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MC LC
CHNG 1. TNG QUAN .................................................................................... 8
1.1. Tng quan nh my PMPC. .................................................................................. 8 Tm tt tnh hnh nh my. ............................................................................... 8 S tng qut nh my v v tr a l nh my: ............................................ 9 S tng qut nh my: ........................................................................... 9 V tr a l nh my: ................................................................................. 10 1.1.1. 1.1.2.

1.1.2.1. 1.1.2.2. 1.1.3. 1.1.4. 1.2.

S cng ngh sn xut PVC: ...................................................................... 11 Sn phm: ........................................................................................................ 14

C cu nhn s:.................................................................................................... 15

CHNG 2. H THNG DCS TRONG NH MY PMPC. ..........................16

2.1. Gii thiu v h thng iu khin trung tm DCS............................................ 16 S ra i ca h thng iu khin trung tm DCS. ........................................ 16 Khi nim DCS (Distributed Control System): .............................................. 17 Phn loi cc h DCS. ..................................................................................... 18 Cc h DCS truyn thng. ........................................................................ 18 Cc h DCS trn nn PLC. ....................................................................... 19 Cc h DCS trn nn PC. ......................................................................... 19 2.1.1. 2.1.2. 2.1.3.

2.1.3.1. 2.1.3.2. 2.1.3.3. 2.1.4. 2.2.

u im ca DCS: .......................................................................................... 20

DCS CENTUM CS3000. ...................................................................................... 20 Gii thiu chung. ............................................................................................. 20 Cu trc c bn ca h thng CENTUM CS3000. ......................................... 21 Quy m h thng. ..................................................................................... 22 Trm vn hnh. ......................................................................................... 23 Trm iu khin-control station. .............................................................. 24

2.2.1. 2.2.2.

2.2.2.1. 2.2.2.2. 2.2.2.3. 2.3.

S v chc nng h thng DCS CS3000 trong nh my PMPC................ 25 S khi DCS trong PMPC. ........................................................................ 25 S tng qut h thng DCS trong nh my PMPC : .................................. 28 Trang 1

2.3.1. 2.3.2.

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H THNG DCS CENTUM CS3000 2.3.3.

NGI HDTT: Mr . TRN MINH NHT

Cc h thng ph tr. ...................................................................................... 30 Hygiene Monitoring System ( h thng gim st v sinh ). ..................... 30 Firing and Gas detection ( F & G ) :......................................................... 32 High Integrated Safety System ( HISS ) : ................................................ 34 VCM Metering System : .......................................................................... 36 Electrical Integrated Monitoring System (EIMS): ................................... 38 Packaged Equipment (PLC) : ................................................................... 41

2.3.3.1. 2.3.3.2. 2.3.3.3. 2.3.3.4. 2.3.3.5. 2.3.3.6. 2.3.4. 2.3.5. 2.4.

Mt s s kt ni dy trong h thng nh my: ........................................ 43 Mt s chc nng iu khin c trng ca DCS trong PMPC. .................... 53

Thc tp site. ........................................................................................................ 53

CHNG 3. TM TT V KT LUN ...........................................................54

3.1. 3.2. Tm tt kt qu thc tp: .................................................................................. 54 Kt lun. ................................................................................................................ 54

TI LIU THAM KHO .......................................................................................55

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DANH MC HNH
HNH 1: Biu c ng nh my ....................................................................................... 9 HNH 2:S tng qut nh my PMPC ............................................................................. 9 HNH 3:Bn nh my PMPC Tnh B Ra Vng Tu ................................................ 10 HNH 4:Bn v tr nh my PMPC trong khu cng nghip Ci Mp ............................ 11 HNH 5:M hnh sn xut nha PVC ca nh my PMPC ................................................ 12 HNH 6 : Biu PVC tiu th ti Vit Nam ..................................................................... 14 HNH 7 : Qu trnh pht trin DCS CENTUM ................................................................... 16 HNH 8:Cu trc h thng iu khin trung tm DCS ....................................................... 18 HNH 9:Cc thnh phn chc nng chnh ca mt PLC..................................................... 19 HNH 10:M hnh h thng ca h thng CENTUM CS 3000 .......................................... 20 HNH 11:Cu trc c bn ca h thng CENTUM CS3000. ............................................. 22 HNH 12:Cc dng ca trm HIS ........................................................................................ 23 HNH 13:Cc trm iu khin FCS cun h thng CENTUM CS3000 ............................. 24 HNH 14: Cc cng u ni trong t FCS .......................................................................... 27 HNH 15: S h thng DCS CENTUM CS3000 trong nh my PMPC ....................... 29 HNH 16 : S kt ni h thng ph tr vi FCS ............................................................ 30 HNH 17: Hygiene Monitoring System vi ACM 12 ......................................................... 31 HNH 18 : Firing and Gas detection ( F & G )vi ACM 12 ............................................... 33 HNH 19: High Integrated Safety System ( HISS ) vi ACM 11 ....................................... 35 HNH 20: VCM Metering System vi ACM12 .................................................................. 37 HNH 21: Electrical Integrated Monitoring System (EIMS) vi ACM 12 ......................... 39 HNH 22:Cng kt ni packaged equipment vi ACM12 .................................................. 41 HNH 23: S kt ni dy vng h ca h thng gim st an ton cp cao (HISS)........ 44 HNH 24:S kt ni dy vng kn thit b iu khin lu lng (FV) .......................... 45 HNH 25: S kt ni dy vng h hin th thit b o dng chy.(FI)........................... 46 HNH 26: S kt ni dy vng h hin th thit b mc cht lng mc thp (LA) ....... 47 HNH 27: S kt ni dy vng kn hin th tn hiu iu khin p sut ........................ 48 HNH 28 : S kt ni dy vng h hin th nt nhn trong DCS .................................. 49 HNH 29 : S kt ni dy vng kn hin th tn hiu iu khin tc thit b. ........... 50 HNH 30 : S u dy vng h hin th tn hiu thit b ng gi trong sn xut......... 51 HNH 31 : S u dy vng h bo hiu c s c trong khu vc ng gi. ................. 52

