Hi ngh ton quc v iu khin v T ng ho - VCCA-2011

Nng cp h thng iu khin SIMATIC S5 ln S7 ca Trm phn phi xi mng Hip Phc Cng ty xi mng Nghi Sn v kinh nghim thc tin Upgrading control system SIMATIC S5 S7 of Nghi Son cement company Hiep Phuoc distribution Terminal Project and real experience
TS. Phan ng Phong Ths. on Vn Minh KS. Dng Tin Din Vin Nghin Cu C kh e-Mail: Minhdv@narime.gov.vn Tm tt
Nng cp cc h thng iu khin cho cc nh my, x nghip cng nghip l cng vic kh phc tp ti Vit Nam. Do tnh cht phc tp, khng ng b ca thit b hin trng sau nhiu ln i tu, sa cha v yu cu kht khe ca ch u t v chc nng, tnh ti u v ng b cng nh thi gian thc hin d n rt ngn nn hu ht cc d n nng cp u do cc cng ty nc ngoi m nhim. Vic Vin Nghin cu C kh (NARIME) thc hin thnh cng d n nng cp, ci to dy chuyn c v lp t, kt ni dy chuyn mi Trm phn phi xi mng Hip Phc Cng ty CP xi mng Nghi Sn vi thi gian dng my trong 04 (bn) ngy m ra nhiu trin vng mi trong lnh vc nng cp cc h thng iu khin cho cc nh my, x nghip cng nghip ti Vit Nam. Phc, x Hip Phc, huyn Nh b Thnh ph H Ch Minh. Phm vi ca d n bao gm: - Thit k, tnh ton la chn, cung cp cc thit b c cng ngh bao gm c h thng cung cp kh nn v b tr dy chuyn sn xut. - Thit k. cung cp h thng cung cp in, iu khin, chiu sng, chng st v ci to h thng iu khin PLC S5 (Siemens) hin c - Thit k, thi cng phn xy dng. Trong phm vi bi vit, nhm tc gi ch i su vo gii php thc hin nng cp h thng iu khin v cc kt qu t c cng nh kinh nghim thc t sau khi hon thin d n.

2. Nng cp h thng iu khin

Phm vi v thi gian thc hin nng cp h thng iu khin Phm vi nng cp phn iu khin bao gm: - Nng cp h thng iu khin PLC S5 hin ti - Kt ni vi h thng iu khin dy chuyn xi mng mi (do NARIME thc hin) v h thng iu khin ti ch xil s 3 mi (do nh thu c thc hin)

Abtracts
Upgrading control system work for plants, industrial factories is also complicated in Vietnam. Due to the complicated, a lot of changes during Owners annual maitenance in comparision with As built documents and strictly high requirements of the Owner on new control systems functions, optimizion, synchorization as well as short excecution time, almost upgraded projects have been done by foreign contractors. With the success of Upgrading existing control system, installing and communication with new building project of Hiep Phuoc Cement Distribution Terminal Nghi Son Cement Company in four (4) days have been opened new opportunities for local automation firms in Vietnam.

Ch vit tt
PLC HMI ET IM B iu khin logic kh trnh Giao din ngi - my Module m rng Module m rng rack PLC

1. Gii thiu chung d n

D n u t xy dng h thng xut xi mng ri cng sut 300T/h ti trm phn phi xi mng Hip Phc thuc Cng ty xi mng Nghi Sn do Cng ty xi mng Nghi Sn lm ch u t. Trm phn phi xi mng Hip phc nm trong khu cng nghip Hip

H.1. Trm xut xi mng Hip Phc Cng ty xi mng Nghi Sn

Thi gian dng my ( nng cp, kt ni) ti a: 04 ngy. Nh vy thc hin d n, ngoi vic kho st k lng hin trng ton Trm phn phi, a ra gii

