The design and implementation of the air compressor automatic control system transformation Luo Fengju (Daily Steel Company Automation Department Shandong Cuisine 271104) and its economic benefits.
The original air compressor control system of the vegetable steel is the backward Siemens S5 series. At present, the modules and HMI panels are difficult to buy spare parts on the market. Because the system is random, the control program is encrypted and the control idea is not clear. Difficulty The system has been in production for more than ten years, and the automatic control system and detection components, secondary instrument aging, serious enzymes have been increasing year by year. In recent years, the main motor running circuit failure, surge and outlet flow fluctuation caused by venting and parking failure Greatly affected production efficiency and hotline supply. Therefore, we have to modify the control system of the air compressor, and the modified system uses the Siemens S7400 control system. Since the official operation of the automatic control system, it has been characterized by advanced functions, stable work, high safety and high reliability. It has a wide range of promotion value and provides a continuous and high-quality gas source for the hot wire production of the vegetable steel to ensure the smooth operation of the thermal production. Created considerable economic benefits.
2 transformation plan 2.1 control system hardware configuration We use Siemens S7400 control system for air compressor device, two upper computer monitoring in the main control room, one engineering station (also as operator station) and another for operator station system application The development software is the Siemens STEP7 software package, and the operating platform is the English version of WINDOWS 2000 or WINDOWSXP operating system. And through the standard TCP / IP protocol Ethernet to achieve automatic control, data communication and host computer management of the host computer's man-machine interface using Siemens WINCC monitoring software to achieve temperature, pressure, flow, vibration and other process parameters Centralized monitoring, recording, archiving and alarming, can completely monitor the production situation of the entire system.
In the above overview, due to the shortage of the original air compressor system, the position of the outlet flow detecting device often appears to be large, and the fluctuation of the measured value causes the air compressor to vent the motor and the feedback signal is unstable, causing the parking; the critical temperature value is broken. The three problems of accidental parking have been specifically modified. The scheme is as follows: the outlet flow of the air compressor is an important parameter of the air compressor, but the parameter loop, but because the electrical components are unstable, the same fault will occur shortly after replacement. We have a single control method from the perspective of automation, so that the current signal When participating in the control, when the current and the motor reverse signal disappear simultaneously, it is confirmed that the true fault state of the air compressor improves the reliability and eliminates the shutdown failure caused by the instability of the electrical components.
The disconnection of the temperature measuring device is a phenomenon that often occurs in the operation of the compressor. The air compressor used in the J oxygen is an integrated device produced by ATLAS. Many of the original inspection components are randomly put into operation and found to have poor stability in the long-term operation. During the operation of the wrist, the load-stopping caused by the fault of the detection circuit due to high temperature, large vibration, electromagnetic interference, etc., not only seriously affects the production, but also causes mechanical damage to the equipment.
Summarize the past experience, develop a set of self-correction procedures based on the different slopes of normal temperature fluctuations and instantaneous disconnection faults.
Fluctuation will cause the air compressor to directly unload the parking performance curve based on the air compressor (see) to develop a PLC lookup program. According to the experience point to determine the frequent operation angle, and the segmentation of the fuzzy curve real-world function point query. Instantaneous simulation of fault response of air compressor outlet pressure (dischangepress) and outlet flow (actual volume flow). When measuring the original broken wire, the unrealistic large-scale fluctuation system is generated. The judgment error signal is excited. The self-correcting program geese calculates the outlet pressure value according to the current inlet HtJT degree and the current flow rate, or calculates the opening degree and the outlet pressure according to the inlet guide vane. The current traffic is provided to the operator, participating in the device interlock and the system alarms to alert the maintenance personnel.
Once the on-site recovery measurement system S jumps out, the corrected measurement value is restored.
Outlet flow V7 (m3 / h) air compressor performance curve (2) main motor running feedback signal instability main motor running anti-Germany directly involved in air compressor heavy fault parking resistance protection self-correction program process transformation effect air compressor control system The transformation achieved good results. The average shutdown rate of the system operation was 7 months since the operation of the new system = (1% + 0 + 2% + 0 + 2% + 0% + 1%) / 7 = 0.86% The system operation efficiency is greatly improved. The software control function design fully meets the on-site production needs. It is of special significance for improving the product output and reducing the equipment downtime. It can be promoted and applied in the same type of air separation unit in China.
Due to the decrease, B and oxygen were added. Reduce the parking by 4 times per year, the maintenance time of one parking is one day, and the oxygen product year (calculated according to 300 days) creates the benefit: 0.78 yuan/m3xl2000m3/hx24hx4=89 million nitrogen product years (calculated according to 300 days) : 4 Conclusion After the completion of the air compressor automatic control system transformation, the system work is stable, full and reliable. The product quality and output of the high unit are stable. The work efficiency of the operator is low. The labor intensity provides the hot steel production for the vegetable hotline. Continuous and high-quality gas products ensure the smooth production of hotlines and create considerable economic benefits.
Wang Lixin System and Control Tutorial Beijing: Jt Jingqing University Press, Zhang Huaiyong. Xizizi Automation System Actually, Beijing People's Posts and Telecommunications Press, 2007. Qiu Gongwei. Programmable Controller Network Communication and Application Beijing: Tsinghua University Press, a professional bachelor's degree in engineering, is engaged in the research and development and maintenance of automation control systems.
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