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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 SLC 500 1746-OX8 -0X8 Output Module Sealed Box NIFSB

ACBE17FPU 17" FLAT PANEL MONITOR UPGRADE KIT

Adtech AX4000 LOADED WITH CARDS

(K6) 1 ALLEN BRADLEY PRO-SET 700 6500-PS7DSP OPERATOR INTERFACE (K6)

MEASUREX 053669-01 USPP 05366901

ALLEN BRADLEY 1352-143678 USPP 1352143678

ALLEN BRADLEY 1334-DOB USPP 1334DOB

INDUSTRIAL DEVICES B8962-FK1-AAAA-XX-FF USPP B8962FK1AAAAXXFF

ROBERTSHAW DMS-3501 USPP DMS3501

POLYSONICS DCT6088 USPP DCT6088

RELIANCE ELECTRIC 0-51890-3 USPP 0518903

Siemens 6ES5 456-7LA11 DIGITAL OUTPUT

Siemens 6ES5-926-3KU12 USPP 6ES59263KU12

SIEMENS 6ES5-430-4UA12 NSFP 6ES54304UA12

Siemens 6ES5 460-7LA13 Analog Input 6ES5460-7LA13

Siemens S5 6ES5 441-8MA11 8x24V DIGITAL OUTPUT

Siemens 7MF4033-1DA00-1AA6-Z Pressure Transmitter

Siemens 6ES7 322-1EH01-0AA0 -FS- 6ES73221EH010AA0

Square D 8003 CP-32

NIB PHOENIX CONTACT PSM-EG-RS232/TTY-P/ 2K INTERFACE CONVERTER MODULE RS-232 24V

WS-SUP720-3BXL WS-X6716-10G-3CXL CiscoDeal

Siemens 6ES7 972-0BB41-0XA0 in Box ping Worldwide

Siemens S7-200 EM231 6ES7 231-0HC21-0XA0 EM 231

Reliance 45C344

Schneider Modicon GOULD REMOTE I/O DRIVER MODEL AS-J820-001

Schneider Modicon AS-B350-001 USPP ASB350001

Schneider Modicon AS-S902-111 USPP ASS902111

Schneider Modicon AS-B873-011 800 I/O ANALOG INPUT MODULE NIB

Schneider Modicon AS-B805-016 B805 115Vac 16Pt Input Molule Mod AS ASB805016 WOW

Modicon Communications Slave Part J474

Siemens S5 6ES5 420-4UA13 6ES54204UA13 Input Module

Siemens 6ES5 464-8MC11 6ES54648MC11

Siemens RS 485-REPEATER 6ES7-972-0AA00-0XA0

SIEMENS 6FC5370-0AA00-0AA0 SINUMERIK 802D /PCU 210.3

WV Communications 19" 3 module Chassis

SIEMENS 6SN1118-0AD11-0AA0 6SN11180AD110AA0

SIEMENS SIMODRIVE 611 6SN1123-1AA00-0CA2 POWER MODULE 6SN11231AA000CA2 (NIB)