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php iu khin kh thi cn phi nh chun kt ni i vi cc h thng iu khin khc v gii php thi cng hp l. 2.2. Qu trnh kho st hin trng ton Trm phn phi Trm phn phi Hip Phc bao gm bn cng on chnh: - Phn iu khin np liu (xi mng) vo xi l - 02 xi l vi tng cng sut lu tr l 30.000 tn - H thng vn chuyn xi mng - 03 dy chuyn xut xi mng bao gm ng bao 50kg, ng bao jumbo, xut xi mng ri ln xe bn Tng s lng tn hiu vo/ra (I/O) l xp x 1.300 u tn hiu. Cc thit b trng cng thay i nhiu trong cc qu trnh vn hnh, bo dng, bo tr nh cc sensor phn hi chuyn ng ca cc bng ti (speed sensor), sensor bo lch bng, kt bao xi mng Cn kim tra, sa cha cc thit b ny m bo tnh ng b, n nh ca h thng mi. Cc ti liu bn giao ca nh thu nc ngoi nh: bn v hon cng, s l gc tun t hat ng ton b h thng khng y nn vic kho st lp trnh li hat ng ca ton b h thng cng cn phi xem xt k trc khi tin hnh dng my nng cp. Ngoi ra, ch u t Cng ty xi mng Nghi Sn cho bit trong qu trnh vn hnh ton b Trm cng pht sinh nhiu vn cng ngh cha ph hp nh tun t hat ng ca cc h thng dy chuyn cng ngh (cc van sc kh trong Silo, h thng np liu t tu, gu ti, h thng bng ti, mt s tn hiu cha c a ln hin th trong giao din ngi my (HMI) v yu cu sa i, hin th d dng gim st hot ng ton Trm. 2.3. Gii php nng cp, cc cng ngh ch yu p dng nng cp v kt qu thc hin. 2.3.1. Gii php nng cp h thng iu khin. a. Hin trng Profibus. Giao din ngi - my HMI c lp trnh bng phn mm Wonderware. b. Yu cu v gii php nng cp. H thng iu khin mi c bn phi p ng c cc yu cu sau: - H thng m bo iu khin, gim st, kt ni thnh cng ton b trm. - Cu hnh ca h thng iu khin phi m bo tnh tng thch vi h thng c, m bo kt ni vi h thng mi (do NARIME m nhim, s dng PLC S7 400), Hng mc iu khin ti ch xi l s 3 (do nh thu c m nhim s dng PLC S7 400). - H thng mi phi m bo k tha h thng c tng thch vi h thng phn cng ca ton b trm. - H thng mi phi m bo tnh m, ng b, hin i. - H thng mi phi m bo thn thin, d s dng. Gii php nng cp: T nhng yu cu trn, NARIME a gii php kt ni nh Hnh 3. H thng iu khin mi l mt h SCADA vi h thng truyn thng xy dng trn trn nn tng profi_net ca Siemens vi 2 CPU thc hin chc nng iu khin c lp cho 2 dy truyn song song trong trm. - CPU S7 400 (do nh thu khc cung cp) iu khin xi l s 3 s kt ni vi CPU S7 400 ca dy chuyn theo chun Profibus-DP Slave - Giao tip gia hai trm S7 400 do NARIME thc hin v vi mn hnh giao din HMI bao gm 2 my tnh, 1 my in theo chun ethernet. - Ti cc module m rng (phn tn) thu thp tn hiu s c thay th bng cc module (I/O) S7300, qua ET kt ni vi trm S7-400 nng cp theo chun Profibus.

H.2. Cu hnh h thng iu khin hin ti Trm phn phi xi mng Hip Phc

H thng iu khin hin ti ca nh my bao gm 01 h thng PLC S5 kt ni vi 09 module m rng ET ly tn hiu iu khin, gim st ton b cc thit b cng ngh trong trm. Mt my tnh vn hnh c kt ni vi PLC S5 cng thng qua cp

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H.3. Cu hnh h thng iu khin mi

Bng lit k cu hnh thay th ti t SC1 (t PLC chnh). STT 1(Rack 1) 2 Tn Module hin hu CPU S5 948 Modul Profibus 6GK1143 Analog module 8Ai 4 module 32DI 24Vdc 5x module 32DO 24Vdc Module m rng rack IM 308 Modul m rng rack IM300 9x module 16DI 220Vac Tn module thay th B ngun 10 A CPU S7400 416 Module Profibus 443-5 extend Module ethenet4431 advance Module analog 8AI 4 module 32DI 24Vdc 5x module 32DO 24Vdc Module IM 460-0 Send B Ngun 4A Module IM 461-0 Receive 9x module 16DI 220Vac

