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　煤氣在使用過程中容易產生管網壓力波動，存在不安全因素。煤氣柜作為調劑煤氣供應、減緩管道波動的有效方法，在冶金和化工等行業得到了廣泛的應用。煤氣柜可以有效回收放散煤氣，充分合理利用企業內部的附產煤氣，調節管網壓力。作為煤氣這個危險性氣體的“歸宿”，煤氣柜的安全運行對于全廠的生產安全具有重要意義。
　　山東金能科技股份有限公司是一家綜合性化工企業。多年來，公司秉承 “資源高效、綠色低碳”的循環發展理念，以技術創新為驅動、以資源高效利用為導向，打造了區別業內其他企業的循環經濟產業鏈，構建了資源利用、產品結構、技術裝備、環保模式四大差異化的盈利模式，實現了煤化工與精細化工的科學整合，做到了資源利用最大化與資源利用價值最大化。
　　由于金能科技現有的30000m2煤氣柜控制系統在設計時不具備硬件的冗余、容錯和復雜邏輯判斷等功能，當現場儀表出現顯性故障時，極易造成工藝事故。為提高全廠的安全水平，金能科技決定利用冗余控制技術，升級現有的煤氣柜監控系統。
　　挑戰
　　煤氣柜監控系統是智能自動化儀表技術、自動化控制系統、計算機技術和網絡技術等多種技術的結合，涉及到多方面的知識。新系統的設計需要重點解決現有系統面臨的以下三方面問題：
　　 故障安全：原有系統配置不能夠排除當現場儀表出現故障或假液位造成的顯性故障，易造成工藝事故。
　　 傳感器的獨立設置：對參與聯鎖的各個傳感器(如活塞高度、氣柜內壓力等值)配置為單臺測量，未使用不同的測量方式，不符合傳感器冗余設置三選二的原則。
　　 硬件的冗余、容錯：模塊前期設計時，未考慮PLC模塊的冗余、容錯設計，如發生儀表的損壞、模塊損壞、電源異常斷電等故障時，極易造成工藝事故。
　　解決方案
　　針對金能科技干式煤氣柜實際情況，基于羅克韋爾自動化組態技術和人機界面檢測技術，金能科技構建了現代化的煤氣柜監控系統，并與原有控制系統實現了無縫的融合與兼容。
　　項目總體實施過程包括五個步驟：氣柜監控監測系統總體的方案設計;氣柜監測系統邏輯關系模型的建立;冗余、容錯目的的達成，及數學模型的建立;完成氣柜監測系統軟件部分的組態設計與開發;最終系統的聯調聯試以及持續改進。
　　新系統采用由羅克韋爾自動化PLC冗余控制系統結構，基于ContrlNet協議、工業以太網協議等通信方式，實現了傳感器、電源、控制單元以及通信的冗余設置，控制精度達到毫秒級，保證系統安全可靠運行。可以完成對現場活塞高度、氣柜內部壓力、油槽液位、頂部泄漏量的數據的采集和進出口閥門等閥門的過程控制。對于輸入、輸出模擬量信號通過加裝防爆安全柵(一入兩出)進行現場與控制系統的安全有效隔離，現場檢測信號一分為二，一路進原有系統顯示報警，另一路進本系統參與聯鎖控制，雙重保證檢測信號的穩定性和安全性。系統所有開關量輸入、輸出信號都通過隔離繼電器隔離，保證測點的干接點輸入和輸出。

SIEMENS SIMODRIVE 6SN1145-1AA01-0AA2

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Allen-Bradley PanelView 1200 Operator Interface 2711TC1MC

Allen-Bradley 1756-0B16I OUTPUT MODULE IN BOX

ABB ACS550-U1-125A-4 AC INVERTER DRIVE 100HP 75KW 3PH 48..63HZ 380...480VAC

ACCURAY 083883-004 USPP 083883004

YSS225-F QTY 50 YAMAHA RARE AND PARTS YSS225 YSS225F

75 HP Rotary Phase Converter with Nema 3 Outdoor Enclosure and Digital Control

INDRAMAT MDD112D-N-030-N2M-130PB0 USPP MDD112DN030N2M1A

VEE ARC 931-048 USPP 931048

FANUC A06B-6055-H112 USPP A06B6055H112

DVT 630-C3E40 USPP 630C3E40

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NEMATRON CORP ICC-5000-01 USPP ICC500001

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Siemens 6ES5-858-0AA11 USPP 6ES58580AA11

SIEMENS 6ES5-377-0AB41 NSPP 6ES53770AB41

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Siemens S5 6ES5 095-8MA03

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WS-X6724-SFP CISCO Gigabit Interface Module 6500/7600 24 ports