SIEMENS 6FC5510-0BA00-0AA0 USPP 6FC55100BA000AA0

Advantech PCA-6186VE PCA-6186 Rev.A1 NIB

Allen-Bradley 1771-OA AC OUTPUT MODULE

ABB ASEA BROWN BOVERI POWER ITE AIR CIRCUIT BREAKER 800A 800 AMP KDON K-DON 800S

ADEPT 90400-60131 AMPLIFIER MODULE MEGATORQUE 300 WATT CONTROLLER

6SE7026-0TP50 SIEMENS COMPACT + MASTERDRIVE 59AMP 30kW 510-620VDC MOTION CNTRL

SYMAX 8020-SCP-424 NSPP 8020SCP424

CUTLER HAMMER IDT0286 NSFP IDT0286

CLEVELAND MOTION CONTROL BNR5110GPA00CS0002 NSPP BNR5110GPAOOCS00

NEMATRON CORP IWS-4824 USPP IWS4824

MITSUBISHI FR-A520-2.2K-NA USPP FRA52022KNA

GE FANUC 44A719348-102 USPP 44A719348102

Siemens 6ES5 246-4UA11 6ES52464UA11

Siemens 6ES5-470-8MB11 NSFP 6ES54708MB11

SIEMENS 6ES5-306-7LA11 NSPP 6ES53067LA11

SIEMENS S5 SERIAL INTERFACE 6ES5 521-8MA21

Siemens 6ES5 441-8MA11 6ES54418MA11

SIEMENS 6FC5203-0AF50-3AA1 6FC5 203-0AF50-3AA1 MCP416C

Siemens TP170B 6AV6545-0BB15-2AX0 6AV6 545-0BB15-2AX0 Seal Opened FreeShip

Siemens 6ES5451-8MD11

Jova Solutions TIMS-0102 USB 12C/SPI Interface Module

ZARAK ABACUS BCG 81-01512-02 MODULE w/ ABACUS BRA Circuit Interface

Siemens 6ES7 210-8XX00-6AA0 6ES7210-8XX00-6AA0 PDS210 in Box, Seal opened

Siemens OP17 6AV3617-1JC20-0AX1 Membrane Keypad , ping worldwide

Patriot WA0750

Schneider Modicon AS-B872-002/ASB872002 Output Module OFFERS ACCEPTED

Schneider Modicon AS-5540-006 NSFP AS5540006

Schneider Modicon AS-M680-108 Memory Module

Schneider Modicon AS-9490-004 USPP AS9490004

Schneider Modicon 800 SERIES 11 SLOT RACK AS-H827-103

Schneider Modicon TSX COMPACT DISCRETE INPUT DEP 216 AS-BDEP-216 LOT OF 5

Siemens TI 505-4108 Low VDC Input Module

Telemecanique ATV11HU09M3A 0.37kW Inverter in Box

SIEMENS SIMATIC SM422 DIGITAL OUTPUT MODULE S7-400 ++

SIEMENS 4700 POWER FUNCTIONS METER OPERATOR INTERFACE PANEL 4700-BDRMC3-11HN

SIEMENS Sinumerik 840C/840CE P/Supp 6FC5114-0AA01-1AA0

CC LINK COMMUNICATIONS MODULE MITSUBISHI FR-E5NC

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

SIEMENS Servo Drive 6FC5247-0AA00-0AA3 6FC52470AA000AA3

Advantech PCA-6184V, no ethernet port,

Allen-Bradley 2711-T6C15L1 Panelview 600

ABB 3HNE00313-1

ACCURAY AIC8 086155-001 SCANNER MODULE CARD CONTROLLER B211850

A2LA 17025 Accredited Calibration with full Data Report

82-1/2" OVER ALL LENGTH 2-1/4" DIAMETER BALLSCREW 55" TRAVEL 5-1/2" FLANGE

SIEMENS 6ES7-623-1DE01-0AE3 USPP 6ES76231DE010AE3

ASEA BROWN BOVERI 750191-001B NSFP 750191001B

ALSTOM ALSPA-MV-1013 USPP ALSPAMV1013

MICRO MOTION DL065-S242SU NSPP DL065S242SU

HUB CITY 88 NSFP 88

ALLEN BRADLEY 1774-KA USPP 1774KA

SIEMENS 6ES5-925-3SA11 USPP 6ES59253SA11

Siemens 6ES5-391-5AA13 USPP 6ES53915AA13

SIEMENS 6ES5 454-7LA11 6ES54547LA11

SIEMENS 6ES5 465-7LA13 Module

Siemens PLC 6ES5-451-4UA12/6ES54514UA12 Output

Siemens 6ES7 323-1BH01-0AA0 6ES7323-1BH01-0AA0 FreeShip

Siemens PLC 6ES7 338-4BC01-0AB0 6ES73384BC010AB0 NIB

PVDM3-32 CISCO 32-CHANNEL HIGH-DENSITY VOICE AND VIDEO DSP MODULE

GSM/GPRS Modem Pool 8 Ports USB interface Wavecom Module AT Commands Q2406

Unico 314-739 314739 Interface Module No Box

