基于PLC的锅炉燃烧控制系统设计
摘要
随着现代工业技术的飞速发展,对能源利用率的要求越来越高。锅炉作为将一次能源转化成二次能源的重要设备之一,其控制和管理水平也日趋提高。燃烧器是锅炉燃烧系统的核心和最大能耗部件,有必要设计先进的燃烧控制系统实现锅炉在最优的空燃比下高效燃烧,从而实现节能环保。本文以某炼油公司自备发电厂所用5台75t/h燃油燃气锅炉燃烧控制为课题,在研究总结现有燃烧控制原理的基础上,改进了基于笔者所在公司生产的燃烧器的控制方法,提出了多种燃料掺烧的控制设计方案,并搭建基于西门子S7-300PLC软冗余环境下的燃烧控制系统软硬件平台。本文主要在以下四个方面开展研究:
1.设计了基于西门子S7-300PLC软冗余环境下的燃烧管理系统(BMS),该系统由冗余、火检与点火系统构成,可完成点火、吹扫、火焰检测、主燃料阀开闭及燃料切换管理、燃油压力、燃气压力等故障开关量检测与安全保护等功能。
2.根据工程要求,设计上引入了冗余热备份控制技术,当一台控制器或电源出现故障时,系统能自动切换到另一台备用控制器上,并延续原断点处继续工作,实现了无缝连接。
3.根据工艺要求,设计了连续燃烧的控制系统(CCS),包括负荷控制、蒸汽压力控制、风燃比控制以及雾化蒸汽压力控制等。
4.为了实现燃油燃气燃烧器的配比计算、掺烧、热态切换,文章引入标准燃料量的概念。以某种燃料量作为标准燃料量,其他燃料则根据标准燃料热值对比,对其进行运算转换。即进入系统的所有燃料量均转换成标准燃料量,将标准燃料量总和看作进入燃烧器一种燃料的燃料量。经过热态试验,任何一种燃料无论在单烧还是混烧情况下,通过标准燃料与送风的函数计算,都能得到合理的风燃比曲线,从而使燃烧器保持高效稳定的运行。
With the rapid development of modern industrial technology, the ratio of energy utilization has to meet more strict demands. As the key equipment to convert primary energy resources to secondary energy resources, the boiler develops with increasing control and management level. The burner, the essential and most energy-consuming part of boiler, requires an advanced burning control system to operate effectively at the optimized air-fuel ratio, so as to save the energy and protect the environment. This article, with the subject of burning control for five 75t/h gas/oil boilers used in the power station provided by some refining company, and with the efforts to improve the control method for the burner made by my company on the basis of current burning control theory study, provides with the control method for multi-fuel mixed burning, and the software and hardware platform for burning control system based on SIEMENS S7-300 PLC software redundant system. This article contains researches from the following four aspects:
1. The burning management system ( BMS ) based on SIEMENS S7-300PLC software redundant system has been worked out. The BMS, composed of redundant system, flame detecting system and ignition system, is mainly responsible for ignition, purge, flame detection, main fuel Valve ON/OFF, fuel switching management, and the detection and security for fault switching value, such as fuel oil pressure, fuel gas pressure, etc.
2. In accordance with the project requirements,the design introduces a redundant hot standby control. In the event of controller or power failure, the system can automatically switch to the alternate controller,resume work from the breakpoint,achieve the seamless connection.
3. According to the technological requirements, the controlled combustion system (CCS), has been designed out. It includes load control, steam pressure control, air-fuel ratio control and atomizing steam pressure control, etc.
4. In order to achieve the ratio of air-fuel burner calculation, mixed burning, thermal switch, the article introduces the concept of the standard fuel quantity. We can set the quantity of a certain fuel as the standard, then compare the heating values of other fuels with that of the standard fuel, and make final calculations. In this way, the total quantity of the fuels coming into the system is converted into standard fuel quantity, and the total standard fuel quantity can be regarded as the quantity for only one fuel. The thermal test has proved that, by means of the curves for both standard fuel conversion and standard fuel-to-air ratio, either single-fuel burning or multi-fuel mixed burning, can achieve reasonable air-fuel ratio, which finally enables the boilers to work effectively and stably.