3 4 5 6-9 10-14

Phn mm iu khin, lp trnh: i vi phn mm lp trnh PLC S7 400: s dng SIMATIC S7 (Siemens). i vi phm mm lp trnh giao din HMI: s dng WINCC (Siemens). H thng giao din mi s gi ton b cc phm thao tc, k hiu (symbol) trn mn hnh hin hu, b sung thm cc tn hiu gim st v b sung thm phn d n nng cp mi lm gim thi gian chuyn giao cng ngh v hng dn vn hnh 2.3.2. Cc phng n v cng ngh ch yu p dng trong d n a. Lp m hnh m phng trc khi thi cng Lp m hnh m phng trc khi thi cng l bc rt quan trng trong mt d n nng cp h thng iu khin. Vic m phng h thng khng nhng gip cho n v nng cp kim tra tnh ng n ca chng trnh m cn gip cho ch u t theo di, nh gi ton b qu trnh thc hin.

15 1(Rack 2)

2 3-11

B.1. Bng k thit b thay th t PLC chnh.

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mm Simatic Step7 s cho php ngi lp trnh c th chuyn i phn mm vit cho h PLC S5 sang h S7. Cu trc phn mm c chuyn i s khng gi c hon ton, ngi lp trnh s phi xy dng li cu trc mi da trn nn cng ngh c v phn s nng cp. Cng c chuyn i s gip ch rt nhiu bi n c th bin dch c hu ht cc FC, FB m trong m t rt r mt quy trnh no ca cng ngh c v vic cn thit i khi ch l b xung cc tn hiu nng cp, vit li mt s on m khng ph hp v tin hnh test ring cho khi chng trnh trc khi s dng li. d. Gii php hiu chnh, chy th v a vo vn hnh: Trm xut xi mng Hip Phc sau khi nng cp, lp mi c tng cng 3 xi l, 2 h thng gu ti, 2 u np liu t tu v nhiu dy chuyn ng bao thng, bao Jumbo, u xut xi mng ri v cc h thng ph tr nh lc bi, h thng qat sc kh v.v m bo hiu chnh cc tn hiu, chy th v a vo vn hnh thnh cng nu ta khng c gii php kh thi s dn n sai st trong khi vn hnh v khng m bo an ton cho cc thit b cng ngh cng nh ngi vn hnh, nh vy s nh hng ln n kinh t cho ch u t v c nh thu v phi dng my hiu chnh nhiu ln c bit, trm xut xi mng Hip Phc c nhiu ln sa cha trc , bn v sai lch so vi thit k. Ngoi ra, mt s tn hiu b u tt do thit b trng b hng hoc hat ng sai. D n c s dng phng n cun chiu, tng dy chuyn s c hiu chnh theo nguyn tc: kim tra, hiu chnh tn hiu ca tng thit b cng ngh trc ri n dy chuyn. Tng dy chuyn trc ri mi n chy h thng. Cc dy chuyn quan trng c hiu chnh trc ri mi n cc dy chuyn t quan trng hn. Ton b qu trnh hiu chnh phi c s gim st ca ch u t, t vn gim st v nh thu v c vn bn kim tra ti hin trng. 2.3.4. Gii php m bo cht lng, v sinh mi trng v an ton lao ng Trong cc d n xi mng, vic thi cng m bo cht lng, v sinh mi trng v an ton lao ng c vai tr quan trng. T khu kho st, thit k, ch to, thi cng, lp t v chy th u c t nht mt cn b gim st, nh gi v hng dn m bo d n m bo cht lng theo cc tiu chun Vit Nam (TCVN) v cht lng, v sinh mi trng v an ton lao ng. c bit vi cc n v thu ph thi cng u phi cam kt v trnh gii php, phng n ph hp m bo cc yu cu trn trc khi thi cng.