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DANH MC BNG
BNG 1: Tng quan nh my .............................................................................................. 8 BNG 2 :Hygiene Monitoring System .............................................................................. 31 BNG 3: Setting Items specification From system view. (Hygiene Monitoring System) 31 BNG 4: F & G module configuration .............................................................................. 33 BNG 5:Setting Items specification From system view ( F & G) .................................... 33 BNG 6 : HISS module configuration .............................................................................. 35 BNG 7 .Setting Items specification From system view (HISS) ...................................... 36 BNG 8 : VCM metering system module configuration................................................... 37 BNG 9 : Setting Items specification From system view (VCM metering system) ......... 38 BNG 10 : EIMS module configuration............................................................................ 39 BNG 11 : Setting Items specification From system view (EIMS) .................................. 40 BNG 12 : Packaged Equipment ( PLC ) module configuration ..................................... 41 BNG 13 :Setting Items specification From system view Packaged Equipment ( PLC) .. 42

DANH MC VIT TT
PMPC VCM DCS F&G PC PHUMY PLASTICS &CHEMICALS VINYL CHLORIDE MONOR Distributed Control System FIRE & GAS Personal Computer PLC TNHH KCN PVC DDC Programmable Logic Control Trch Nhim Hu Hn Khu Cng Nghip Polyvinyl Chloride Direct Digital Control

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BNG TRA
INSTRUMENTATION GENERAL INSTRUMENT TYPE / LETTER CODING CH CI U TIN (CC CCH BIN I) A : ANALYSIS B : FLAME F : FLOW KW : POWER J : ENERGY L : LEVEL P : PRESSURE S : SPEED T : TEMPERATURE Tq : TORQUE E : POWER/CURRENT/VOLTAGE U : COMMON V : VIBRATION W : WEIGHING X : UNCLASSIFIED Z : POSITION CH CI PHA SAU (MT HAY NHIU ) T : TRANSMITTER I : INDICATOR R : RECORD ( TO HARD RECORDER ONLY ) C : CONTROL A : ALARM Q : INTEGRATOR G : GAUGE S : SWITCH Y : SELECTOR D : DIFFERENTIAL E : MEASURING ELEMENT V : VALVE

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MISCELLANEOUS OTHER ITEMS OF INSTRUMENTATION / CONTROL EQUIPMENT ( CC S XO TRN KHC TRONG MT VI THIT B/ TRONG IU KHIN THIT B) XV : ON-OFF VALVE PV/TV/FV : CONTROL VALVE M : MOTOR DRIVER HS : MANUAL ( ON OFF ) SWITH HV : HAND VALVE PB : PUSH BUTTON ZS : LIMIT SWITH ALARM SYSMBOLS(N BO H THNG) HH : HIGH HIGH H : HIGH L : LOW LL : LOW LOW

Cc k hiu:

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CHNG 1.
1.1.

TNG QUAN

Tng quan nh my PMPC.

1.1.1. Tm tt tnh hnh nh my.

Cng Ty TNHH Nha v Ha Cht Ph M( Phu My Plastics and Chemicals Co. Ltd) (PMPC ) : KCN Ci Mp ,Tn Thnh B Ra Vng Tu -Vit Nam

BNG 1: Tng quan nh my

Ngy thnh lp Tng vn u t Nhn lc Cng sut thit k Sn phm Cung cp cng ngh Nh thu chnh Tng din tch nh my Ngy khi cng Hon thin lp t Sn phm a ra th trng Ngy khnh thnh t chng ch ISO 9001:2000 C ng nh my 8/8/1997 70 triu USD 142 ngi 100.000 tn/nm ht nha PVC Inovyl ,EVC, Europe Samsung Eng.,S.Korea 15ha 6/2001 7/2002 8/2002 10/2002 2/2004 Petronas 93% ; Vng tu Shipyard 7%

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HNH 1: Biu c ng nh my

1.1.2. S tng qut nh my v v tr a l nh my: 1.1.2.1. S tng qut nh my:

HNH 2:S tng qut nh my PMPC

Nh my nha v ha cht Ph M c phn ra 2 khu vc chnh bao gm : Khu vc khng sn xut: o Khu vc nh hnh chnh : ni iu hnh v qun l nhn s. GVHDTT: ThS . NGUYN L TNG Trang 9

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o Khu vc phi sn xut : ni ng gi v lu tr sn phm. Khu vc sn xut. o Khu lu tr kh VCM(nhin liu). o Khu cng ngh. o Khu tin ch. o V tr bn nc

1.1.2.2. V tr a l nh my:
Nh my Nha v Ha Cht Ph M thuc khu cng nghip Ci Mp , huyn Tn Thnh tnh B Ra Vng Tu. Hnh 3 .V tr nh my cng vi cc thnh ph ln trong khu vc pha Nam : HO CHI MINH CITY , BIEN HOA CITY , VUNG TAU CITY ,PMPC PVC PLANT.

HNH 3:Bn nh my PMPC Tnh B Ra Vng Tu

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Hnh 4 V tr nh my PMPC PVC PLANT v cc nh my ln cn gn khu vc sng Th Vi.

HNH 4:Bn v tr nh my PMPC trong khu cng nghip Ci Mp

1.1.3. S cng ngh sn xut PVC:

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S cng ngh sn xut PVC ( t tri sang phi):

HNH 5:M hnh sn xut nha PVC ca nh my PMPC

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Quy trnh cng ngh sn xut PVC t VCM

VCM lng (Nhin liu chnh )

VCM

Nc khong Bn phn ng Ha cht & cht xc tc

PVC nho Kh VCM d

Bn thu hi kh VCM d

Hi nc nng

Ct lng bt nho
PVC nho sau khi lng

Bm ly tm

Nc

Hi Nc Nng & Kh Nng

PVC m

H thng sy

Kh X

Bt PVC c lm kh

Bt PVC (sn phm)

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Cc phn ng ha hc to ra PVC

1.1.4. Sn phm:
Ht nha PVC ( Polyvinyl Chloride): t l tiu th ti Vit Nam

HNH 6 : Biu PVC tiu th ti Vit Nam

Ht nha PVC c c tnh l ha l tng cho nhiu loi sn phm khc nhau p ng hu ht nhu cu cuc sng. nh: Trong ng gi: chai nha, bao b thc phm, thng ng cht ty ra Trong y t: b thit b truyn mu, ti plasma, cc ng dn Trong cng ngh t: thng tay, cc b phn trong b li hp, bc gh Trong may mc: o ma, o bi cu h, o phn quang, gi da, giy, ng Trong xy dng: h bi, th tn dng, bn phm my tnh, ng nha, khung ca

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1.2.