Siemens 6ES7 332-5HD01-0AB0 6ES73325HD010AB0

Siemens PLC CPU 221 6ES7 211-0BA23-0XB0 CPU221 NIB FS

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Schneider Modicon ADU-212/AS-BADU-212 Univ Analog in Bplane Pwr ADU212 ASBADU212

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Schneider Modicon AS-B370-001 Register Output ASB370001

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SIEMENS 6DD1-660-0AK0 USPP 6DD16600AK0

SIEMENS Simens Sinumerik 802SE MembraKeypad Free Ship

SIEMENS 6SN1-111-0AA00-0BA1 NSPP 6SN11110AA000BA1

SIEMENS Simodrive 6SC6101-2A_6SC61012A_6SC61O1-2A_6SC61O12A_T 128M123

SIEMENS 802S 6FC5500-0AA00-1AA0 Membrane Keypad 6FC5 500-0AA00-1AA0

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ALLEN-BRADLEY 1771-OWNA CONTACT OUTPUT MODULE 1771-0WNA

ABB ACS550-U1-023A-4+B055 DRIVE IN A

ACTUS POWER NPSA-20NN-51 NPSA20NN51 Nikki Denso

6ES7431-1KF20-0AB0 Brand , Factory Sealed,

900' 3/0 3/0 1/0 Hollins Aluminum URD Cable Triplex 600 volt USE XLP

SQUARE D ATV-58EU54N4 NSFP ATV58EU54N4

CAMCO 60-500RGDH40-90-90-90-90 USPP 60500RGDH4090909

BANNER ENGINEERING SLSP14900Q88 NSFP SLSP14900Q88

MODICON MMPMF2-400 USPP MMPMF2400

LANDIS & GYR 545-797 NSFP 545797

DATALOGIC MATRIX-2055 NSFP MATRIX2055

Siemens 6ES5 095-8MD02 6ES50958MD02

Siemens 6ES5-464-8MA21 USPP 6ES54648MA21

SIEMENS 6ES5 941-7UA12 6ES5941-7UA12 115U CPU 941

SIEMENS S5 6ES5 951-7LB14 6ES59517LB14

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Siemens 6ES7315-1AF01-0AB0 CPU315 6ES73151AF010AB0

Siemens Simodrive C98043-A1204-L Control Board

Siemens 6ES5256-3AA11

HP/Agilent 54657A MEASUREMENT / STOREGE HP-IB INTERFACE module for 54600 Series

XpressKIT Interface and Bypass Modules from Directed Electronics PKFM

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Omron CJ1W-OD212

Schneider Modicon AS-BDEP-211 INPUT MODULE FACTORY SEALED

Schneider Modicon AS-212P-210 USPP AS212P210

Schneider Modicon AS-J830-001 MODULE INTERFACE 884/800 ASCII

Schneider Modicon AS-506P-F12 CNC Memory Board Rev C17 (UVG)

