基于PLC的工业汽轮机控制系统的研究
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摘要
随着工业技术的飞速发展,工业汽轮机被广泛应用于石化、电力、冶金、建材、环保和能源等工业领域。由于工业汽轮机具有高温、高压、高转速的特点,因此其承担着转速和负荷调节及工况控制任务的控制系统直接影响着机组运行的安全性、可靠性、经济性以及自动化程度。目前,工业汽轮机多采用机械液压控制系统,存在着调节精度和自动化程度低、难于实现与集散控制系统(DCS)的通信、工作特性固定、调节功能少等缺点;而进口电液控制系统存在着成本过高、不便于维护、通用性差等缺点。因此,有必要研制开发出适用于工业汽轮机的性能优良、可靠性高、通用性好、性价比高的电液伺服控制系统。
本文从工业汽轮机安全运行的实际需要出发,以基于S7-300 PLC的工业汽轮机电液伺服控制系统的研制过程为主线,重点讨论了工业汽轮机控制系统电液伺服部分和控制器S7-300 PLC部分的开发。文中综述了目前国内外工业汽轮机控制系统的发展现状。在确立了基于S7-300 PLC的工业汽轮机电液伺服控制系统方案的基础上,对工业汽轮机控制系统进行了总体方案设计,然后对工业汽轮机电液伺服系统进行了设计,建立了电液伺服系统的数学模型,并用MATLAB进行了仿真分析。控制器采用SIEMENS公司的S7-300 PLC,介绍了S7-300 PLC的工作原理、系统结构及硬件组成,对S7-300 PLC进行了硬件、软件和通信部分的组态。人机界面采用SIEMENS公司的工业组态软件WinCC和触摸屏TP170B,对上位计算机和触摸屏进行了组态,开发出了友好的人机界面。
结果表明,基于PLC的工业汽轮机电液伺服控制系统能有效地对工业汽轮机起到调节和保护作用。电液伺服系统的使用提高了工业汽轮机的控制精度和响应速度。上位计算机和触摸屏的应用提高了系统的自动化水平,方便了操作员对现场仪表监控状况的了解和管理,实现了监控数据的远程传输,有利于实现全厂一体化(TPS)。本控制系统安装维护方便,系统工作稳定、运行可靠、调节和测量精度高,监控软件功能完善,人机界面友好。
With the rapid development of industry technology, the industrial steam turbine is widely applied to the field of industry, such as petrifaction, electric power, metallurgy, architectural material, environment protection, energy sources, etc. Since the characteristic of industrial steam turbine is of high temperature, high pressure and high rotate speed, the control system which takes on the task of controlling rotate speed, load and run status directly affects security, reliability, economy and automation degree of running unit. Nowadays, the industrial steam turbine almost adopts to mechanism-hydraulic control system. It has some disadvantages, such as low governing precision and automatization degree, difficult realization of communication with Distributed Control System (DCS), fixed work characteristic, small governing function, etc. However, the import electro hydraulic control system has some disadvantages of high cost, inconvenient maintenance, bad currency, etc. So it is indispensable to develop the electro hydraulic control system with excellent performance, high reliability, good currency and high performance-price ratio for industrial steam turbine.
For the running safety of industrial steam turbine, the article discusses the design of electro hydraulic servo system and S7-300 PLC controller according to development process of industrial steam turbine electro hydraulic servo control system based on S7-300 PLC. The thesis outlines the development of domestic and aboard industrial steam turbine control system. The thesis establishes the scheme of the control system as a whole, and designs the part of electro hydraulic servo, and establishes the mathematical model of the system. Then, the system of dynamic simulation is performed by means of Matlab. The controller is SIEMENS S7-300 PLC. The thesis introduces its principle, structure and hardware, and configurates hardware, software and communication. Human-computer interface is WinCC and TP170B. The configuration of upper computer and touch panel was performed. The friendly interface has been developed.