C cu nhn s:

C cu t chc qun l ca nh my PMPC General Director Tng Gim c

Deputy GD Ph TG Nh My My

HRD Phng Nhn S

Deputy GD Ph TG Ti chnh

Deputy GD Ph TG - i ngoi

General Manager Trng phng Tng hp Kinh doanh

Marketing Dept

HSE Dept Phng An Ton

Operation Dept Phng Vn Hnh

Engineering Dept Phng K Thut

Technical Support Dept

PWH & Logistics Kho thnh phm &vn

Finance Dept

Admin Dept Phng Hnh Chnh

Phng Kinh Doanh Procurement Dept Phng Vt t

Phng H tr KT

ti

Phng Ti Chnh

Shift No.1

Shift No.2

Shift No.3

Shift No.4 Ca 4

Shift No.5 Ca 5

Electrical Section T in

I&C Section T Thit b t ng

Mechanical Section T C Kh

ThS L Ca 1 GVHDTT:Ca 2 . NGUYNCa 3TNG

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CHNG 2. H THNG DCS TRONG NH MY PMPC. 2.1. Gii thiu v h thng iu khin trung tm DCS. 2.1.1. S ra i ca h thng iu khin trung tm DCS.

HNH 7 : Qu trnh pht trin DCS CENTUM

Sn phm DCS u tin l h TDC2000 do Honeywell v Yokogawa a ra u tin vo nm 1975. T ti nay, cc sn phm DCS lin tc c pht trin v tin ho. DCS s dng b iu khin s a vng lp thc hin iu khin. DCS tri qua trong 33 nm qua v c nhiu s thay i. Nhng g l h thng iu khin n gin trc y l h thng h tr ra quyt nh v t quyt nh. Ngi s dng mun h thng a con ngi cng cc vai tr l mt k s, nh qun l, bo dng, lp k hoch, mi trng v dy chuyn cung cp lin kt vo qu trnh. Chng ta mong mun thu thp nhiu d liu hn, lu tr lu hn v bin n thnh thng tin hu ch. Chng ta cng mun thng bo cc vn trn c s c bit vi mt cch thc hp l ti ng ngi khng ch l ngi vn hnh v t ng ra nhng quyt nh phc tp nh ti u ha qu trnh thi gian thc. GVHDTT: ThS . NGUYN L TNG Trang 16

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2.1.2. Khi nim DCS (Distributed Control System):

Distributed Control System H thng iu khin trung tm H thng iu khin trung tm da trn cc phn cng v phn mm iu khin v thu thp d liu trn c s 1 ng truyn thng tin tc cao, cc module c phn tn v t chc theo 1 cu trc nht nh vi mt chc nng v nhim v ring. Cc thit b giao tip trn ng truyn tc cao ny cho php ghp ni d dng vi cc b PLC, Controller , cc my tnh iu khin gim st khc. H thng iu khin trung tm DCS c th c hiu l h thng iu khin

trong chc nng iu khin c phn b khp h thng. Mt h thng DCS tiu biu c cc trm iu khin hot ng c lp v iu khin tng b phn chuyn dng ca nh my. Cc chc nng iu khin c phn b khp h thng thay v x l tp

trung trn mt my tnh n l. Mt h thng DCS tiu biu c cc trm iu khin hot ng c lp v iu khin tng b phn chuyn dng ca nh my Kh nng x l tn hiu tng t v chy cc trnh t phc tp l th mnh

ca h thng DCS.

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HNH 8:Cu trc h thng iu khin trung tm DCS

2.1.3. Phn loi cc h DCS. 2.1.3.1. Cc h DCS truyn thng.

Cc h ny s dng cc b iu khin qu trnh c chng theo kin trc ring ca nh sn xut. Cc h c thng ng kn, t tun theo cc chun giao tip cng nghip, cc b iu khin c s dng cng thng ch lm nhim v iu khin qu trnh, v vy phi

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s dng kt hp PLC cho cc bi ton iu khin logic v iu khin trnh t. Cc h mi c tnh nng m tt hn, mt s b iu khin lai m nhim c cc chc nng iu khin qu trnh, iu khin trnh t v iu khin logic (hybrid controller).

2.1.3.2. Cc h DCS trn nn PLC.

Vi cu trc ghp ni vo/ra linh hot, nguyn tc lm vic n gin theo chu k, kh nng lp trnh v lu tr chng trnh trong b nh khng cn can thip trc tip ti phn cng, PLC nhanh chng thu ht s ch trong gii chuyn ngnh. Vo thi im cc my tnh iu khin chuyn dng v khng chuyn dng u c kch c rt ln v gi thnh rt cao, th vic s dng PLC l gii php l tng thay th cc mch logic t hp v tun t rong iu khin cc qu trnh gin on.

HNH 9:Cc thnh phn chc nng chnh ca mt PLC

2.1.3.3.

Cc h DCS trn nn PC.

DCS trn nn PC l mt hng gii php tng i mi, mi c mt s sn phm trn th trng nh PCS7 (Siemens, gii php Slot-PLC), 4Control (Softing), Stardom (Yokogawa), Ovation (Westinghouse-Emerson Process Management) Hng gii php ny th hin nhiu u im v mt gi thnh, hiu nng tnh ton v tnh nng m. Mt trm iu khin cc b chnh l mt my tnh c nhn cng nghip c ci t mt h iu hnh thi gian thc v cc card giao din bus trng v card giao din bus h thng. Trong gii php iu khin dng my tnh c nhn th mt vn thng rt c quan tm l tin cy ca my tnh. Mt phn ta c th yn tm bi vi cu trc vo/ra phn GVHDTT: ThS . NGUYN L TNG Trang 19

H THNG DCS CENTUM CS3000

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tn, my tnh iu khin c t trong phng iu khin trung tm vi iu kin mi trng lm vic tt. Mt khc, trn th trng cng c rt nhiu loi my tnh c nhn cng nghip, m bo tin cy cao khng km mt PLC. Mt khi my tnh ch c ci t h iu hnh v phn mm iu khin th kh nng gy li do phn mm cng s c gim thiu.