Siemens 6AV6 640-0DA11-0AX0 Touch Panel NIB

Siemens Logo 230RC 6ED1 052-1FB00-0BA3

MTT ms2304

Schneider Modicon Connector/Cable AS-W801-002/ASW801002

Schneider Modicon 800 SERIES AS-H827-103 11 PORT RACK ASH827103

Schneider Modicon AS-E685-904 USPP ASE685904

Schneider Modicon Gould AS-B804-016 PLC I/O Module

Schneider Modicon AS-B804-116

Schneider Modicon Output Module True High AS-B824-016

Schneider XBTGT5230 Touchscreen Glass

Schneider Modicon TSXPCX3030+ Optical Isolated Cable

SiemensSimatic6AV6641-0CA01-0AX16AV66410CA01

Siemens 6AV6642-0BC01-1AX0 6AV6 642-0BC01-1AX0 SIMATIC TP 177B 6" Touch Panel

SIEMENS SE47.1 6DD1681-0EH1 OPTICAL COUPLER MODULE

GE Fanuc IC697RCM711C 90-70 Redundancy Communication Module IC697RCM711-C

SIEMENS Simodrive Posmo A 1FK6032-2AF1 s/n 22253202 6SN2155-2BD10-1BAO

SIEMENS SINUMERIK 6FC5203-0AF01-0AA0 Membrane Keypad

SIEMENS Moore 63SD Differential Type Flow Controller

Allen-Bradley Panel View 600 Plus

AB 1336S-A030-AN-EN 30HP 240VAC VFD QUANTITY TESTED

ABB/ACS 500 150 HP Drive 440-500 VAC Cat# H502125400P2BBB200 3000

A06B-0332-B069#7000 FANUC SERVO MOTORS REMANUFACTURED

75 HP ELECTRIC MOTOR 1200 RPM 405T FRAME NEMA PREMIUM EFFICIENT SEVERE DUTY

RELIANCE ELECTRIC 6V41-096TA NSPP 6V41096TA

ALLEN BRADLEY 2711-K14C1 USPP 2711K14C1

ALLEN BRADLEY 1771-IF05 USPP 1771IF05

HONEYWELL 30731737-006 NSFP 30731737006

WESTINGHOUSE DBL-25-1200 USPP DBL251200

TEXAS INSTRUMENTS PLC VPU500-3104 USPP VPU5003104

GENERAL ELECTRIC DS3800DMEC1D1D USPP DS3800DMEC1D1D

Siemens 6ES5-188-3UA12 PLC Rack 21 Slot

SIEMENS 6ES5 375-0LC31 6ES53750LC31

SIEMENS 6ES5-988-3NA11 USPP 6ES59883NA11

Siemens 6ES5 930-8MD11/6ES5930-8MD11 POWER SUPPLY XLNT

Siemens 6ES5 944-7UB11 in Sealed Box

Siemens Micromaster 430 6SE6430-2UD31-8DA0 18.5KW

RELIANCE ELECTRIC 61C-350 USPP 61C350

Texas Instruments 500-2151

Spirent Adtech AX/4000 401381 L3 Gigabit MM Interface

VIA Artigo A2000 Barebones Storage Server 1.5 GHz VIA C7-D Brand

Siemens C98043-A1604-L3-03 no packaging

Modicon AS-W510-002

Schneider Modicon Automation AS-BDEP-216 Discrete Input -

Schneider Modicon AS-H819-209 CHASSIES ASH819209

Schneider Modicon AS-BDAP-112 USPP ASBDAP112

Schneider Modicon ASB872002 Excellent Analog OUT Module AS-B872-002

Schneider Modicon Automation Output Module DAP 210/AS-BDAP-210

Schneider Modicon AS-W801-006 ASW801006 Extender Cable NIB

Schneider Modicon 140CRA93100 / 140CRA 931 00

SCXI Accelerometer Input Modules NI SCXI-1531

RELEASE SuperMicro X9DRT-F MB ※Check W/ Us for Availability FIRST※

Siemens 6ES7 132-4BD00-0AA0 6ES71324BD000AA0 Output Module

SIEMENS SINUMERIK 840D/DE NCU 572.3 6FC5357-0BB22-0AE0

MODULE COMMUNICATION ALLEN BRADLEY 1203-GD1

SIEMENS SIMODRIVE 611 BOARD 6SN1118-0DJ21-0AA1NIB

SIEMENS SINUMERIK OP 010S 6FC5203-0AF04-0AA0 NIB

SIEMENS Caterpillar D6H / D6H Series II Tractors Service Manual 8KB 4RC 6FC

ALLEN-BRADLEY1756-OFCI/AOUTPUTMODULE1756-0FCI

Allen Bradley SLC 500 Output Module 1746-OX8 Ser. A

ABB ROBOT DSQC345B - RECTIFIER DC1 - 3HAB8101-2

A06B-0128-B575#7076 FANUC SERVO MOTORS REMANUFACTURED

