002
[59]西门子公司SIMATIC PCS7过程控制系统手册,2000