2.1.4. u im ca DCS:
Bao gm nhiu b phn tch hp/kim tra trc v c b nh lu tr d liu v thng tin ring. Chnh iu ny m rng HMI v iu khin truyn thng sang cc lnh vc chc nng khc nh cc h thng thit b an ton, tch hp h thng in v ti u ha ti sn.

2.2. DCS CENTUM CS3000. 2.2.1. Gii thiu chung.

T nm 1997, Yokogawa la chn cc gii php cng ngh ETS Enterprise Technology Solutions cho nhng khi nim kinh doanh mi. ETS m bo cho mc ch cung cp cc gii php ti u trn quan im qun l doanh nghip tho mn mi yu cu ca khch hng v s hy vng vo trnh pht trin ca khoa hc k thut trong phm vi t cp iu khin n cp qun l thng tin doanh nghip. L sn phm ct li ca h thng iu khin qu trnh trong cc gii php ETS, Yokogawa gii thiu h thng iu khin tch hp CENTUM CS3000 h thng iu khin qu trnh quy m ln.

HNH 10:M hnh h thng ca h thng CENTUM CS 3000

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p ng yu cu h thng m, h thng s dng h iu hnh Windows NT cho giao din ngi dng Human Interface. Cc chc nng iu khin ca h thng c thit lp m bo s tin cy ca h thng. S thay i mnh m trong c cu t chc ca cng nghip sn xut, ch to thc y nhu cu ci tin sn xut gim nhn cng, tng hiu qu v cc yu t thun li cho sn xut. Mt khc, vn hnh nh my an ton, cng khng th b qua vic tng tin cy v s an ton trong sn xut. Nhim v ca h thng iu khin qu trnh nhm n gin ho cc thao tc iu khin qu trnh, nhng khi c s pht trin mnh m trong lnh vc cng ngh thng tin th yu cu hin nay i hi cn c s trao i thng tin gia h thng qun l v h thng sn xut. Trong xu hng pht trin chung, h thng cu trc m s dng cc chun ph bin tr thnh yu cu kh quan trng. Vo nm 1997, Yokogawa gii thiu h thng iu khin phn tn CENTUM CS1000 cho cc nh my nh v trung bnh. CENTUM CS1000 l mt h thng DCS m, s dng h iu hnh Windows NT. Hin nay, h thng CENTUM CS3000 c pht trin t h CENTUM CS1000 l mt h thng iu khin qu trnh thch hp vi quy m nh my ln. K tha v pht trin cc c im ca nhng h CENTUM trc , h thng CENTUM CS3000 cung cp cho ngi dng nhng thun li c bn sau: Tng hiu qu vn hnh sn xut bng h thng a ca s theo di v kh nng cp nht cng ngh mi. Kt ni thng tin ca cp iu khin gim st vi h thng thng tin thuc cp iu hnh. Pht trin mnh kh nng t ng ho v iu khin.

2.2.2. Cu trc c bn ca h thng CENTUM CS3000.

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HNH 11:Cu trc c bn ca h thng CENTUM CS3000.

2.2.2.1. Quy m h thng. S vng iu khin ti a S trm ti a cho mt vng iu khin S trm ti a trong h thng S i tng qun l ti a : 16 vng : 64 trm (16 trm HIS ti a) : 256 trm : 100.000 tag.

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2.2.2.2. Trm vn hnh.

Trong h thng CENTUM CS3000, cc trm vn hnh OS thng c lin quan n cc giao din ngi my HIS (Human Interface Stations). HIS c s dng ch yu cho vic vn hnh v gim st: theo di s thay i ca cc thng s qu trnh, cc gi tr iu khin v a ra cc cnh bo khi cn thit ngi vn hnh c th nm bt nhanh chng trng thi vn hnh ca qu trnh sn xut. HIS cho php kt hp vi cc giao din m cc my tnh gim st c th truy cp vo h thng c s d liu, thng tin sn xut. Vic s dng h iu hnh Windows NT cho php HIS c th h tr cc chc nng h thng thng thng v cc ng dng kinh doanh thng dng khc nh MS Excel nh thc hin cc chc nng gim st v vn hnh. ng thi, HIS s dng kh nng cp nht d liu tc cao trong cc iu khin p sut v lu lng.

HNH 12:Cc dng ca trm HIS

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2.2.2.3. Trm iu khin-control station.

Cc trm iu khin trong h thng CENTUM CS3000 c gi l cc trm iu khin hin trng FCS Field Control Station. y l trung tm ca mi h thng iu khin v l thit b cn thit dng cho vic iu khin nh my lin tc do FCS x l cc chc nng iu khin qu trnh lin tc hay theo nhm trong h thng CENTUM CS3000.

HNH 13:Cc trm iu khin FCS cun h thng CENTUM CS3000

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H THNG DCS CENTUM CS3000

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Cc trm FCS s dng cc giao din truyn thng kt ni h thng vi cc thit b logic kh trnh PLC hoc cc thit b thu thp d liu DAU Data Acquisition Units (nh khi thu thp d liu Darwin ca hng Yokogawa). C 2 dng FCS trong h thng CENTUM CS3000 nhm p ng yu cu sn xut: Dng FCS chun - Standard FCS (nh LFCS v KFCS) v Dng FCS thu gn SFCS - Compact FCS (nh SFCS). Dng Standard FCS: hai dng Standard FCS: LFCS Standard FCS for RIO v KFCS Standard FCS for FI/O. LFCS s dng cng ngh bus RIO (Remote I/O bus) cho vic lin h gia FCS vi cc nt vo/ra, cn KFCS s dng cng ngh bus ESB (Extended Serial Board) v ER(Enhanced Remote) cho s kt ni trn. LFCS thch hp cho cc h thng iu khin vi s lng ln cc im vo/ra. Vi KFCS thch hp cho cc h thng iu khin i hi tc cao. Dng Compact FCS: b iu khin SFCS thng c t gn cc thit b hoc h iu khin qu trnh, v l gii php l tng cho vic lin kt vi cc h thng ph.

