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　煤气在使用过程中容易产生管网压力波动，存在不安全因素。煤气柜作为调剂煤气供应、减缓管道波动的有效方法，在冶金和化工等行业得到了广泛的应用。煤气柜可以有效回收放散煤气，充分合理利用企业内部的附产煤气，调节管网压力。作为煤气这个危险性气体的“归宿”，煤气柜的安全运行对于全厂的生产安全具有重要意义。
　　山东金能科技股份有限公司是一家综合性化工企业。多年来，公司秉承 “资源高效、绿色低碳”的循环发展理念，以技术创新为驱动、以资源高效利用为导向，打造了区别业内其他企业的循环经济产业链，构建了资源利用、产品结构、技术装备、环保模式四大差异化的盈利模式，实现了煤化工与精细化工的科学整合，做到了资源利用最大化与资源利用价值最大化。
　　由于金能科技现有的30000m2煤气柜控制系统在设计时不具备硬件的冗余、容错和复杂逻辑判断等功能，当现场仪表出现显性故障时，极易造成工艺事故。为提高全厂的安全水平，金能科技决定利用冗余控制技术，升级现有的煤气柜监控系统。
　　挑战
　　煤气柜监控系统是智能自动化仪表技术、自动化控制系统、计算机技术和网络技术等多种技术的结合，涉及到多方面的知识。新系统的设计需要重点解决现有系统面临的以下三方面问题：
　　 故障安全：原有系统配置不能够排除当现场仪表出现故障或假液位造成的显性故障，易造成工艺事故。
　　 传感器的独立设置：对参与联锁的各个传感器(如活塞高度、气柜内压力等值)配置为单台测量，未使用不同的测量方式，不符合传感器冗余设置三选二的原则。
　　 硬件的冗余、容错：模块前期设计时，未考虑PLC模块的冗余、容错设计，如发生仪表的损坏、模块损坏、电源异常断电等故障时，极易造成工艺事故。
　　解决方案
　　针对金能科技干式煤气柜实际情况，基于罗克韦尔自动化组态技术和人机界面检测技术，金能科技构建了现代化的煤气柜监控系统，并与原有控制系统实现了无缝的融合与兼容。
　　项目总体实施过程包括五个步骤：气柜监控监测系统总体的方案设计;气柜监测系统逻辑关系模型的建立;冗余、容错目的的达成，及数学模型的建立;完成气柜监测系统软件部分的组态设计与开发;最终系统的联调联试以及持续改进。
　　新系统采用由罗克韦尔自动化PLC冗余控制系统结构，基于ContrlNet协议、工业以太网协议等通信方式，实现了传感器、电源、控制单元以及通信的冗余设置，控制精度达到毫秒级，保证系统安全可靠运行。可以完成对现场活塞高度、气柜内部压力、油槽液位、顶部泄漏量的数据的采集和进出口阀门等阀门的过程控制。对于输入、输出模拟量信号通过加装防爆安全栅(一入两出)进行现场与控制系统的安全有效隔离，现场检测信号一分为二，一路进原有系统显示报警，另一路进本系统参与联锁控制，双重保证检测信号的稳定性和安全性。系统所有开关量输入、输出信号都通过隔离继电器隔离，保证测点的干接点输入和输出。

ALLEN-BRADLEY 1201-DMA HMI DOOR MOUNT BEZEL

ABB DSQC266C 3HAB-8798-1/2B

York Solid State Motor Starter SSS14L-46A

800-1650nm + 23 to -70dBm 90

MULTILIN T60-G03-ACH-F8H-H6M-MXX-PXX-UXX-WXX NSFP T60G03ACHF8HH6MM

SIEMENS 6SE9-221-5DC40 NSFP 6SE92215DC40

ASEA BROWN BOVERI 57171847 USPP 57171847

ALLEN BRADLEY 1336S-B015-AX-EN-GM1 USPP 1336SB015AXENGM1

CONTROL TECHNIQUES 6180-8110 USPP 61808110

OMRON C500-CT041 NSFP C500CT041

MODCOMP 551-100689-001 NSPP 551100689001

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KENWOOD KCA-SR50 SIRIUS RADIO INTERFACE MODULE ADAPTER

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ADVANTECH PCL-711B REV A1+ PCLD-7115 REV A1

