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COKE LTD
Stage documentation BE
Документация стадии BE
Automation
2022 г.
LIST OF DRAWINGS
ПЕРЕЧЕНЬ ЧЕРТЕЖЕЙ
No. of
Drawing No. sheets Rev. Description
№ чертежа Кол. Изм. Наименование
листов
1 2 3 4
Title sheet
1 00 Титульный лист
General data
01113-1 3 00
Общие данные
Explanatory note
01113-3 37 00
Пояснительная записка
The content of this document or any part of it shall remain the property of “ S.T.A. COKE LTD", therefore, it
is strictly forbidden to use it (in whole or in part) without written permission granted by “S.T.A. COKE LTD
", for copying, processing, reusing, transferring to third parties, for other facilities and purposes.
Instead inv. no.
CO-643676
Original inv. no. Signature and date
CO-643676 01113-1
JSW Steel Dolvi Works
Implementation of technology of individual pressure control
Rev. Sec.N. Sheet Doc.N. Signature Date in the chamber and HPLA system
Project manager Kogan 05.22 Coke oven battery A,B. GIPRO Stage Sheet Sheets
Head of dept. Trunov 05.22 Automation
Коксовая батарея A,B. ГИПРО BE 1 3
Chief specialist Kuksenko 05.22 Автоматизация
Group leader Osipovich 05.22
General data
Designed by Sambuk 05.22 S.T.A. COKE LTD
Общие данные
Checked by Luchinsky 05.22
GENERAL INSTRUCTIONS
Automation system of pressure control for each single oven (SPC) GIPRO is a
distributed system that is a set of specialized and general-purpose computing facilities and
nodes of distributed data processing, which are integrated by a structured communication
system. It is intended for maintaining a slight overpressure on the bottom of the coke oven
chambers under the sealing frame of the door from +5 to +30 Pa during the entire coking
period.
General automation system structural diagram is given in drawing 01113-2.
The hardware/software complex of automation system is built on the base of the
microprocessor and computing equipment and consists of the following main parts:
control stations of Level 1 (microprocessor controllers);
remote input/output stations;
network communication equipment;
operator workstations;
engineering station and programmator;
application software;
The tasks of direct control and monitoring of the operation of the automation system for
individual pressure control are implemented on the controllers of the Siemens S7-1500H
series and remote I/O stations of the Siemens ET200SP series, made in a block-modular
design with the ability to quickly replace removable modules in the case of failure.
Visualization and operator control for this automation system are implemented on both
operator workstations independently using human-machine interface.
All system components are connected between each other using Ethernet switches of
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ОБЩИЕ УКАЗАНИЯ
и электрическим линиям.
.
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Project Manager
Head of dept.
Chief specialist
Group leader
Designed by
Checked by
EXPLANATORY NOTE
ПОЯСНИТЕЛЬНАЯ ЗАПИСКА
The content of this document or any part of it shall remain the property of “ S.T.A. COKE LTD ", therefore, it
is strictly forbidden to use it (in whole or in part) without written permission granted by “ S.T.A. COKE
LTD", for copying, processing, reusing, transferring to third parties, for other facilities and purposes.
Instead inv. no.
CO-643676
Original inv. no. Signature and date
01113-3
The automation system of the pressure control for each single coke oven chambers
(SPC) GIPRO is developed for existing coke oven battery JSW Steel Dolvi Works (India).
The project foresees the re-construction of coke oven battery consisting of two blocks
A and B, each of 55 ovens, with the coking process of the stamping coal charge.
Automation system is designed for whole coke oven battery (110 coke ovens) and is
based on the following technical assignments:
2. SYSTEM PURPOSE
The main purpose of the GIPRO pressure control system is to maintain a small
overpressure on the bottom of the coke oven chambers under the sealing frame of the door
from +5 to +30 Pa throughout the entire coking period. It makes possible to exclude gas
emission in the first hours after charging and air infiltration into the coking chambers at the
Instead inv. no.