1.设计了基于西门子S7-300PLC软冗余环境下的燃烧管理系统(BMS),该系统由冗余、火检与点火系统构成,可完成点火、吹扫、火焰检测、主燃料阀开闭及燃料切换管理、燃油压力、燃气压力等故障开关量检测与安全保护等功能。
2.根据工程要求,设计上引入了冗余热备份控制技术,当一台控制器或电源出现故障时,系统能自动切换到另一台备用控制器上,并延续原断点处继续工作,实现了无缝连接。
3.根据工艺要求,设计了连续燃烧的控制系统(CCS),包括负荷控制、蒸汽压力控制、风燃比控制以及雾化蒸汽压力控制等。
4.为了实现燃油燃气燃烧器的配比计算、掺烧、热态切换,文章引入标准燃料量的概念。以某种燃料量作为标准燃料量,其他燃料则根据标准燃料热值对比,对其进行运算转换。即进入系统的所有燃料量均转换成标准燃料量,将标准燃料量总和看作进入燃烧器一种燃料的燃料量。经过热态试验,任何一种燃料无论在单烧还是混烧情况下,通过标准燃料与送风的函数计算,都能得到合理的风燃比曲线,从而使燃烧器保持高效稳定的运行。
With the rapid development of modern industrial technology, the ratio of energy utilization has to meet more strict demands. As the key equipment to convert primary energy resources to secondary energy resources, the boiler develops with increasing control and management level. The burner, the essential and most energy-consuming part of boiler, requires an advanced burning control system to operate effectively at the optimized air-fuel ratio, so as to save the energy and protect the environment. This article, with the subject of burning control for five 75t/h gas/oil boilers used in the power station provided by some refining company, and with the efforts to improve the control method for the burner made by my company on the basis of current burning control theory study, provides with the control method for multi-fuel mixed burning, and the software and hardware platform for burning control system based on SIEMENS S7-300 PLC software redundant system. This article contains researches from the following four aspects:
1. The burning management system ( BMS ) based on SIEMENS S7-300PLC software redundant system has been worked out. The BMS, composed of redundant system, flame detecting system and ignition system, is mainly responsible for ignition, purge, flame detection, main fuel Valve ON/OFF, fuel switching management, and the detection and security for fault switching value, such as fuel oil pressure, fuel gas pressure, etc.
2. In accordance with the project requirements,the design introduces a redundant hot standby control. In the event of controller or power failure, the system can automatically switch to the alternate controller,resume work from the breakpoint,achieve the seamless connection.
3. According to the technological requirements, the controlled combustion system (CCS), has been designed out. It includes load control, steam pressure control, air-fuel ratio control and atomizing steam pressure control, etc.
4. In order to achieve the ratio of air-fuel burner calculation, mixed burning, thermal switch, the article introduces the concept of the standard fuel quantity. We can set the quantity of a certain fuel as the standard, then compare the heating values of other fuels with that of the standard fuel, and make final calculations. In this way, the total quantity of the fuels coming into the system is converted into standard fuel quantity, and the total standard fuel quantity can be regarded as the quantity for only one fuel. The thermal test has proved that, by means of the curves for both standard fuel conversion and standard fuel-to-air ratio, either single-fuel burning or multi-fuel mixed burning, can achieve reasonable air-fuel ratio, which finally enables the boilers to work effectively and stably.
引文
[1]赵欣新,惠世恩.燃油燃气锅炉.西安:西安交通大学出版社. 2000: 303.
[2]赵欣新,葛升群,惠世恩等.中小型燃油燃气锅炉运行操作与维护.北京:机械工业出版社. 2003: 2-5.
[3]赵晓红,王爱洁.浅谈我国燃气燃烧器的发展.工业锅炉. 2003 (5): 26.
[4]王善武.中国工业锅炉行业现状分析及前景展望.工业锅炉. 2004 (1): 5-6.