Schneider Modicon DEP216/AS-BDEP-216

Schneider Modicon /AS-P451-622 Remote I/O Processor UVG

SIMATIC S7 INPUT MODULE S7300 16DI 48-125VDC EXT 6ES7 321-1CH80-0AA0

Schneider TSX08EAV8A2 Telemecanique NESA PLC NIB

Siemens TB16 SC Terminal block 6ES7120-0AH00-0AA0

SIEMENS 505-4816 AC OUTPUT MODULE 5054816

SIEMENS Sinumerik 802S 802C Mechanical Keypad

Delta DeviceNet DN-02 Communication Module

SIEMENS SIMODRIVE E/R MODUL INT. 36/47KW 6SN1145-1BA02-0CA0

SIEMENS SIMODRIVE 6SN1145-1BA01-0AA1SINUMETIK 840D NCU-BOX 6FC52476FC5356 2BO

Advantech AIMB-212

ALLEN-BRADLEY 77131-015-51 Hardware Kit

ABB 3BSE018104R1 AC 800M Processor PM856 K01 XLNT PM856K01

ACCURAY 064892-002 USPP 064892002

A06B-6079-H106 FANUC SERVO AMPLIFIER REMANUFACTURED Refurbished

800A GE Low Voltage Power Circuit Breaker E/O D/O

SIEMENS 6DD1-606-1AA0 USPP 6DD16061AA0

ALLEN BRADLEY SA3100-B020-AA-L6R USPP SA3100B020AAL6R

ALLEN BRADLEY 6181-AAECBCEZZ USPP 6181AAECBCEZZ

KLOCKNER MOELLER DIL10AM/22 NSFP DIL10AM22

GIDDINGS & LEWIS 401-34401-00 USPP 4013440100

YASKAWA ELECTRIC USASEM-35TV12 USPP USASEM35TV12

OMRON NT20M-DT125E NSPP NT20MDT125E

Siemens 6ES5-314-3UR11 USPP 6ES53143UR11

SIEMENS 6ES5 434-7LA12 DIGITAL INPUT MODULE

SIEMENS S5 6ES5 712-8BF006ES57128BF00

Siemens Interface Controller Part 6ES5 605-0UB11

Siemens 6ES7 223-1PH00-0XA0 6ES7223-1PH00-0XA0 FreeShip

Siemens OP37 6AV3637-1ML00-0CX0 Membrane Keypad ping Worldwide

Quantum 8pt Thermoc Input Module model 140 ATI 030 00

Genuine Cisco VIC-2FXS 2-Port Voice Interface Card/VOIP Router Module

TEXAS INSTRUMENTS TI 500-5038 NETWORK INTERFACE MODULE

Siemens 2M MMC 6ES7 953-8LL20-0AA0 6ES79538LL200AA0 NIB

Siemens EPROM 64KB 6ES5376-1AA31

Modicon PC-A984-120

Schneider Modicon High Speed Counter Module AS-BZAE-204 ++

Schneider Modicon AS-BDEP-218 SEALED 16 Pt 115VAC ASBDEP218

Schneider Modicon AS-C916-100 USPP ASC916100

Schneider Modicon AS-J890-001

Schneider Modicon NUL 200/ AS-BNUL-200 ASBNUL200

Schneider Modicon MEMORY CARTRIDGE AS-M780-032

Schneider Telemecanique XB4-BL42 Push Button Switch

Schneider 140CPU53414A Modicon Quantum 95%

PROTECH PS-6509 15" TERMINAL MSR POS READY ALDELO

SIEMENS 6ES5 470-8MC12 ANALOG OUTPUT MODULE

SIEMENS 6DD1-684-0BH1/6DD1684-0BH1 RIBBON CABLE APPROX. 2 METERS XLNT

IC610CCM105D GE Fanuc data Communication Module

SIEMENS SIMODRIVE 6SN1145-1BA01-0AA1SINUMETIK 840D NCU-BOX 6FC52476FC5356 #2BO

SIEMENS SINUMERIK 820 T 6FC3261-1AC-Z CONTROL PANEL 5703029301.00 TESTED

SIEMENS MOORE PRODUCTS 15484-11-4 PC BOARD APACS RFB

Allen-Bradley PanelView 900 2711-K9C3 Series C Revision B WARRANTY

54645D 100MHz Mixed Signal Oscilloscope, all Accessories, Calibrated,

ABB Soft Start PTSB 570-600-70 (1SFA894017R7000)

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7030WS-DS21 VEE ARC CONTROLLERS REMANUFACTURED

RELIANCE ELECTRIC 0-52501-1 USPP 0525011

ALLEN BRADLEY 1785-L20E NSPP 1785L20E

ALLEN BRADLEY 1336VT-B025-EOP-FA2-L1 USPP 1336VTB025EOPFA2

GENERAL ELECTRIC DS3800NHVE1C1A USPP DS3800NHVE1C1A

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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

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RME HAMMERFALL HDSP 9632 HDSP9632 PCI SOUND CARD

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Wago 750-316 MODBUS FIELDBUS COUPLER

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Modicon AS-T190-401

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Schneider Modicon AS-9385-001

Schneider Modicon OUTPUT MODULE AS-B804-116 ASB804116

Schneider Modicon AS-P120-000 PLC Power Supply PS

SCHNEIDER AUTOMATION 8-POINT OUTPUT MODULE TSX-DST-882 TSXDST882

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SIEMENS SINUMERIK SIROTEC MODULE 6FX1190-1AA00

Omron PLC Module CJ1W-SCU21-V1 CJ1WSCU21V1 Serial Communications

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

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

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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

SIEMENS 6FX1-113-2AA01 USPP 6FX11132AA01

SEIKO-SEIKI EL6535-10098 USPP EL653510098

YOKOGAWA 371122-B-O/D USPP 371122BOD

Siemens 6ES5 700-2LA11 6ES57002LA11

Siemens Power Supply 6ES5 951-7LD12 V5 NIB OPENED FOR PICTURES

SIEMENS 6ES5-458-7LB11 NSFP 6ES54587LB11

Siemens 6ES5 421-8MA11 USPP 6ES54218MA11

Siemens S5 PLC 6ES5 431-8MA11 Input E-Stand 2

SIEMENS CPU 224 6ES7-214-1BD22-0XB0 6ES72141BD220XB0 Worldwide

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

Square D 8030 RIM-101

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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

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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

SIEMENS 6ES5-385-8MA11 USPP 6ES53858MA11

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

Siemens S5 6ES5 318-8MB12 ET200U

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Reliance 0-56313-1