一、KULICKE & SOFFA 01483-4029-000-13引言
大慶油田原油生產(chǎn)已進(jìn)入高含水階段，所采用的油水分離方法分為沉降脫水和復(fù)合電脫水兩個(gè)階段。主要工藝設(shè)備有游離水脫除器和電脫水器。油水分離的效果與對(duì)這些設(shè)備的控制方式有直接關(guān)系。大慶油田采油六廠某聯(lián)合站的原油水分離控制部分均采用手動(dòng)控制，數(shù)據(jù)采集，填寫(xiě)報(bào)表等都用人工完成，工人勞動(dòng)強(qiáng)度大，又很難保證控制和采集數(shù)據(jù)的準(zhǔn)確性。為此，該廠提出了對(duì)聯(lián)合站的油水分離控制系統(tǒng)進(jìn)行自動(dòng)化改造，要求系統(tǒng)不僅要實(shí)現(xiàn)油水分離的自動(dòng)控制，而且能將主控制室內(nèi)的二次儀表用計(jì)算機(jī)上的形象直觀畫(huà)面來(lái)取代，以監(jiān)視和控制現(xiàn)場(chǎng)設(shè)備運(yùn)行狀況。本文根據(jù)這些要求設(shè)計(jì)了油水分離自動(dòng)控制系統(tǒng)。
二、KULICKE & SOFFA 01483-4029-000-13工藝過(guò)程及工藝要求
來(lái)自各中轉(zhuǎn)站的高含水油，首先進(jìn)入游離水脫除器，脫掉原油中的大部分含水，再經(jīng)加熱爐加熱，然后到電脫水器進(jìn)行油水分離，最后經(jīng)由凈化油緩沖罐向外輸送。聯(lián)合站現(xiàn)場(chǎng)分為游離水脫除區(qū)、加熱爐區(qū)、電脫水區(qū)和成品油外輸區(qū)四個(gè)部分。
其中游離水脫除區(qū)有三臺(tái)游離水脫除器，它是聯(lián)合站轉(zhuǎn)油脫水過(guò)程中的主要裝置。電脫水區(qū)有四臺(tái)電脫水器，是原油脫水的核心裝置。游離水脫除器和電脫水器的油水界面高度和罐內(nèi)及輸油管壓力是保證油水分離質(zhì)量的重要參數(shù)。在實(shí)際生產(chǎn)過(guò)程中利用放水閥來(lái)調(diào)節(jié)油水界面的高度，油出口調(diào)節(jié)閥來(lái)調(diào)節(jié)罐內(nèi)和輸油管壓力。這兩個(gè)參數(shù)不是獨(dú)立的，無(wú)論是調(diào)整放水閥還是油出口調(diào)節(jié)閥，這兩個(gè)參數(shù)都同時(shí)受到影響，在控制系統(tǒng)中需要綜合考慮這兩個(gè)參數(shù)，以使系統(tǒng)能夠安全、穩(wěn)定地運(yùn)行。
經(jīng)過(guò)沉降脫水得到的原油再經(jīng)加熱爐升溫后，才進(jìn)入電脫水器。溫度過(guò)低會(huì)影響生產(chǎn)，溫度過(guò)高造成能源的浪費(fèi)。因此，系統(tǒng)中需要根據(jù)原油脫水工藝設(shè)定的溫度值，對(duì)加熱爐燃燒情況進(jìn)行自動(dòng)調(diào)節(jié)。
外輸油區(qū)有一個(gè)凈化油罐和凈化油緩沖罐，其中凈化油緩沖罐的出口流量由油出口調(diào)節(jié)閥和變頻器根據(jù)緩沖罐的液位和壓力來(lái)自動(dòng)控制，其中變頻器控制外輸油泵的轉(zhuǎn)速。
根據(jù)工藝要求，控制系統(tǒng)中需要監(jiān)控的參數(shù)主要有：油水界面高度、液位、壓力、溫度和流量。
三、KULICKE & SOFFA 01483-4029-000-13控制系統(tǒng)總體結(jié)構(gòu)
該聯(lián)合站的幾個(gè)工作區(qū)相距100米左右，而且要求總控室和外輸段能夠自動(dòng)監(jiān)控各個(gè)工作區(qū)設(shè)備的運(yùn)行狀況，并根據(jù)檢測(cè)的參數(shù)對(duì)系統(tǒng)進(jìn)行自動(dòng)控制?？刂葡到y(tǒng)中上位機(jī)采用工控機(jī)，控制器采用羅克韋爾自動(dòng)化的SLC500可編程序控制器，對(duì)于距離較遠(yuǎn)的工作區(qū)采用DeviceNet現(xiàn)場(chǎng)總線通訊。系統(tǒng)硬件組成如圖1 所示。
現(xiàn)場(chǎng)中，總控室位于電脫水區(qū)和加熱爐區(qū)之間，SLC控制器也在總控室中，通過(guò)DH+網(wǎng)絡(luò)與工控機(jī)相 連。因此SLC控制器的本地輸入/輸出模塊直接控制電脫水段和加熱爐段。游離水段作為DeviceNet的一個(gè)節(jié)點(diǎn)，用FlexI/O與現(xiàn)場(chǎng)的液位、壓力 變送器和調(diào)節(jié)閥相連。凈化油外輸段的FlexI/O、變頻器和人機(jī)接口界面PanelView1400分別是DeviceNet的一個(gè)獨(dú)立站點(diǎn)，其中FlexI/O連接現(xiàn)場(chǎng)的液位、壓力變送器和調(diào)節(jié)閥；變頻器控制外輸油的流量；PanelView1400用于在外輸段監(jiān)控整個(gè)系統(tǒng)的運(yùn)行狀況。