[5]辛广路.锅炉运行与操作指南.北京:机械工业出版社. 2006: 75-76.
[6]赵晓红,王爱洁.浅谈我国自动燃气燃烧器的发展.工业锅炉. 2003 (5): 27-28.
[7]杨智明,丽萍,吕雪艳. 21世纪燃气锅炉在中国的发展前景.锅炉制造. 2001 (5): 24-26.
[8]黄思明.国外全自动燃烧机技术现状及发展趋势.热能动力工程. 2001 16 (95): 468-470.
[9]林宗虎,徐通.实用锅炉手册.北京:化学工业出版社. 1996: 184-185.
[10]金维强.大型锅炉运行.北京:中国电力出版社. 1998: 11-15.
[11]秦裕琨.燃油燃气锅炉实用技术.北京:中国电力出版社. 2000:54-56..
[12]朱传标.工业锅炉技术基础.上海:上海远东出版社. 1996: 12.
[13]杨献勇.热工过程自动控制.北京:清华大学出版社. 2000: 307-312.
[14]张福安.工业锅炉计算机控制技术.科技情报开发与经济. 2004, 1(4):126-127.
[15]叶伟. VACON变频器在火力发电厂75吨锅炉风机应用.中国工控网. 2008 (3): 23.
[16]向立志,张喜东,李荣等.多变量预测控制在锅炉燃烧系统中的应用.化工自动化及仪表. 2006,33 (2): 22-24.
[17]张亮明,夏桂娟.工业锅炉热工检测与过程控制.天津:天津大学出版社. 1992: 80-81.
[18]边立秀,周俊霞等.热工控制系统.北京:中国电力出版社. 2001: 45-46.
[19]曾光奇,胡军安.模糊控制理论与工程应用.武汉:华中科技大学出版社. 2006: 120-187.
[20]牟岳泰,徐东来,赵永军等.燃气锅炉的PLC自动控制系统.微计算机信息. 2005 (28): 34.
[21] Obernberger Ingwald. Decentralized biomass combustion,State of the art and future development[J]. Biomass and Bio-energy. 140(1), p30-45, 1998.
[22] Tao L. Use of a computer model for evaluation of combustion and NOx control alternatives in a craft recovery boiler [J]. International chemical recovery conference, TAPPI press,(1) , p228-350, 1998.
[23]西门子自动化与驱动集团客户服务与支持中心.西门子PLC系统软件冗余的说明与实现.北京.西门子中国有限公司. 2008.
[24] Excellence in Automation & Drives:Siemens.西门子ProfiBus-S7协议PLC设备驱动使用说明. 2005: 3-4.
[25] Excellence in Automation & Drives: Siemens. Assignment & Description of Active Bus Backplane For ET200M. 2004: 11.
[26] Excellence in Automation & Drives:Siemens. Software Redundancy for SIMATIC S7-300 and S7-400. 2003: 4-7.
[27] Siemens AG Automation and Drives Postfach. SIMATIC S7-300模块数据. 2007: 2-9.
[28] Siemens AG Automation and Drives Postfach. SIMATIC S7-300 Automation System Module Data. 2007: 1-12.
[29]吴晓军,杨向明.电气控制与可编程控制器应用.北京:中国建筑工业出版社. 2004: 50-62.
[30]李强,王磊. PLC软件冗余系统在燃油锅炉中的应用.西安理工大学自动化与信息工程学院. 2008: 43.
[31]廖常初主编. S7-300/400 PLC应用技术.北京:机械工业出版社. 2005: 30-45.
[32] Kauto Merja. Oilon burner general introduction manual. lahti, p23-32, FIN2003.
[33] T.S. Pedersen. Process-optimization multivariable control of a boiler system. IEE conference Publication 427/2, 1996.
[34]贾胜海,刘明东. DCS在锅炉控制系统的应用.应用能源技术. 2003(2): 45-46.
[35] D.A.Conrad, D.P.Muldon. Design and application of a PC/PLC utility boilercontrol system, Instrument Society of America, p340-372, Jun 1995.