The results show that the system effectively adjusts and protects the industrial steam turbine. The use of electro hydraulic servo system improves control precision and response speed of the industrial steam turbine. The application of upper computer and touch panel improves automatization degree, which is convenient for monitoring and management of operator, and realizes remote transmission of monitoring data, and is in favor of realizing Total Plant Solution (TPS). It is facility to mount and maintain, reliable to operate, and precise to adjust and detect. The monitoring software has abundant functions and kind interface.
本文从工业汽轮机安全运行的实际需要出发,以基于S7-300 PLC的工业汽轮机电液伺服控制系统的研制过程为主线,重点讨论了工业汽轮机控制系统电液伺服部分和控制器S7-300 PLC部分的开发。文中综述了目前国内外工业汽轮机控制系统的发展现状。在确立了基于S7-300 PLC的工业汽轮机电液伺服控制系统方案的基础上,对工业汽轮机控制系统进行了总体方案设计,然后对工业汽轮机电液伺服系统进行了设计,建立了电液伺服系统的数学模型,并用MATLAB进行了仿真分析。控制器采用SIEMENS公司的S7-300 PLC,介绍了S7-300 PLC的工作原理、系统结构及硬件组成,对S7-300 PLC进行了硬件、软件和通信部分的组态。人机界面采用SIEMENS公司的工业组态软件WinCC和触摸屏TP170B,对上位计算机和触摸屏进行了组态,开发出了友好的人机界面。
结果表明,基于PLC的工业汽轮机电液伺服控制系统能有效地对工业汽轮机起到调节和保护作用。电液伺服系统的使用提高了工业汽轮机的控制精度和响应速度。上位计算机和触摸屏的应用提高了系统的自动化水平,方便了操作员对现场仪表监控状况的了解和管理,实现了监控数据的远程传输,有利于实现全厂一体化(TPS)。本控制系统安装维护方便,系统工作稳定、运行可靠、调节和测量精度高,监控软件功能完善,人机界面友好。
With the rapid development of industry technology, the industrial steam turbine is widely applied to the field of industry, such as petrifaction, electric power, metallurgy, architectural material, environment protection, energy sources, etc. Since the characteristic of industrial steam turbine is of high temperature, high pressure and high rotate speed, the control system which takes on the task of controlling rotate speed, load and run status directly affects security, reliability, economy and automation degree of running unit. Nowadays, the industrial steam turbine almost adopts to mechanism-hydraulic control system. It has some disadvantages, such as low governing precision and automatization degree, difficult realization of communication with Distributed Control System (DCS), fixed work characteristic, small governing function, etc. However, the import electro hydraulic control system has some disadvantages of high cost, inconvenient maintenance, bad currency, etc. So it is indispensable to develop the electro hydraulic control system with excellent performance, high reliability, good currency and high performance-price ratio for industrial steam turbine.
For the running safety of industrial steam turbine, the article discusses the design of electro hydraulic servo system and S7-300 PLC controller according to development process of industrial steam turbine electro hydraulic servo control system based on S7-300 PLC. The thesis outlines the development of domestic and aboard industrial steam turbine control system. The thesis establishes the scheme of the control system as a whole, and designs the part of electro hydraulic servo, and establishes the mathematical model of the system. Then, the system of dynamic simulation is performed by means of Matlab. The controller is SIEMENS S7-300 PLC. The thesis introduces its principle, structure and hardware, and configurates hardware, software and communication. Human-computer interface is WinCC and TP170B. The configuration of upper computer and touch panel was performed. The friendly interface has been developed.
The results show that the system effectively adjusts and protects the industrial steam turbine. The use of electro hydraulic servo system improves control precision and response speed of the industrial steam turbine. The application of upper computer and touch panel improves automatization degree, which is convenient for monitoring and management of operator, and realizes remote transmission of monitoring data, and is in favor of realizing Total Plant Solution (TPS). It is facility to mount and maintain, reliable to operate, and precise to adjust and detect. The monitoring software has abundant functions and kind interface.