系統(tǒng)中的界面高度、壓力、溫度等信號(hào)都由對(duì)應(yīng)的一次儀表傳感器或變送器檢測(cè)出來(lái)并轉(zhuǎn)變?yōu)?～20mA 電流信號(hào)，經(jīng)安全柵送入SLC500控制器的本地輸入模塊或DeviceNet網(wǎng)上的FlexI/O輸入模塊。控制信號(hào)由相應(yīng)的輸出模塊以4～20mA電 流形式控制氣動(dòng)調(diào)解閥。整個(gè)系統(tǒng)中輸入信號(hào)有8個(gè)界面高度傳感器；4個(gè)液位傳感器；4個(gè)溫度傳感器；10個(gè)壓力變送器，輸出信號(hào)有8個(gè)液位調(diào)解閥，7個(gè)壓 力調(diào)解閥。外輸油流量的測(cè)量是通過(guò)一次儀表把流量信號(hào)轉(zhuǎn)換為脈沖信號(hào)，經(jīng)屏蔽電纜傳輸?shù)絊LC的高速計(jì)數(shù)模塊，從而測(cè)得輸送到下個(gè)站的凈化油流量。
四、程序設(shè)計(jì)
控制系統(tǒng)的軟件設(shè)計(jì)由顯示操作程序和過(guò)程控制程序兩部分組成。顯示操作程序包括上位機(jī)和人機(jī)接口界面兩部分，上位機(jī)顯示操作采用羅克韋爾軟件的RSView32TM組態(tài)軟件，在上位計(jì)算機(jī)編制顯示控制程序，完成各種顯示、控制與生產(chǎn)報(bào)表等功能。人機(jī)接口界面使用PanelBuilder軟件編制界面顯示和控制程序，由此實(shí)現(xiàn)生產(chǎn)過(guò)程的遠(yuǎn)程監(jiān)視和控制。過(guò)程控制程序使用羅克韋爾軟件的Rslogix500 軟件編制SLC500控制程序，實(shí)現(xiàn)對(duì)生產(chǎn)過(guò)程的直接控制和數(shù)據(jù)采集。上位計(jì)算機(jī)與SLC500控制器之間是通過(guò)DH+網(wǎng)實(shí)現(xiàn)數(shù)據(jù)通信的。一方面將過(guò)程控 制中的參數(shù)傳送給上位機(jī)，用于存儲(chǔ)、顯示、制表、打印；另一方面將工作人員通過(guò)顯示操作站設(shè)置的控制參數(shù)發(fā)送給SLC500控制器。由控制器按操作員的要 求實(shí)現(xiàn)對(duì)生產(chǎn)過(guò)程的直接控制。
1.顯示操作程序設(shè)計(jì)
sview32TM軟件是羅克韋爾軟件公司提供的上位機(jī)組態(tài)軟件，通過(guò)編程可以實(shí)現(xiàn)監(jiān)控系統(tǒng)所需的人機(jī)界面。PLC采集的數(shù)據(jù)可以根據(jù)需要通過(guò)數(shù)字、圖 形、動(dòng)畫(huà)、等多種形式顯示出來(lái)，該軟件還具有存儲(chǔ)數(shù)據(jù)歷史紀(jì)錄、趨勢(shì)圖顯示、報(bào)警監(jiān)視和自動(dòng)生成報(bào)表和打印等功能。利用RSView32TM軟件的開(kāi)放式 設(shè)計(jì)還可以很容易地與Microsoft產(chǎn)品共享信息。
在油水分離控制系統(tǒng)中上位機(jī)和人機(jī)接口界面顯示操作程序都有：工藝參數(shù)顯示、各控制回路的ＰＩＤ調(diào)節(jié)、手/自動(dòng)控制切換、報(bào)警監(jiān)視等界面，其中工藝參數(shù)是以工藝流程圖的形式顯示的。另外上位機(jī)控制界面還有參數(shù)匯總、參數(shù)設(shè)置、歷史數(shù)據(jù)紀(jì)錄、趨勢(shì)圖、報(bào)表打印等界面。在編成時(shí)，充分利用RSView32TM軟件圖形處理能力強(qiáng)的優(yōu)點(diǎn)，繪制出形象直觀的工藝流程畫(huà)面。圖2是用RSView32TM軟件繪制 的游離水段和加熱爐段工藝流程圖，在工藝流程圖上直接顯示監(jiān)測(cè)點(diǎn)和控制點(diǎn)的位置和參數(shù)值。另外還將在RSView32TM軟件上繪制的流程圖導(dǎo)入PanelBuilder的程序中作為PanelView的背景圖，使上位機(jī)和人機(jī)接口界面以相同的畫(huà)面顯示，KULICKE & SOFFA 01483-4029-000-13這樣既實(shí)現(xiàn)了工作站與遠(yuǎn)程監(jiān)控界面的一致 性，又充分彌補(bǔ)了PanelBuilder軟件在圖形處理能力不強(qiáng)和漢字顯示不夠靈活方面的不足。在上位機(jī)和人機(jī)接口界面上都能圖文并茂的實(shí)時(shí)顯示過(guò)程變量和控制變量。
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RELIANCE ELECTRIC 0-52712-9 USPP 0527129
Details about ALTECH CORP LK11-U NSFP LK11U
Details about LEUZE RK-72/4-200-L.1 USPP RK724200L1
Details about AQUAFINE 19385-12 USPP 1938512