[36]刘晨阳.混合煤气锅炉燃烧自动控制系统的研究与实现[硕士论文].北京:北京科技大学. 2006: 10-12.
[37]曹巍. GT50L奥林分体式燃烧器燃气模糊控制系统设计.工业锅炉. 2008 (5): 26-30.
[38]易磊,龚金科,成志明等.全自动轻油燃烧机的设计和分析.工业加热. 2004,33(6): 21-23.
[39] Marti Latenon. Oilon T range gas operation and after-service manual. Lahti, p10-15, FIN2003.
[40] Siemens Co.Ltd. SIMATIC WinCC flexible 2007 Manual. Siemens Co. Ltd .2003.
[41] IA&DT Service & Support. MP277 Panel download manual. p9-20, 2008.
[42] Excellence in Automation & Drives:Siemens. S7-300 CPU Memory Introduction & Memory Card Application. p4-12, 2007.
[43]冯良,郭定云.全自动燃气燃烧器的设计.工业锅炉. 2002 (4): 20-22
[44]西门子股份有限公司自动化与驱动集团工业自动化系统部.语句表(STL)编程手册. 2004: 2-15.
[45]高洪斌.西门子PLC与工业控制网络应用.北京:电子工业出版社,2006: 23-30.
[46] PLC在锅炉控制系统中的应用. http://www.autooo.net/自动化在线. 2007,3.
[47]张云波. PLC梯形图设计中的关键技术.长春工程学院学报. 2000,1(1):30-32.
[48]喻亮.基于BP网络的神经动态规划在锅炉燃烧控制中的应用[硕士论文].广西:广西大学. 2008.
[49]齐从谦,王士兰. PLC技术与应用.北京:机械工业出版社. 2000,08: 32-37.
[50]张云刚,宋小春,郭武强.从入门到精通—西门子S7-300/400PLC技术与应用.北京:人民邮电出版社. 2007: 30-58.
[51]刘揩,周海.深入浅出西门子S7-300 PLC.西门子中国有限公司自动化与驱动集团. 2005: 56-90.
[52]陆克山,于松义,羌学武.提高燃油(气)锅炉运行效率的措施.能源研究与利用. 2004 (4): 6-8.
[2]赵欣新,葛升群,惠世恩等.中小型燃油燃气锅炉运行操作与维护.北京:机械工业出版社. 2003: 2-5.
[3]赵晓红,王爱洁.浅谈我国燃气燃烧器的发展.工业锅炉. 2003 (5): 26.
[4]王善武.中国工业锅炉行业现状分析及前景展望.工业锅炉. 2004 (1): 5-6.
[5]辛广路.锅炉运行与操作指南.北京:机械工业出版社. 2006: 75-76.
[6]赵晓红,王爱洁.浅谈我国自动燃气燃烧器的发展.工业锅炉. 2003 (5): 27-28.
[7]杨智明,丽萍,吕雪艳. 21世纪燃气锅炉在中国的发展前景.锅炉制造. 2001 (5): 24-26.
[8]黄思明.国外全自动燃烧机技术现状及发展趋势.热能动力工程. 2001 16 (95): 468-470.
[9]林宗虎,徐通.实用锅炉手册.北京:化学工业出版社. 1996: 184-185.
[10]金维强.大型锅炉运行.北京:中国电力出版社. 1998: 11-15.
[11]秦裕琨.燃油燃气锅炉实用技术.北京:中国电力出版社. 2000:54-56..
[12]朱传标.工业锅炉技术基础.上海:上海远东出版社. 1996: 12.
[13]杨献勇.热工过程自动控制.北京:清华大学出版社. 2000: 307-312.
[14]张福安.工业锅炉计算机控制技术.科技情报开发与经济. 2004, 1(4):126-127.
[15]叶伟. VACON变频器在火力发电厂75吨锅炉风机应用.中国工控网. 2008 (3): 23.
[16]向立志,张喜东,李荣等.多变量预测控制在锅炉燃烧系统中的应用.化工自动化及仪表. 2006,33 (2): 22-24.