引文
1 伍爱民.工业汽轮机市场需求结构与预测.工程建设与设计,2000,(2):8~10
2 张晓亮,魏守平.热电联供汽轮机数字电液控制系统.水电能源科学,1999,(2):31~33
3 K.Wirz. Control of the industrial steam turbine. Brown Boveri Review, 1976,63(6):354~359
4 侯曼西.工业汽轮机.机械工业出版社,1995:5~26
5 王爽心,葛晓霞.汽轮机数字电液控制系统.中国电力出版社,2004:15~46
6 S.Shibata, U.Inoue, H.Abe and T.Tanaka. Development and operation of micro turbine - Combined package of steam generator with supplemental firing. Kami Pa Gikyoshi/Japan Tappi Journal, 2001,55(5):30~33
7 Krattiger Hansueli, Bondoni Carlos, Kobi Heinz and Remorini Hector Daniel. Increase competitive level by replacing steam turbines with electric adjustable speed drive system. Record of Conference Papers - Annual Petroleum and Chemical Industry Conference, Record of Conference Pappers - IEEE Industry Applications Society, 51st Annual Petroleum and Chemical Industry Conference, 2004:17~23
8 A.M. Graham and M. Etezadi-Amoli. Design, implementation, and simulation of a PLC based speed controller using fuzzy logic. Proceedings of the IEEE Power Engineering Society Transmission and Distribution Conference, 2000,(4) :2475~2480
9 严建华等.大型乙烯装置裂解气压缩机用汽轮机的研究开发设计.汽轮机技术,2002,44(1):1~4
10 勾亚峰.智能 8000 系列汽轮机监控系统硬件实现及软件监控系统的开发.武汉理工大学硕士论文,2003:1~4
11 王晓霞.给水泵小汽轮机的在线监测和热力计算.华北电力大学硕士论文,2003:7~10
12 蔡松波.火电机组小汽轮机保护及监控装置.华北电力大学硕士论文,2001:27~38
13 廖常初.S7-300/400 PLC 应用技术.机械工业出版社,2005:1~9
14 吴中俊,黄永红.可编程序控制器原理及应用.第二版.机械工业出版社,2004:28~35
15 殷洪义.可编程序控制器选择、设计与维护.机械工业出版社,2002:1~6
16 Shikles, Ernest. Increasing reliability on steam turbine values controls. Proceedings of the Annual Symposium on Instrumentation for the Process Industries, 2003:129~145
17 Orsagh Rolf, Meyer Theodore and Hester Stephen. Risk assessment of nuclear steam turbine destructive overspeed. Proceedings of the 2003 International Joint Power Generation Conference, 2003:343~348
18 蒋伟.模糊自适应 PID 控制算法在电液伺服系统中的应用.南京理工大学硕士论文,2004:254~258
19 王晓婷.电液伺服系统的非线性控制.西北工业大学硕士论文,2002:1~3
20 王占林.近代液压控制.机械工业出版社,1997:1~8
21 马常水,叶俊之,李金良.液压伺服控制系统.煤炭工业出版社,1988:5~11
22 郑勇斌.减摇水舱试验台架及横摇和横荡运动实验研究.哈尔滨工程大学硕士论文,2002:10~12
23 赵显新.工程机械液压传动装置原理与检修.辽宁科技出版社,2000:1~5
24 Philip S. Bartells and Christine K. Kovach. Development of a Dual-Extraction Industrial Turbine Simulator using General Purpose Simulation Tools.ISA TECH/EXPO Technology Update Conference Proceedings, 2002:300~309
25 Cepak, Milan and Havlena, Vladimir. Modelling of the multipart steam turbine in matlab environment. Proceedings of the International Conference on Systems Science, Proceedings of the 15th International Conference on Systems Science - Knowledge Engineering and Intelligent Systems, Information Systems, Technical Applications, Non-technical Applications, 2004:410~417
