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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 1336F-BX040-AA-EN-HAS2-L6 USPP 1336FBX040AAENHA

CUTLER HAMMER S801V36N3S USPP S801V36N3S

ALLEN BRADLEY 1336F-BRF15-AF-EN-GMS1-HJ2-L6 NSPP 1336FBRF15AFENGM

GE FANUC IC752WTA055-GC USPP IC752WTA055GC

SIEMENS 6ES5-512-5BC21 NSFP 6ES55125BC21

MODICON AM-S985-032 USPP AMS985032

STRUTHERS DUNN DIRECTOR 4000 76736-32 NSPP 7673632

FANUC A05B-2330-C191 NSPP A05B2330C191

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SIEMENS 6ES5 308-3UA11 6ES5308-3UA11 XLT

SIEMENS 6ES5-910-0AA41 USPP 6ES59100AA41

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SIEMENS 6EC10003A 6EC10003A

Siemens LOGO! 6ED1 052-1CC01-0BA6 NIB + LOGO USB Cable

RME HAMMERFALL HDSP 9632 HDSP9632 PCI SOUND CARD

Telemecanique TSXTE01

SIMATIC 6ES7461-1BA01-0AA0 S7-400 IM461-1 RECEIVER INTERFACE MODULE

Wago 750-316 MODBUS FIELDBUS COUPLER

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Modicon AS-T190-401

Schneider Modicon Automation TSX Compact AS-BDAP-216NOutput Module

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Omron PLC Module CJ1W-SCU21-V1 CJ1WSCU21V1 Serial Communications

SIEMENS SIMO DRIVE 1P 6SN1145-1AA0-0BA0

SIEMENS SINUMERIK840DE NCU 571.2 6FC5357-0BB11-0AE0

SIEMENS QTY 10 OP015 6FC5203-0AF03-0AA0 Membrane Keypad

AllenBradley1771-OPProtectedACOutputModule

ALLEN BRADLEY SLC500 OUTPUT MODULE 1746-OV32

ABB Network Interface Slave Module Part No. INNIS21

ZTEC ZT4441 PXI 800Ms/s, 14 bit, 256MS Digital Storage Oscilloscope

(Y2-3) 1 NIB ALLEN BRADLEY 810-A02A SER B MAGNETIC OVERLOAD RELAY Y2-3

MODICON 557VIC12640 NSFP 557VIC12640

ALLEN BRADLEY 1392-B150-RL-MC-A-F1 USPP 1392B150RLMCAF1

GENERAL ELECTRIC L90-A00-HCH-F8A-H6C-LXX-N6B-SXX-U6H-W7C NSFP L90A00HCHF8AH6CL

FUJI ELECTRIC 6KF11H044X1A1 USPP 6KF11H044X1A1

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SEIKO-SEIKI EL6535-10098 USPP EL653510098

YOKOGAWA 371122-B-O/D USPP 371122BOD

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Sharp JW-31LM I/O MODULE 32-SLAVE STATIONS 345.6KB 504 POINTS

Square D 8030 RIM-101

Siemens 505-7339 Network Interface Module 5057339

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Siemens 6GK1502-3CA10 NIB

Siemens TP177A 6AV6 642-0AA11-0AX1 Touch Glass + Film

Schneider Modicon SEALEDAUTOMATION AS-P120-000

Schneider Modicon ASBDEP218 AS-BDEP-218

Schneider Modicon AS-B805-000 ASB805000 Input Module Rev B

Schneider Modicon Memory Module Prom AS-521P-008

Schneider Modicon AS-J892-101 SURPLUS ASJ892101

Schneider Modicon AS-B875-102 HIGH SPEED INPUT MODULE

SchneiderElectricXBTGT4330Panel

SIEMENS 6ES7 331-7PF10-0AB0 SIMATIC S7 THERMO-COUPLE ANALOG INPUT MODULE

SBE INC M68K10 USPP M68K10

Siemens HMI 6AV6 642-0BA01-1AX1 NIB 6AV66420BA011AX1

SIEMENS Sinumerik 6FX1820-0AX01 Module E Stand 06

SIEMENS 6GK1143-0TA01 COMMUNICATION MODULE W/FLASH XLNT

SIEMENS 6SN1130-1AA11-0EA0 6SN11301AA110EA0 SIMODRIVE XLNT

SIEMENS 6SN1-118-0DK23-0AA0 DRIVE SIMODRIVE 611 DIGITAL CONTR LOOP H PERF

SIEMENS 6FC5-203-0AB11-0AA2 USPP 6FC52030AB110AA2

AllenBradleyPanelView900OperatorInterface2711-T9C1SeriesC

ALLEN BRADLY VersaView 1700M OPERATOR INTERFACE DISPLAY 6186-M17ALTR SER. B

ABB Drive ACS800-02-0170-5+H358+P901 150 HP 3 Phase

ADEPT TECHNOLOGY PA-4 30336-31000 4 S ROBOT POWER SUPPLY RACK CHASSIS

(7432) Kawasaki Robotics PC Board 50999-1384 SEALED (7432)