2.3. 2.3.1.

S v chc nng h thng DCS CS3000 trong nh my PMPC. S khi DCS trong PMPC.

Nh my PMPC s dng h iu khin tp trung DCS CENTUM CS3000 bao gm nhng thnh phn chnh : Phn cng : gm cc cng vo ra(IN/OUT) v cc u u ni. Phn mm : gm cc khi chc nng , s u dy , cc biu hiu ng , biu lit k , c tnh cc thit b ph , mu bo co , v s kim sot. S kim sot h thng: kim sot v bo co tnh hnh h thng .

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H THNG DCS CENTUM CS3000 S DCS ( CENTUM CS3000)

NGI HDTT : Mr. TRN MINH NHT

HARDWARE (PHN CNG)

I/O LIST & TERMINAL ALLOCATION (LIST I/O V CC U NI)

DCS FUNCTIONAL SPECIFICATION (KHI CHC NNG CA DCS)

DDC LOOP DIAGRAM (S VNG DDC) GRAPHICS SPECIFICATION (BIU LIT K)

GRAPHICS LAYOYT DRAWINGS (BNG V BIU

DCS (CENTUM CS3000)

SOFTWARE (PHN MM)

HIU NG)
SUBSYSTEM COMMUNICATION SPECIFICATION ( C TNH TRUYN THNG CA THIT B PH)

REPORT FORMS (MU BO CO)

INSPECTION AND TEST PROCEDURE (KIM SOT V

PHNG PHP KIM SOT)

INSPECTION (KIM SOT)

INSPECTION AND TEST REPORT (KIM SOT V BO CO)

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H THNG DCS CENTUM CS3000 LIST I/O V CC U NI :

NGI HDTT : Mr. TRN MINH NHT

HNH 14: Cc cng u ni trong t FCS

KHI CHC NNG CA DCS:

Mt s khi chc nng ca DCS : EWS 0164
View process Modify recipe x Report (full) Trend(N/A) History(full) Alarm(full) HIS 0160 View process x Ctrl Report(pack 1) Trend(pack 1) History(full) Alarm(pack 1) HIS 0161 View process x Ctrl Report(pack 1) Trend(pack 1) History(full) Alarm(pack 1) HIS 0162 View process x Ctrl HIS 0163 View process x Ctrl

Report(pack2) Report(pack2) Trend (pack2) Trend(pack2) History(full) Alarm(pack2) History(full) Alarm(pack2)

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H THNG DCS CENTUM CS3000 NGI HDTT : Mr. TRN MINH NHT S VNG DDC: (xem mc 2.3.4). C TNH TRUYN THNG CA THIT B PH:(xem mc 2.3.3 : cc h thng ph tr) BNG V BIU HIU NG: th hin trn giao din iu khin ( HIS )

2.3.2. S tng qut h thng DCS trong nh my PMPC :

EWS : Engineering Work Station HIS : Human Interface Station ( Trm t Giao din gia ngi v my) FCS : Field Control Station (Trm iu khin thit b trng) ACM : Communication Gateway Unit ( Cng truyn thng) M/P : Marshalling Panel IRP : Interposing Relay Panel PDP : Power Distribustion Panel( T phn phi in nng) HISS : High Intergrated Safety System (H thng an ton cp cao) EIMS : Electrical Intergrated Monitoring System( H thng kim tra tch hp in) F & G : Firing & Gas Detection ( Cnh bo la v kh c) VCM Metering System:( H thng o lng kh VCM) Hygine Monitoring System : H thng gim st v sinh. Packaged Equipment( PLC) : khi thit b.

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H THNG DCS CENTUM CS3000

NGI HDTT : Mr. TRN MINH NHT

HNH 15: S h thng DCS CENTUM CS3000 trong nh my PMPC

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H THNG DCS CENTUM CS3000

NGI HDTT : Mr. TRN MINH NHT

2.3.3. Cc h thng ph tr.

HNH 16 : S kt ni h thng ph tr vi FCS

Station Number module ACM 12 FCS 01 ACM12 ACM11 FCS02 ACM12 ACM12 FCS 03 ACM12 Cable RS-485 RS-485 RS-232C RS-485 RS-485 RS-485 Subsystem Hygiene Monitoring System F&G HISS VCM Metering System EIMS Packaged Equipment (PLC) Remark Redundant Redundant Redundant Redundant Redundant Redundant

2.3.3.1. Hygiene Monitoring System ( h thng gim st v sinh ).

Nhim v: h thng gim st v sinh thc hin chc nng gim st v sinh ton b h thng m bo h thng lun hot ng mt cch tt nht, khng nh hng n sn phm, khng gy hng hc h thng, S dng hai kiu dy cp khi kt ni h thng gim st v sinh ti b card truyn thng ACM12 . Vic k tip thc hin khi modun PLC v card ACM12 kt ni trc tip .

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H THNG DCS CENTUM CS3000 Ch thch: TERMINAL NAME TX + TX RX+ RX SG FG

NGI HDTT : Mr. TRN MINH NHT PISCRIPTION Send date Send date Receive date Receive date Signal date Frame ground

R1 : termination resistance of 120 ohm ( in tr t gia l 120 ohm ). R2 : according to the instruction on the subsystem side ( gi tr in tr ph thuc vo ch dn bn h thng ph ).