[17]张亮明,夏桂娟.工业锅炉热工检测与过程控制.天津:天津大学出版社. 1992: 80-81.
[18]边立秀,周俊霞等.热工控制系统.北京:中国电力出版社. 2001: 45-46.
[19]曾光奇,胡军安.模糊控制理论与工程应用.武汉:华中科技大学出版社. 2006: 120-187.
[20]牟岳泰,徐东来,赵永军等.燃气锅炉的PLC自动控制系统.微计算机信息. 2005 (28): 34.
[21] Obernberger Ingwald. Decentralized biomass combustion,State of the art and future development[J]. Biomass and Bio-energy. 140(1), p30-45, 1998.
[22] Tao L. Use of a computer model for evaluation of combustion and NOx control alternatives in a craft recovery boiler [J]. International chemical recovery conference, TAPPI press,(1) , p228-350, 1998.
[23]西门子自动化与驱动集团客户服务与支持中心.西门子PLC系统软件冗余的说明与实现.北京.西门子中国有限公司. 2008.
[24] Excellence in Automation & Drives:Siemens.西门子ProfiBus-S7协议PLC设备驱动使用说明. 2005: 3-4.
[25] Excellence in Automation & Drives: Siemens. Assignment & Description of Active Bus Backplane For ET200M. 2004: 11.
[26] Excellence in Automation & Drives:Siemens. Software Redundancy for SIMATIC S7-300 and S7-400. 2003: 4-7.
[27] Siemens AG Automation and Drives Postfach. SIMATIC S7-300模块数据. 2007: 2-9.
[28] Siemens AG Automation and Drives Postfach. SIMATIC S7-300 Automation System Module Data. 2007: 1-12.
[29]吴晓军,杨向明.电气控制与可编程控制器应用.北京:中国建筑工业出版社. 2004: 50-62.
[30]李强,王磊. PLC软件冗余系统在燃油锅炉中的应用.西安理工大学自动化与信息工程学院. 2008: 43.
[31]廖常初主编. S7-300/400 PLC应用技术.北京:机械工业出版社. 2005: 30-45.
[32] Kauto Merja. Oilon burner general introduction manual. lahti, p23-32, FIN2003.
[33] T.S. Pedersen. Process-optimization multivariable control of a boiler system. IEE conference Publication 427/2, 1996.
[34]贾胜海,刘明东. DCS在锅炉控制系统的应用.应用能源技术. 2003(2): 45-46.
[35] D.A.Conrad, D.P.Muldon. Design and application of a PC/PLC utility boilercontrol system, Instrument Society of America, p340-372, Jun 1995.
[36]刘晨阳.混合煤气锅炉燃烧自动控制系统的研究与实现[硕士论文].北京:北京科技大学. 2006: 10-12.
[37]曹巍. GT50L奥林分体式燃烧器燃气模糊控制系统设计.工业锅炉. 2008 (5): 26-30.
[38]易磊,龚金科,成志明等.全自动轻油燃烧机的设计和分析.工业加热. 2004,33(6): 21-23.
[39] Marti Latenon. Oilon T range gas operation and after-service manual. Lahti, p10-15, FIN2003.
[40] Siemens Co.Ltd. SIMATIC WinCC flexible 2007 Manual. Siemens Co. Ltd .2003.
[41] IA&DT Service & Support. MP277 Panel download manual. p9-20, 2008.
[42] Excellence in Automation & Drives:Siemens. S7-300 CPU Memory Introduction & Memory Card Application. p4-12, 2007.
[43]冯良,郭定云.全自动燃气燃烧器的设计.工业锅炉. 2002 (4): 20-22
[44]西门子股份有限公司自动化与驱动集团工业自动化系统部.语句表(STL)编程手册. 2004: 2-15.
[45]高洪斌.西门子PLC与工业控制网络应用.北京:电子工业出版社,2006: 23-30.
[46] PLC在锅炉控制系统中的应用. http://www.autooo.net/自动化在线. 2007,3.
[47]张云波. PLC梯形图设计中的关键技术.长春工程学院学报. 2000,1(1):30-32.
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