26 雷天觉.液压工程手册.机械工业出版社,1998:1202~1239
27 梁群华.C50 型机组汽轮机调速系统油动机的改进. 华东电力,2002,(9):48~51
28 葛晓霞等.汽轮机调节系统动态特性的数学模型及应用.汽轮机技术,2001,43(1):20~23
29 WOODWARD GOVERNOR COMPANY. WOODWARD Installation andOperation Manual of TG-13 and TG-17 Governors. WOODWARD, 2002:1~3
30 温占波.大型循环流化床燃烧气化热电气多联产试验台监控系统的开发与研究.浙江大学硕士论文,2002:16~17
31 Filemon, Lloyd Van Limmen, Peter. Overspeed incident at refinery results in destruction of turbine casing. 2005 AIChE Spring National Meeting, Conference Proceedings, 2005:791~796
32 王青.提高机组热工保护正确率动作的措施.华北电力技术,2003,(7):47~48
33 苏昆哲,何华.深入浅出西门子 WinCC V6.北京航空航天大学出版社,2004:1~4
34 刘志强,冯建玉,王乘.WinCC 与 S7-300 PLC 在火电厂锅炉吹灰监控系统中的应用.华中电力,2005,(1):7~13
35 Siemens AG.SIMATIC WinCC 系统描述.Siemens,2000:13~16
36 陈奎生.步进梁液压系统的 PLC 控制及其在线监测.武汉科技大学硕士论文,2004:33~46
37 Siemens AG.SIMATIC HMI ProTool/Pro V6.0 Service Pack2 如何组态基于Windows 的系统用户手册.Siemens,2002:29~45
38 Siemens AG.SIMATIC HMI Touch Panel TP 170A、TP 170B、Operator Panel OP 170B 设备手册.Siemens,2001:26~50
39 韩星海.PROFIBUS-DP 在横剪生产线控制系统上的应用.山东大学硕士论文,2004:35~46
40 Siemens AG.SIMATIC HMI ProTool 如何组态给予图形的单元用户手册.Siemens,2001:74~95
2 张晓亮,魏守平.热电联供汽轮机数字电液控制系统.水电能源科学,1999,(2):31~33
3 K.Wirz. Control of the industrial steam turbine. Brown Boveri Review, 1976,63(6):354~359
4 侯曼西.工业汽轮机.机械工业出版社,1995:5~26
5 王爽心,葛晓霞.汽轮机数字电液控制系统.中国电力出版社,2004:15~46
6 S.Shibata, U.Inoue, H.Abe and T.Tanaka. Development and operation of micro turbine - Combined package of steam generator with supplemental firing. Kami Pa Gikyoshi/Japan Tappi Journal, 2001,55(5):30~33
7 Krattiger Hansueli, Bondoni Carlos, Kobi Heinz and Remorini Hector Daniel. Increase competitive level by replacing steam turbines with electric adjustable speed drive system. Record of Conference Papers - Annual Petroleum and Chemical Industry Conference, Record of Conference Pappers - IEEE Industry Applications Society, 51st Annual Petroleum and Chemical Industry Conference, 2004:17~23
8 A.M. Graham and M. Etezadi-Amoli. Design, implementation, and simulation of a PLC based speed controller using fuzzy logic. Proceedings of the IEEE Power Engineering Society Transmission and Distribution Conference, 2000,(4) :2475~2480
9 严建华等.大型乙烯装置裂解气压缩机用汽轮机的研究开发设计.汽轮机技术,2002,44(1):1~4
10 勾亚峰.智能 8000 系列汽轮机监控系统硬件实现及软件监控系统的开发.武汉理工大学硕士论文,2003:1~4
11 王晓霞.给水泵小汽轮机的在线监测和热力计算.华北电力大学硕士论文,2003:7~10