HNH 17: Hygiene Monitoring System vi ACM 12 BNG 2 :Hygiene Monitoring System
Station number Node Address Unit Slot Module Cable FCS0101 5 2 1&2 ACM12 RS-485 Redundant 2-wire type cable

BNG 3: Setting Items specification From system view. (Hygiene Monitoring System)

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H THNG DCS CENTUM CS3000 Items Interface Transmission method Cable Synchronization method Transmission speed Transmission procedure

NGI HDTT : Mr. TRN MINH NHT Description ACM12:RS-485 Half duplex 2-wire type cable Start stop synchronozation 9600 bps Modbus protocol(RTU mode) 1 8 Even 1 1000ms

Start bit Data bit Data type Parity bit Stop bit Transmission cable monitoring time Time monitoring Reception character interval 10ms monitoring time Start of text None Text frame End of text No ne XON/XOFF flow control No RS control DR check CD check No response time setpoint Number of communication retries upon error Recovery communication time interval Transmission wait time Number of words that can be handled in one communication packet

No Yes No 4 seconds 1 times 30 seconds 1 second 125 words(AI/AO),8 words(DI/DO)

2.3.3.2. Firing and Gas detection ( F & G ) :

Nhim v : h thng pht hin cht d chy v kh t c chc nng v cng quan trng trong h thng phng chy cha chy cho nh my sn xut PVC , pht hin v x l mt cch nhanh v c hiu qu bo v tt nht an ton cho ngi v nh my. S dng hai kiu dy cp khi kt ni b F & G ti b card truyn thng ACM12. Vic tip theo thc hin khi b modun PLC v b card ACM12 kt ni trc tip.

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H THNG DCS CENTUM CS3000 Ch thch: TERMINAL NAME TX + TX RX+ RX SG FG

NGI HDTT : Mr. TRN MINH NHT PISCRIPTION Send date Send date Receive date Receive date Signal date Frame ground

R1 : termination resistance of 120 ohm ( in tr t gia l 120 ohm ) R2: according to the instruction on the subsystem side ( gi tr in tr ph thuc vo ch dn bn h thng ph ).

HNH 18 : Firing and Gas detection ( F & G )vi ACM 12 BNG 4: F & G module configuration
Station number Node Address Unit Slot Module Cable FCS0101 5 3 1&2 ACM12 RS-485 Redundant 2-wire type cable

BNG 5:Setting Items specification From system view ( F & G)

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H THNG DCS CENTUM CS3000 Items Interface Transmission method Cable Synchronization method Transmission speed Transmission procedure Start bit Data type Data bit Parity bit Stop bit

NGI HDTT : Mr. TRN MINH NHT Description ACM12:RS-485 Half duplex 2-wire type cable Start stop synchronozation 9600 bps Modbus protocol(RTU mode) 1 8 Even 1 1000ms 10ms None No ne No No Yes No 4 seconds 1 times 30 seconds 1 second 125 words(AI/AO),8 words(DI/DO)

Time monitoring

Transmission cable monitoring time Reception character interval monitoring time Start of text End of text

Text frame

XON/XOFF flow control RS control DR check CD check No response time setpoint Number of communication retries upon error Recovery communication time interval Transmission wait time Number of words that can be handled in one communication packet

2.3.3.3. High Integrated Safety System ( HISS ) :

Nhim v : H thng gim st an ton cp cao thc hin gim st an ton mt cch cao nht cho nh my khi vn hnh. HISS s dng cc hm logic v cc thut ton x l

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H THNG DCS CENTUM CS3000 NGI HDTT : Mr. TRN MINH NHT cc trng hp s c hng hc nguy him, c th ng ngt thit b bo v an ton mt cch kp thi v nhanh nht khi s c xy ra. S dng dy cp vi RS232 D-sub 25 chn khi kt ni tip ti b modun truyn thng ACM11. Vic k tip thc hin khi b modun PLC v b modun ACM11 kt ni trc tip. Pin number 1 2 3 4 5 6 7 8 20 Signal name FG SD RD RS CS DR SG CD ER Title Fraine ground Send data Receive data Request to send Clear to send Data ready Signal ground Carrier detected Data terminal ready

HNH 19: High Integrated Safety System ( HISS ) vi ACM 11 BNG 6 : HISS module configuration
Station number Node Address Unit Slot Module FCS0101 3 2 1&2 ACM11 Redundant Trang 35

GVHDTT: ThS . NGUYN L TNG

H THNG DCS CENTUM CS3000 NGI HDTT : Mr. TRN MINH NHT Cable RS-232C 25-pin connector

BNG 7 .Setting Items specification From system view (HISS)

Items Interface Transmission method Cable Synchronization method Transmission speed Transmission procedure Start bit Data bit Data type Parity bit Stop bit Transmission cable monitoring time Time monitoring Reception character interval monitoring time Start of text Text frame End of text XON/XOFF flow control RS control DR check CD check No response time setpoint Number of communication retries upon error Recovery communication time interval Transmission wait time Number of words that can be handled in one communication packet Description ACM11: RS-232C Half duplex 25-pin connector Start stop synchronozation 9600 bps Modbus protocol(RTU mode) 1 8 Even 1 1000ms 10ms None No ne No No Yes No 4 seconds 1 times 30 seconds 1 second 125 words(AI/AO),8 words(DI/DO)

2.3.3.4. VCM Metering System :

Nhim v: H thng o lng kh VCM l h thng gim st lng kh VCM trong bn cha v nhit , p sut , th tch VCM bn cnh cho ta gim st c lng kh VCM m nh cung cp kh VCM cung cp cho nh my.

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H THNG DCS CENTUM CS3000 NGI HDTT : Mr. TRN MINH NHT S dng hai kiu dy cp khi kt ni h thng o kh VCM ti b modun ACM12. Vic k tip thc hin khi b modun PLC v b modun ACM12 kt ni trc tip. Ch thch: TERMINAL NAME TX + TX RX+ RX SG FG PISCRIPTION Send date Send date Receive date Receive date Signal date Frame ground

R1 : termination resistance of 120 ohm ( in tr t gia l 120 ohm ) R2 : according to the instruction on the subsystem side ( gi tr in tr ph thuc vo ch dn bn h thng ph ).