Allen-Bradley 2711P-B6C20D PanelView Plus 600; Color/Touch/Ethernet/RS-232

ABB 52614759 CPU86-NDP Allen Bradley Stromberg

ACME 500 KVA 480 208Y/120 VAC T-1-53319-3S TRANSFORMER

A-60HS3712SSLP Hoffman 60" x 37.38" x 12" SS Enclosure

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ASEA BROWN BOVERI EHDB520M2P-1L NSFP EHDB520M2P1L

ASCO D300-B-2-200-F-1X-F USPP D300B2200F1XF

MITSUBISHI A-985-GOT-TBA-EU USPP A985GOTTBAEU

INDRAMAT DKC1.1-040-7-FW USPP DKC110407FW

ALLEN BRADLEY 284D-FVD6P0Z-25-CR-3 NSFP 284DFVD6P0Z25CR3

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Allen-Bradley MobileView Guard G750 2727-G7P20D106

AB 4100-232-RL 4100232RL 2 AXIS CONTROLLER SER.H IMC S

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RELIANCE ELECTRIC 802420-R USPP 802420R

ALLEN BRADLEY 2750ASPR NSPP 2750ASPR

ALLEN BRADLEY 1771-QDC NSFP 1771QDC

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XYCOM 9450 USPP 9450

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GRACO C27340 NSFP C27340

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Texas Instruments 500-5023

Spirent/Zarak Abacus 81-01504-00 Analog Circuit Interface Module

USON CORP 403-X300H NSFP 403X300H

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Schneider Modicon AS-BDAP-217 NSPP ASBDAP217

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Schneider Modicon TSX Discrete Output Module DAP210 / AS-BDAP-210

Schneider Modicon B827 24VDC Input Module - AS-B827-032

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Mitsubishi MELSEC Communication Module AJ71UC24 FreShip

SIEMENS SIMODRIVE 611-D 6SN1118-0DG23-0AA1 NIB

SIEMENS SINUMERIK MACHINE CONTROL PANEL MCP 416C-TKEY MPI 6FC5203-0AF50-4AA1

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Allen Bradley SLC 500 Output Module 1746-OA16 35344

ABB robot S4C+ IRB4400 60KG

A06B-0142-B088#7000 FANUC SERVO MOTORS REMANUFACTURED

0010-11997 Assy., Heater, TxZ, 200mm SNNF

MODICON MM-PMC3-10S USPP MMPMC310S

ALLEN BRADLEY 150-A97NBDA USPP 150A97NBDA

ALLEN BRADLEY 1326AB-B3E-11 USPP 1326ABB3E11

GENERAL ELECTRIC 104X984BAG6 USPP 104X984BAG6

SQUARE D 8538-SFA23 USPP 8538SFA23

SIEMENS 6FX1-135-7BB01 NSPP 6FX11357BB01

ALPHA GEAR DRIVES SPK-100-MF2-10-141-000 NSFP SPK100MF21014100

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Siemens Simatic S5 6ES5 242-1AA13 6ES52421AA13 NNB

SIEMENS 6ES5-700-0LA11 USPP 6ES57000LA11

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Siemens 3RK1903-1CB00 3RK19031CB00

SIEMENS FLASHING PULSE GENERATOR 6DS1922-8AA IN BOX, Seal opened,

SBE INC M68K10 USPP M68K10

Square D ATV66D12N4U

SIEMENS -CERBERUS CXL/MXL INTERFACE MODULE CMI-300

We buy Lucent Telica Plexus DMX CBX Genband STINGER

SIEMENS 6SE7 090-0XX84-0BA0 Vesion A NIB

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Schneider Modicon AS-H827-209 984 SERIES 11 SLOT RACK HOUSING