12 蔡松波.火电机组小汽轮机保护及监控装置.华北电力大学硕士论文,2001:27~38
13 廖常初.S7-300/400 PLC 应用技术.机械工业出版社,2005:1~9
14 吴中俊,黄永红.可编程序控制器原理及应用.第二版.机械工业出版社,2004:28~35
15 殷洪义.可编程序控制器选择、设计与维护.机械工业出版社,2002:1~6
16 Shikles, Ernest. Increasing reliability on steam turbine values controls. Proceedings of the Annual Symposium on Instrumentation for the Process Industries, 2003:129~145
17 Orsagh Rolf, Meyer Theodore and Hester Stephen. Risk assessment of nuclear steam turbine destructive overspeed. Proceedings of the 2003 International Joint Power Generation Conference, 2003:343~348
18 蒋伟.模糊自适应 PID 控制算法在电液伺服系统中的应用.南京理工大学硕士论文,2004:254~258
19 王晓婷.电液伺服系统的非线性控制.西北工业大学硕士论文,2002:1~3
20 王占林.近代液压控制.机械工业出版社,1997:1~8
21 马常水,叶俊之,李金良.液压伺服控制系统.煤炭工业出版社,1988:5~11
22 郑勇斌.减摇水舱试验台架及横摇和横荡运动实验研究.哈尔滨工程大学硕士论文,2002:10~12
23 赵显新.工程机械液压传动装置原理与检修.辽宁科技出版社,2000:1~5
24 Philip S. Bartells and Christine K. Kovach. Development of a Dual-Extraction Industrial Turbine Simulator using General Purpose Simulation Tools.ISA TECH/EXPO Technology Update Conference Proceedings, 2002:300~309
25 Cepak, Milan and Havlena, Vladimir. Modelling of the multipart steam turbine in matlab environment. Proceedings of the International Conference on Systems Science, Proceedings of the 15th International Conference on Systems Science - Knowledge Engineering and Intelligent Systems, Information Systems, Technical Applications, Non-technical Applications, 2004:410~417
26 雷天觉.液压工程手册.机械工业出版社,1998:1202~1239
27 梁群华.C50 型机组汽轮机调速系统油动机的改进. 华东电力,2002,(9):48~51
28 葛晓霞等.汽轮机调节系统动态特性的数学模型及应用.汽轮机技术,2001,43(1):20~23
29 WOODWARD GOVERNOR COMPANY. WOODWARD Installation andOperation Manual of TG-13 and TG-17 Governors. WOODWARD, 2002:1~3
30 温占波.大型循环流化床燃烧气化热电气多联产试验台监控系统的开发与研究.浙江大学硕士论文,2002:16~17
31 Filemon, Lloyd Van Limmen, Peter. Overspeed incident at refinery results in destruction of turbine casing. 2005 AIChE Spring National Meeting, Conference Proceedings, 2005:791~796
32 王青.提高机组热工保护正确率动作的措施.华北电力技术,2003,(7):47~48
33 苏昆哲,何华.深入浅出西门子 WinCC V6.北京航空航天大学出版社,2004:1~4
34 刘志强,冯建玉,王乘.WinCC 与 S7-300 PLC 在火电厂锅炉吹灰监控系统中的应用.华中电力,2005,(1):7~13
35 Siemens AG.SIMATIC WinCC 系统描述.Siemens,2000:13~16
36 陈奎生.步进梁液压系统的 PLC 控制及其在线监测.武汉科技大学硕士论文,2004:33~46
37 Siemens AG.SIMATIC HMI ProTool/Pro V6.0 Service Pack2 如何组态基于Windows 的系统用户手册.Siemens,2002:29~45
38 Siemens AG.SIMATIC HMI Touch Panel TP 170A、TP 170B、Operator Panel OP 170B 设备手册.Siemens,2001:26~50
39 韩星海.PROFIBUS-DP 在横剪生产线控制系统上的应用.山东大学硕士论文,2004:35~46
40 Siemens AG.SIMATIC HMI ProTool 如何组态给予图形的单元用户手册.Siemens,2001:74~95