INDRAMAT TDM1.2-100-300-W1/000 USPP TDM12100300W1000

WESTINGHOUSE A200M5CXXZ1 USPP A200M5CXXZ1

FANUC A06B-6059-H212 USPP A06B6059H212

EEC AEG 029.111.329 NSPP 029111329

RELIANCE ELECTRIC 801429-5RE USPP 8014295RE

NOVA 402AS3 USPP 402AS3

NIOBRARA R&D CORP EPE5-TCP-A NSPP EPE5TCPA

Siemens 6ES5 432-4UA12 -FS- 6ES54324UA12

Siemens 6ES5-900-7FC11/6ES5900-7FC11 CPU MODULE XLNT

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Siemens 6ES5 431-8MA11 6ES54318MA11 24VDC Input ModuleXLNT

Siemens S5 6ES5 318-8MB12 ET200U

Siemens 6SE7041-8EK85-0LA0 C98043-A1695-L Control Board

Siemens 6ES7 332-5RD00-0AB0 6ES73325RD000AB0

Siemens U-01Z

Mitsubishi QJ71PB92D Q-Series PROFIBUS-DP Interface Module

WS-X6148-GE-TX Cisco Classic Interface Module Expansion module 48 ports

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Siemens Profibus PCI Card 6GK1561-1AA00 in Sealed Box Worldwide

Reliance 0-56313-1

Schneider Modicon MINT AS-S911-801 ASS911801 Processor

Schneider Modicon AS-B243-105 USPP ASB243105

Schneider Modicon AS-P930-104 USPP ASP930104

Schneider Modicon AS-B827-032 INPUT MODULE 800 I/O 24 VDC TRU HIIN 32PT

Schneider Modicon AS-B55A-001 Module

Modicon Modbus Plus T-Connector 990NAD23000

SIEMENS SIMATIC 6ES5 482-3BA11 OUT INPUT MODULE MO

Siemens 6ES5-453-7LA11 PLC

SIEMENS S7-300 SET / RACK - INPUT OUTPUT MODULES POWER SUPPLY / 318-2AJ00-0AB0

SIEMENS 6DD1681-0DH1 USPP 6DD16810DH1

SIEMENS SINUMERIK 802D SL 6FC5303-0DT12-1AA0 CNC KEYBOARD

SIEMENS 6SN1111-0AB00-0AA0 SURGE ARRESTOR OVERVOLTAGE LIMITING 611U

SIEMENS Simodrive 6RA 8261-2 Spin Board C98043-A1098-L

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Advantech EVOC IPC-6106P3B Board

ALLEN-BRADLEY 1771-OG 1771OG TTL Output Module NIB NOS Free USA Shipping

ABB ACS60100096000B1200901 AC Drive 10HP 3 Phase 600V WOW

AD208BY QTY 10 IN AD208B ANALOG DEVICES IC AMP ISOL 4KHZ PREC 2MA 38SIP

6ES7468-1DE50-0AA0 Brand , Factory Sealed,

900' Syracuse aluminum urd 2/0-2/0-2/0-1 quadruplex wire direct burial cable

SQUARE D MHL3670035DC2351 NSFP MHL3670035DC2351

CONSULTRONICS DLS400 USPP DLS400

BAUMULLER BUS21-30/60-30-001 USPP BUS21306030001

MOOG D122-F022-A022 NSPP D122F022A022

MARATHON DM0140 USPP DM0140

ELECTRON MACHINE MPR83C-W/U5 USPP MPR83CWU5

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Siemens 6ES5-465-4UA11 USPP 6ES54654UA11

SIEMENS 6ES5 984-2UA11 6ES59842UA11

SIEMENS S5 6ES5436-4UA12 6ES54364UA12

Siemens /Van Dorn Output Module 6ES5 454-7LA11 33426

SIEMENS 6ES7-331-7PF00-0AB0 6ES7331-7PF00-0AB0

Siemens Sinumerik 802S 802C Mechanical Keypad

Siemens 6ES5318-8MA12

iConnect-FM.2 universal iPod adapter interface iPhone FM modulator transmitter

YASKAWA JVOP-112 REMOTE INTERFACE MODULE

SIEMENS 6ES5458-7LA11

Siemens MP270 6AV6542-0AD15-2AX0 Membrane Keypad

Omron G2A-434A

Schneider Modicon AS-BDAP-209 8PT OUTPUT MODULE

Schneider Modicon AS-506P-008 USPP AS506P008

Schneider Modicon AS-J890-102 ASJ890102 Free Ship

Schneider Modicon AS-516P-008 CNC Memory Board Rev C23 (UVG)

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SIEMENS/TI U-05N/9303 16 POINT 24VDC INPUT MODULE NIB

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SIEMENS SINUMERIK PROGRAM PANEL 6FC 5203 5210 5253

SIEMENS 505-4532 OUTPUT MODULE 5054532

SIEMENS SINUMERIK 810 BOARD 6FX1126-1AA01

COMMUNICATION PROCESSOR MODULE 6GK1543-0AA01

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SIEMENS SIMODRIVE 6SN1145-1AA01-0AA1SINUMETIK 840D NCU-BOX 6FC52476FC5357 6SN