Details about SIEMENS TH70400676 USPP TH70400676
Details about KOGANEI SHM62J NSPP SHM62J
Details about FURNAS ELECTRIC CO T46 NSPP T46
WESTINGHOUSE QC2060 USPP QC2060
Details about DODGE 099123 USPP 099123
Mitsubishi Mazak CAM T FX01C BNA9G1A tested
Details about Micro Motion Basis 1/2" mass flow sensor IFT9701I6M1M transmitter F025S1113SM
WESTINGHOUSE PB1T1B USPP PB1T1B
DODGE P2BSXRB103 NSFP P2BSXRB103
Details about JACKES EVANS DIVISION 63CHMPRLRS14MC-150.0 USPP 63CHMPRLRS14MC15
RELIANCE ELECTRIC 802802-6RB USPP 8028026RB
Details about RELIANCE ELECTRIC ECNR-90 NSFP ECNR90
Details about PANASONIC 4LR44 NSFP 4LR44
Details about ITE SIEMENS HED42B035 USPP HED42B035
Details about CUTLER HAMMER E50-DT1 NSFP E50DT1
Details about UREMCO 7-7523 NSFP 77523
Details about FESTO ELECTRIC DNC-40-25-PPV USPP DNC4025PPV
Details about FURNAS ELECTRIC CO 42CF35AGAWW USPP 42CF35AGAWW
Details about FURNAS ELECTRIC CO 3TY7443-0AK6 NSPP 3TY74430AK6
Details about Filton 1in Rotary Joint Union Swivel dual flow high temp type CB/ST 14386
Details about DODGE 2012-X-I USPP 2012XI
WESTINGHOUSE PB1AAHAB NSFP PB1AAHAB
Details about STRUTHERS DUNN RELAYS 219-XBX-PM-120VAC NSFP 219XBXPM120VAC
Details about PYROTRONICS 500-033420 NSFP 500033420
Details about Pro-Face Proface Digital GP370-LG11-24V touch screen HMI 27505620131
Details about Nadex Phase 5 SCR spot weld welding controller contactor PH5 nadesco
Details about SQUARE D MHL360006M1625 NSFP MHL360006M1625
Details about ITE SIEMENS 5SY6-206-8 USPP 5SY62068
Details about ITE SIEMENS Q23020 USPP Q23020
WESTINGHOUSE PB1VQR NSFP PB1VQR
SICK OPTIC ELECTRONIC FGSE1050-111 NSFP FGSE1050111
Details about SIEMENS A5E02356504 NSPP A5E02356504
Details about SIEMENS 6FC5-247-0AA17-0AA0 USPP 6FC52470AA170AA0
Details about HOFFMAN ENCLOSURES A8N6P USPP A8N6P
Details about RELIANCE ELECTRIC 411627-02AJ NSFP 41162702AJ
Details about SIEMENS SFH19 NSFP SFH19
WESTINGHOUSE 1541A11G01 USPP 1541A11G01
Allen Bradley 440N-N15027 Guardmaster Sentinel 1 Safety Interlock Switch
Details about POWER ONE NRG3A35B1V5W3 NSFP NRG3A35B1V5W3
Details about DODGE 117167 USPP 117167
Details about KEYENCE CORP LS-5001 USPP LS5001
MITSUBISHI MC-1 USPP MC1
Details about BENDIX DYNAPATH 4200431 USPP 4200431
WESTINGHOUSE LA2600 USPP LA2600
Details about SQUARE D 2510-KG2C FNFP 2510KG2C