H.4. Ch u t, n v gim st v lnh o Vin kim tra qu trnh m phng.

Trong qu trnh m phng, ch u t, t vn gim st c th gp , yu cu thay i mt s cc chng trnh con hoc giao din HMI. Tm li, qu trnh m phng trong mt d n nng cp h thng iu khin l bc khng th thiu gip cho ch u t, t vn gim st, nh thu thng nht ton b chng trnh trc khi dng my thc hin vic nng cp. b. ng dng cng ngh mi v thit b c chng. i vi mt s h thng iu khin, vic thay th, nng cp phi thc hin th cng tc l tho di tng module PLC, thay th cc module mi, u ni th cng cc tn hiu vo h thng Tuy nhin, vi h thng iu khin ca Trm phn phi xi mng Hip Phc, tng lng tn hiu l xp x 1,300 tn hiu. Vi s lng ln tn hiu nh vy v thi gian dng my khng qu 4 ngy, khng gian lm vic ti phng iu khin hn ch phi tm v p dng cc thit b c chng cho nng cp gim thiu s sai st, gim thi gian thi cng l vn quyt nh s thnh cng ca d n. Mt trong nhng thit b Vin Nghin cu C kh ng dng cho d n l b chuyn i tn hiu S5S7 Interface Module Adaptor.

H.5. Interface module adapter S5 S7.

Nh cc thit b ny m thi gian u ni d kin t 3 ngy xung cn 1,5 ngy (mt s module S5 khng s dng c S5-S7 Interface Module Adapter). c. Chuyn i phn mm t h S5 sang h S7: vic tm hiu cng ngh c l rt quan trng trong qu trnh nng cp chuyn i. Mt cng c trong phn

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2.3.3. Kt qu t c.

H.6. Mn hnh giao din Overview trc (hnh nh) v sau khi nng cp.

Ton b d n c thc hin trong ng 04 ngy dng my (dp tt Nguyn n) m bo theo ng k hoch ca ch u t. H thng mi m bo thn thin, d s dng. Trong thi gian ngn hng dn, cng nhn vn hnh c th vn hnh ton Trm. Cc chng trnh m bo p ng c s cng ngh, logic vn hnh. c bit, h thng mi c nhiu ci tin tng tnh an ton, m bo cht lng, gim tiu hao nng lng v.v do c thng nht trong qu trnh m phng. H thng mi m bo tnh m, tnh d phng, ng b v kt ni thnh cng vi h thng iu khin ti ch xi l s 3 do nh thu c thc hin.

Vin Nghin cu C kh ang nghin cu cc gii php ng dng v thnh tu khoa hc mi t cc hng sn xut nh Siemens, ABB, Schneider v.v phc v ring cho cc d n nng cp h thng iu khin ng b trong cc nh my, x nghip cng nghip v n nay c nhng thnh cng nht nh v d kin s hp tc vi mt s cc nh my, x nghip cng nghip p dng cc thnh tu nghin cu vo lnh vc nng cp cc dy chuyn v nh my x nghip cng nghip trong tng lai.

Ti liu tham kho

[1] Krstc, M.; Kanellakopoulos I.; Kokotovc, P.: Nonlinear and Adaptive Control Design. John Wiley & Sons, Inc., New York 1995 Quang. Ng.Ph.; Dittrich, J.-A.: Praxis der feldorientierten Drehstromantriebs-regelungen. 2. Aufl., Expert-Verlag, 1999. GS Phm Vn t; K thut lp trnh C. NXB khoa hc v k thut nm 1999.

3. Kt lun
Thnh cng trong vic nng cp cc h thng iu khin trong cc nh my v x nghip cng nghip khng nh trnh ca k s in iu khin ti Vin Nghin cu C kh ni ring v Vit Nam ni chung, kh nng ca cc doanh nghip Vit Nam trong vic tip cn, cnh tranh v thc hin cc gi thu v nng cp cc nh my, x nghip cng nghip vi gi thnh h, h thng mi m bo tnh n nh cao, hin i, ng b, thi gian dng my ngn. [2]

[3]

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