Advantech ECM-3610 REV.A1.2

ALLEN-BRADLEY 6182-AGAZAC INDUSTRIAL COMPUTER 100 TO 240VAC 50/60HZ 0.4/0.25AMP

ABB 3HAA3563-AHA S3 DSQC249B RECTIFIER BOARD

ACCURAY 083689-001 NSFP 083689001

A06B-6102-H226#H520

803-B64RH ALLEN BRADLEY LIMIT SWITCH

SIEMENS 6ES5-470-7LA13 NSFP 6ES54707LA13

ASEA BROWN BOVERI 3AFE61004955 NSFP 3AFE61004955

ALLEN BRADLEY 6182-AGAZAC USPP 6182AGAZAC

KROHNE IFM5090CAP/D/HART NSFP IFM5090CAPDHART

GROTH 1260A-04-555-TOZ NSPP 1260A04555TOZ

ACTUS POWER PUB33AX1B USPP PUB33AX1B

PMI MOTION AXA-180-10-30 USPP AXA1801030

Siemens 6ES5-340-3KB41 NSPP 6ES53403KB41

SIEMENS 6ES5 441-4UA13 -- 6ES54414UA13

SIEMENS S5 PLC6ES53067LA11 6ES5-306-7LA11

Siemens Memory Sub Module 6ES5 375-0LD11 37470

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SIEMENS OP7 6AV3607-1JC20-0AX1

Q64TDV-GH Mitsubishi PLC Milivolt Analog Input 4 Pt Isolated Q64TDVGH

GOOD SEW EURODRIVE SERIAL INTERFACE MODULE RS485

Toyopuc TLK-2685 PC1 I/O I/F Interface Module XLNT

Siemens 4AV3000-2AB

Siemens G85139-E1721-A88

Modicon PE-0001-000

Schneider Modicon Gould AS-C484-266 484 Controller Programmable

Schneider Modicon AS-BZAE-204 High Speed Counter ASBZAE204

Schneider Modicon AS-D008-040 USPP ASD008040

Schneider Modicon AS-P452-025

Schneider Modicon AS-B828-016 5V TTL Output TH Module

Schneider Modicon MM-16MP-001 Interface Panel AS-040A-003

Schneider Telemecanique XBTGT5330 Touchscreen Glass

Schneider M340 CPS3500 BMXCPS3500

PROFACE FN-HC10SK41 NSFP FNHC10SK41

SIEMENS 6ES5 451-8MA11 DIGITAL OUTPUT MODULE

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Honeywell Communication Module 620-0044 13832

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SIEMENS SINUMERIK 810D CCU-BOX 6FC5447-0AA01-0AA0

SIEMENS Moore 61F 7200-17NC Pneumatic Booster Relay

ALLEN-BRADLEY Panelview 300 24VDC 2711-B5A1L1 Series F

553VIC14430 MODICON MONITORS CRT REMANUFACTURED

ABB TEACH PENDANT 3HNE 00313-1

A06B-0153-B084#0008 FANUC SERVO MOTORS REMANUFACTURED

7171 OLYMPUS ENCORE HIGH SPEED CAMERA MOTION ANALYSIS CAMERA

RELIANCE ELECTRIC 2EC4040 NSPP 2EC4040

ALLEN BRADLEY 1785-L40L/E NSPP 1785L40LE

ALLEN BRADLEY 1398-PDM-010 USPP 1398PDM010

GENERAL ELECTRIC DS3800NRTB1A USPP DS3800NRTB1A

TOSHIBA VT130H2-U-4330 USPP VT130H2U4330

SYMAX 8030-CRM-540 NSPP 8030CRM540

FISHER ROSEMOUNT 1153DB5RC NSFP 1153DB5RC

Siemens 6ES5-095-8ME03 USPP 6ES50958ME03

SIEMENS 6ES5 318-8MB13 ET200U - DP Profibus INTERFACE

SIEMENS 6ES5-931-7AA11 NSPP 6ES59317AA11

Siemens 6ES5 727-2DB00/6ES5727-2DB00 CP 526 PBT 982 CABLE XLNT

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Siemens LOGO! AM2 PT100 6ED1 055-1MD00-0BA0

Rigol Digital Color Oscilloscope 60MHz dual CH DS1062CA

Terasaki Electric TM-30D

SNMP Web based IP Interface Four4 Way Relay Module Board Controller

VWIC2-2MFT-T1/E1 CISCO

Siemens C7-633 6ES7 633-1DF02-0AE3 #2 ping Worldwide

Modicon AS-T584-103

Schneider Modicon Automation Inc DAP 216/AS-BDAP-216 DAP216ASBDAP216 Output Module

Schneider Modicon AEG/GOULD// AS-B548-000 I/O HOUSING XLNT

Schneider Modicon AS-B885-100 USPP ASB885100

Schneider Modicon AS-B266-501

Schneider Modicon PC-0984-385 Programmable Controller with AS-9770-000

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SIEMANS SIMATIC TI305-02N INPUT MODULE TI30502N