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Schneider Modicon AS-E680-902 AS-9491-003 Memory Module -

Schneider PLC Output Module 140DD035300 NIB

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Roland VG-99 V-Guitar Multi Effects Processor System with GK-3 Pickup

Siemens Coros Op 15 6AV3515-1EB01

SIEMENS Sinumerik 840D 810D FM-NC Operators Guide_2001

RELIANCE REMOTE I/O COMMUNICATIONS MODULE 57404-1E

SIEMENS Amplifier 6SN1130-1AD11-0CA0 VSA module 25/50A

SIEMENS 650 AC Simodrive 6SC 6101-4A-Z _ 6SC6101-4A-Z additional boards removed

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Allen Bradley VersaView 1700P Interface Panel Catalog 6181F-17TPXPH Series D

ABB EI803F 3BDH000017R1 good in condition for industry use

Advanced Energy 3152603-005, E'wave Power Supply, 3 channels 48V,

(L23) 1 SIEMENS 1FT5062-0AC01-1-Z SERVOMOTOR L23

LECROY 9112 USPP 9112

ALLEN BRADLEY 1100-AOD93 USPP 1100AOD93

FUJI ELECTRIC FRN7.5G11S-4EN USPP FRN75G11S4EN

FANUC A06B-0632-B011 USPP A06B0632B011

SICK OPTIC ELECTRONIC LUT1-420 USPP LUT1420

RELIANCE ELECTRIC 0-52855 NSFP 052855

SICK OPTIC ELECTRONIC CLV430-6010 NSFP CLV4306010

Siemens 6ES5 464-8MF21 ANALOG INPUT MODULE IN BOX

Siemens 6ES5-942-7UA12 NSPP 6ES59427UA12

SIEMENS 6ES5-431-8MC11 USPP 6ES54318MC11

Siemens 6ES5 700-8MA11

Siemens S5 6ES5 700-8MA11 6ES57008MA11 Base

SIEMENS C73040-A51-C154-02-85 J2 Worldwide

Siemens 6ES5-453-7LA11 PLC

Square D 8010 SFI-510

Nortel Passport 15000 multiservice switch Mac Address interface module NTHR11BA

WS-C6506-E CATALYST 6506 ENHANCED CHASSIS 6 12RU

Siemens 6ES7221-0AA22-0XB0 6ES7 221-0AA22-0XB0 CPU221

Siemens Simatic CPU 221 6ES7211-0BA21-0XB0

Reliance 57C421B

Schneider Modicon GOULD 24VDC INPUT MODULE CAT AS-B827-032

Schneider Modicon AS-B360-001 USPP ASB360001

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Schneider Modicon AS-B814-108 Output Module Relay NO/NC 5A/30VDC 4A/230VAC 8PT

MODICON AS-B824-016 OUTPUT MODULE ASB824016

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TLS-350 WPLLS Communication Module 330812-001

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ADVANTECH PCL-849 PCL-849A RS-232 Comm Card

Allen-Bradley 1756-OB16E/A F Output Module

ABB Bailey Infi 90 INIPT02 Plant Loop Remote Transfer Module in the

ADEPT TECH 10171-00020 NSPP 1017100020

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HONEYWELL 945-L4Y-2D-001 NSFP 945L4Y2D001

TAYLOR ELECTRONICS 6214BZ10110G USPP 6214BZ10110G

DANFOSS VLT3504 USPP VLT3504

CONTROL TECHNIQUES M75R-14ICD USPP M75R14ICD

OMRON Z4M-T30V2 USPP Z4MT30V2

MODICON 557VIC12430 USPP 557VIC12430

GENERAL ELECTRIC TB63T600 USPP TB63T600

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Siemens 6ES5 100-8MA02 S5-100U CPU 100 6ES51008MA02 with EPROM

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Kingspec Flash DOM Disk On Module 32GB 40Pin Vertical IDE PATA Interface MLC

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Red Lion dt500000

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