0.1-1250 μm LPA-9Z Desktop Intelligent Laser Particle Size Analyzer Sizer

MODICON AS-M909-001 USPP ASM909001

ALLEN BRADLEY 1398-PDM-150B USPP 1398PDM150B

ADEPT TECH 10332-00500 USPP 1033200500

GE FANUC IC640WMI910 NSFP IC640WMI910

SIEMENS LMXD63B700 NSPP LMXD63B700

SIEMENS 6ES5-928-3UB12 USPP 6ES59283UB12

ALLEN BRADLEY 2755-DD1A-R1 NSFP 2755DD1AR1

Siemens 6ES5 928-3UB21 6ES59283UB21

Siemens SIMATIC 6ES5 926-3SA12

SIEMENS 6ES5-512-5BC12/6ES5512-5BC12 INTERFACE MODULE XLNT

Siemens 6ES5 441-4UA14/6ES54414UA14 Digital Input SEALED OFFERS ACCEPTED

SIEMENS 1FT6105-8SB71-1AA0 3-phase Brushless Servomotor

Siemens EM235 6ES7235-0KD00-0XA0 6ES72350KD000XA0

Schneider Digital Input Block Fuse 140CFB03200 3436

Square D 9006-PBF121

Siemens 6ES7460-0AA01-0AB0 SIMATIC S7-400 IM460-0 Transmitter Interface Module

WE SHIP SAME CISCO SLM2024T SG200-26 SLM2024T-NA 26PORT GIGABIT SMART

Siemens 6RA7018-6DV62-0-Z 6RA7018-6DV62-0 DC DRIVE

Siemens TP27-10 6AV3 627-1QL00-0AX0 Touch Glass, Bergquist Touch Products

Schneider Modicon TSX COMPACT DISCRETE OUTPUT AS-BDAP-210 4

Schneider Modicon ASBDAP210 AS-BDAP-210Compact output

Schneider Modicon AS-B825-016 NSFP ASB825016

Schneider Modicon MODULE AS-E908-131 S35D

Schneider Modicon AS-W192-015

Schneider Modicon AS-BZAE-204 HIGH SPEED COUNTER IN BOX FACTORY SEALED

SCHNEIDER TC2000 OPERATOR INTERFACE 3515 KPM PARTS/REPAIR BROKEN NOB

Siemens 6ES7 131-4BB00-0AA0 Digital Input Module 24 VDC /Un

RSP720-3CXL-GE Cisco Route Switch Processor 720-3CXL Router

SIEMENS D215 USPP D215

SIEMENS Sinumerik 840C 6FC5110-0BA01-1AA0 NC-CPU .

RTI CM-232 Serial Communication Module

SIEMENS 6SN1162-0EB00-0AA0 SIMODRIVE SHIELD CONNECTION PLATE 50MM

SIEMENS 6SC 6101-4A Simodrive Case -NO BOX

SIEMENS 6FC5-111-0CA02-0AA2 USPP 6FC51110CA020AA2

AllenBradley6182H-10TLH4DVersaViewCE1000HWorkstationPanel

Allen Bradley VersaView Display 17" to 19" Repair Service $169.99

ABB E3N-A20 600V 2000A PR112/P-A L/S/I/G INSULATED CASE CIRCUIT BREAKER

Adtech Spirent AX-4000 ATM Testing Solution AX4000

(H2-1) 1 EATON 92-00944-02 POWER SUPPLY H2-1

KENT TAYLOR 6202NZ10000B-1342 USPP 6202NZ10000B1342

ACUITY IMAGING 010-PV9040 USPP 010PV9040

FLUID POWER DIVISION PMC-20T NSFP PMC20T

FANUC A06B-0146-B675 USPP A06B0146B675

SEIKO INSTRUMENTS & ELECS LTD OFL-760A-26 USPP OFL760A26

RAPID POWER TECH SPSAA100012 USPP SPSAA100012

RELIANCE ELECTRIC 86466-47T NSFP 8646647T

Siemens 6ES5 460-4UA13 -FS- 6ES54604UA13

Siemens 6ES5-928-3UA11 USPP 6ES59283UA11

SIEMENS 6ES5-430-7LA11 USPP 6ES54307LA11

Siemens 6ES5 490-7LB21 CONNECTOR IN BOX

Siemens S5 6ES5 464-8MC11

SIEMENS 802Dsl Membrane Keypad

SIEMENS 6ES7 223-1BL22-0XA8 EM 223 CN I/O MODULE

Square D 8005 MP-1

Nokia NIF4303FRU 2-Port X.21 PMC Interface Card Module

WS-F6K-DFC3A DIST FWD CARD-3A FOR 65XX 6816 MODULES WITH SUP720

SIEMENS 6ES7-151-1AA03-0AB0

Siemens SCD 1597-ET 6AV8100-1BB00-0AA0

Reliance 45C940

Schneider Modicon GOULD B805 AS-B805-016 INPUT MODULE 115 V AC

Schneider Modicon AS-B352-001 USPP ASB352001

Schneider Modicon AS-S908-021 USPP ASS908021

Schneider Modicon AS-B883-101