HNH 20: VCM Metering System vi ACM12

BNG 8 : VCM metering system module configuration

Station number Node Address Unit Slot FCS0102 3 3 1&2 Redundant

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H THNG DCS CENTUM CS3000 Module Cable

NGI HDTT : Mr. TRN MINH NHT ACM12 RS-485 2-wire type cable

BNG 9 : Setting Items specification From system view (VCM metering system)
Items Interface Transmission method Cable Synchronization method Transmission speed Transmission procedure Start bit Data bit Data type Parity bit Stop bit Transmission cable monitoring time Time monitoring Reception character interval monitoring time Start of text Text frame End of text XON/XOFF flow control RS control DR check CD check No response time setpoint Number of communication retries upon error Recovery communication time interval Transmission wait time Number of words that can be handled in one communication packet Description ACM12:RS-485 Half duplex 2-wire type cable Start stop synchronozation 9600 bps Modbus protocol(RTU mode) 1 8 Even 1 1000ms 10ms None No ne No No Yes No 4 seconds 1 times 30 seconds 1 second 125 words(AI/AO),8 words(DI/DO)

2.3.3.5. Electrical Integrated Monitoring System (EIMS):

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H THNG DCS CENTUM CS3000 NGI HDTT : Mr. TRN MINH NHT Nhim v :H thng gim st tch hp in l h thng gim st ton b in cung cp v x l s c in trong nh my. S dng hai kiu dy cp khi kt ni h thng EIMS ti b modun ACM12. Vic k tip thc hin khi b modun PLC v b modun ACM12 kt ni trc tip.

Ch thch: TERMINAL NAME TX + TX RX+ RX SG FG

PISCRIPTION Send date Send date Receive date Receive date Signal date Frame ground

R1 : termination resistance of 120 ohm ( in tr t gia l 120 ohm ) R2 : according to the instruction on the subsystem side ( gi tr in tr ph thuc vo ch dn bn h thng ph ).

HNH 21: Electrical Integrated Monitoring System (EIMS) vi ACM 12 BNG 10 : EIMS module configuration
Station number Node Address Unit Slot FCS0103 5 1 1&2 Redundant Trang 39

GVHDTT: ThS . NGUYN L TNG

H THNG DCS CENTUM CS3000 Module Cable

NGI HDTT : Mr. TRN MINH NHT ACM12 RS-485 2-wire type cable

BNG 11 : Setting Items specification From system view (EIMS)

Items Interface Transmission method Cable Synchronization method Transmission speed Transmission procedure Start bit Data type Data bit Parity bit Stop bit Transmission cable monitoring time Reception character interval monitoring time Start of text Description ACM12:RS-485 Half duplex 2-wire type cable Start stop synchronozation 9600 bps Modbus protocol(RTU mode) 1 8 Even 1 1000ms 10ms None No ne No No Yes No 4 seconds 1 times 30 seconds 1 second 125 words(AI/AO),8 words(DI/DO)

Time monitoring

Text frame

End of text XON/XOFF flow control RS control DR check CD check No response time setpoint Number of communication retries upon error Recovery communication time interval Transmission wait time Number of words that can be handled in one communication packet

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H THNG DCS CENTUM CS3000 NGI HDTT : Mr. TRN MINH NHT 2.3.3.6. Packaged Equipment (PLC) : Khi thit b ( PLC ). S dng hai kiu dy cp khi kt ni Packaged Equipment ( PLC ) ti b modun ACM12. Vic k tip thc hin khi b modun PLC v b modun ACM12 kt ni trc tip. Ch thch: TERMINAL NAME TX + TX RX+ RX SG FG

PISCRIPTION Send date Send date Receive date Receive date Signal date Frame ground

HNH 22:Cng kt ni packaged equipment vi ACM12 BNG 12 : Packaged Equipment ( PLC ) module configuration
Station number Node Address Unit Slot FCS0103 5 2 1&2 Redundant

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H THNG DCS CENTUM CS3000 NGI HDTT : Mr. TRN MINH NHT Module ACM12 Cable RS-485 2-wire type cable

BNG 13 :Setting Items specification From system view Packaged Equipment ( PLC)
Items Interface Transmission method Cable Synchronization method Transmission speed Transmission procedure Start bit Data type Data bit Parity bit Stop bit Transmission cable monitoring time Reception character interval monitoring time Start of text End of text Description ACM12:RS-485 Half duplex 2-wire type cable Start stop synchronozation 9600 bps Modbus protocol(RTU mode) 1 8 Even 1 1000ms 10ms None No ne No No Yes No 4 seconds 1 times 30 seconds 1 second 125 words(AI/AO),8 words(DI/DO) Trang 42

Time monitoring

Text frame

XON/XOFF flow control RS control DR check CD check No response time setpoint Number of communication retries upon error Recovery communication time interval Transmission wait time Number of words that can be handled in one communication packet GVHDTT: ThS . NGUYN L TNG

H THNG DCS CENTUM CS3000

NGI HDTT : Mr. TRN MINH NHT

2.3.4. Mt s s kt ni dy trong h thng nh my: Ghi ch:

Control room Field ELCO Arrestor Connector Cable : : : : : : Phng iu khin Khu vc sn xut. T cp ngun. b chng nhiu. B chng st. b kt ni. b dy cp.

Marshalling cabinet:

Sub junction box (SJP): hp u ni ph. Interlock Alarm(INLK): n bo kha an ton. FT FV FIC LA PA LS PS XV PB ST SIC UA ZSL : : : : : : : : : : : : : flow transmistor. flow valve. flov indicator control. low alarm. Pressure alarm Level Switch Pressure Switch. Unclassified Valve.. Push Button. Speed Transmitter. Speed Indicator Control. Common Alarm. Limit Switch Low.

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H THNG DCS CENTUM CS3000

NGI HDTT : Mr. TRN MINH NHT

HNH 23: S kt ni dy vng h ca h thng gim st an ton cp cao (HISS)

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H THNG DCS CENTUM CS3000

NGI HDTT : Mr. TRN MINH NHT

HNH 24:S kt ni dy vng kn thit b iu khin lu lng (FV)

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H THNG DCS CENTUM CS3000

NGI HDTT : Mr. TRN MINH NHT

HNH 25: S kt ni dy vng h hin th thit b o dng chy.(FI)

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H THNG DCS CENTUM CS3000

NGI HDTT : Mr. TRN MINH NHT

HNH 26: S kt ni dy vng h hin th thit b mc cht lng mc thp (LA)

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H THNG DCS CENTUM CS3000

NGI HDTT : Mr. TRN MINH NHT

HNH 27: S kt ni dy vng kn hin th tn hiu iu khin p sut GVHDTT: ThS . NGUYN L TNG

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H THNG DCS CENTUM CS3000

NGI HDTT : Mr. TRN MINH NHT

HNH 28 : S kt ni dy vng h hin th nt nhn trong DCS

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H THNG DCS CENTUM CS3000

NGI HDTT : Mr. TRN MINH NHT

HNH 29 : S kt ni dy vng kn hin th tn hiu iu khin tc thit b.

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H THNG DCS CENTUM CS3000

NGI HDTT : Mr. TRN MINH NHT

HNH 30 : S u dy vng h hin th tn hiu thit b ng gi trong sn xut

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H THNG DCS CENTUM CS3000

NGI HDTT : Mr. TRN MINH NHT

HNH 31 : S u dy vng h bo hiu c s c trong khu vc ng gi.

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H THNG DCS CENTUM CS3000

NGI HDTT : Mr. TRN MINH NHT

2.3.5. Mt s chc nng iu khin c trng ca DCS trong PMPC.

T ng iu khin mt quy trnh sn xut theo cng thc c ci sn Nh Cng thc trong bn phn ng: iu khin ly a tn kh VCM. iu khin ly b kg cc nguyn vt liu ph. iu khin thi gian (t) phn ng. iu khin nhit (to) phn ng . iu khin p sut (P) phn ng. Cng thc ti khu Dryer( my sy) iu khin nhit l sy. iu khin p sut trong l sy. iu khin thi gian. iu khin ti ( iu khin lng PVC sy trong 1 gi,) .. Cp lnh cho php khi ng hoc dng cc h thng h tr khc ( h thng ph tr, t in khin, local,) Cnh bo khi mt trong cc thng s lin quan n an ton ca quy trnh sn xut . Cho php nhn vin vn hnh iu khin theo manual . Vn hnh theo quy trnh cc thao tc. o Dng ton b nh my khi cn thit. o Kim tra ton b nh my trc khi bt u chy. ..

2.4.

Thc tp site.

MT S CNG VIC THC T: c trang b kin thc v an ton lao ng ti cng ty PMPC. Tham gia bui tp hun training boiler equipment ca Spirax Sarco. Tham quan v c gii thiu tng qut v nh my, dy chuyn sn xut ca PMPC. Tham quan v c gii thiu cc thit b trong h thng sn xut PVC nh : h thng iu khin trung tm DCS, dy chuyn ng gi sn phm, cc h thng ph tr v.v c gii thiu h thng DCS CENTUM CS3000 ca YOKOGAWA ti phng vn hnh ca nh my( h thng u dy, PDP, M/P, FCS, HIS,HISS,F&G,). H tr cc nhn vin phng k thut kim tra, sa cha v thay th mt s thit b trong h thng sn xut PVC. GVHDTT: ThS . NGUYN L TNG Trang 53

H THNG DCS CENTUM CS3000 NGI HDTT : Mr. TRN MINH NHT Kim tra r r kh tai khu vc thu hi kh VCM d. Kim tra n nh ca mt s b pht tn hiu( p sut, lu lng, chnh p, ). Sa cha v thay th mt s thit b trong h thng ( valve, transmitter, ).

CHNG 3. TM TT V KT LUN 3.1. Tm tt kt qu thc tp:

Trong thi gian thc tp ti cng ty Nha v Ha Cht Ph M chng ti tp trung tm hiu h thng DCS CENTUM CS3000 trong nh my PMPC. Trong khong thi gian , chng ti tham kho mt s ti liu trn mng v c bit l nhng ti liu m cng ty cung cp cng vi s hng dn tn tnh ca Mr.Trn Minh Nht vi cc thit b thc t trong cng ty m t chng ti tm hiu h thng DCS iu khin v gim st qu trnh sn xut PVC trong cng ty theo cc mng sau: S khi h thng DCS CENTUM CS3000 ca PMPC. Cc h thng ph tr (HISS, EIMS, F&G, ). S u dy trong h thng. Mt s chc nng iu khin c trng ca DCS trong PMPC. Ngoi ra, chng ti trc tip quan st cc thit b vn hnh ca h thng, cc thit b iu khin, thit b chp hnh trong quy trnh sn xut . Bn cnh ,chng ti cn tham gia vo qu trnh kim tra v bo tr mt s thit b trong h thng.

3.2.

Kt lun.

Sau thi gian thc tp ti cng ty chng ti hiu s lc v h thng DCS CENTUM 3000 c s dng trong h thng sn xut PVC ti cng ty Nha V Ha cht Ph M (PMPC). Qua , chng ti hnh dung c mt cch khi qut v mt h thng sn xut cng ngh trong mt nh my cng nghip hin i s dng h thng iu khin tp trung vi nhiu chc nng ca tng thit b. Bn cnh , chng ti b sung thm vo vn kin thc thc t ca mnh cch u dy trong h thng, b tr v lp t thit b mt cch an ton v ti u nht,. Qua t thc tp ny,chng ti rn luyn cho mnh mt phong cch lm vic trong mi trng cng nghip hin i v hiu bit thm mt s thit b trong thc t, t trang b cho mnh trong qu trnh lm vic sau ny.

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H THNG DCS CENTUM CS3000

NGI HDTT : Mr. TRN MINH NHT

TI LIU THAM KHO

[1] P&ID for Vietnam PVC Project . PhuMy Plastics and Chemicals Co.,Ltd [2] TECHNICAL DATA BOOK DCS SYSTEM . PhuMy Plastics and Chemicals Co.,Ltd [3] TS. Hong Minh Sn . H THNG IU KHN PHN TN . B MN IU KHIN T NG, KHOA IN I HC BCH KHOA H NI [4] http://dientuvietnam.net [5] http://www.Yokogawa.com

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