Pressure control based on given algorithm when a continuous control for poppet
(disk) valve is chosen;
Original inv. no. Signature and date
Step opening and closing of poppet (disk) valve when a coke oven battery is
operating without an pressure control for each single coke oven;
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An acquisition, processing, documentation and display of information about the
process of maintaining pressure and its control according to a given algorithm;
The information interchange with general automation system of coke oven battery
and coordination system of coke machines, which are not included in this project.
3. SYSTEM STRUCTURE
From a structural point of view, the system built on hierarchical principle and it have
two levels:
Level 0
control actuators;
Level 1
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The structural diagram of automation system is given on drawing 01113.2-3 and
includes the specification of hardware used in automation system.
From a topological point of view, the automation system elements are installed in
operator’ control room, instrumentation room and inside into remote input/outputs rooms on
gas collecting mains’ bench.
The Level 0 equipment are installed directly to gas extruding constructions of coke
ovens: ascending pipes necks and covers and gas collecting mains.
The Level 1 are installed into instrumentation room and into special premises at end
bench. Level 1 workstations are installed in main control room of coke oven batteries.
For communication between the elements of the system, Profinet/CAN bus networks
(for connecting remote input/output devices), Industrial Ethernet (for connecting
programmable controllers to workstations) and Basic Communication Ethernet (for
workstations) are used.
From the operation point of view, the system assumes the availability of personnel
trained and qualified to work with the system and its maintenance.
4. SYSTEM HARDWARE
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Input signals:
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with using of smart sensors;
Digital signals.
Output signals:
The automation structure for coke oven batteries A and B is shown on following P&I
drawings:
Automatic control:
Remote control:
Signalization:
system.
Automatic control:
Remote control:
Signalization:
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Pressure drop of nitrogen for “GIPRO” system.
Local control:
Local control:
Local control:
Attention:
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Local control:
Attention:
Local control:
Local control:
Automatic control:
Remote control:
injection;
flow of ammonia liquor for coke oven batteries A and B hydraulic injection;
Original inv. no. Signature and date
Local control:
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ammonia liquor pressure on pump’ inlet (main);
The system uses programmable logic controllers A_PLC1 and B_PLC1 of the
SIMATIC S7-1500H series with full hot-redundant for control of blocks A and B standpipes.
The central processor of the controller provides high performance and the ability to execute
technological programs of great complexity. The built-in field bus interface allows connect
remote peripheral devices directly to the CPU. Communication modules inserted into a
common rack with a CPU provide redundant connection of the controller to a common
Industrial Ethernet network as an equal subscriber at a speed of up to 100 Mbps. Built-in
processor diagnostic provide the ability to monitor and analyze the health of each CPU at
higher-level operator stations.
The programmable logic controller AB_PLC1 of the SIMATIC S7-1500 series is used
for control of common hydraulic system for blocks A and B standpipes and hydraulic injection
unit, as such as bridge between A_PLC1 and B_PLC1 controllers. This system have not a hot
redundancy.
All sensors and data collection devices are connected to the controllers via the remote
peripheral I/O stations using CAN bus interface or physical I/O wires. All I/O stations are
connected to the controller via a redundant Profinet network, which ensures the reliability of
the communication lines and guarantees reliable monitoring and control of the system.
Instead inv. no.
SIEMENS ET200SP series devices are used as distributed I / O stations. Built-in diagnostic of
modules and stations provide the ability to monitor the status of each module and the entire
rack as a whole at upper-level operator stations. Interface modules IM155-6PN for Profinet are
used to connect a remote station
digital input module (16 digital 24VDC inputs, embedded diagnostic, possibility of
hot replacing);
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analog output module (4 isolated analog outputs, 16bit DAC, embedded diagnostic,
current output of 4…20 mA) — only for AB_PLC1 controller;
CAN bus interface modules are installed in the I/O stations for communication with
data collection devices.
Operator stations OS1 and OS2 provides a human-machine interface between the
operator and the process, realizing the full capabilities of monitoring the current state of the
process, controlling individual mechanisms, viewing archived data on the history of the
process, messages about the state of the object, generating technological reports. Operator
stations receive up-to-date information on the process from the controllers of Level 1 via the
Industrial Ethernet network.
4.5. Programmer
For communication between the elements of the system, the network communication
equipment that connects remote I/O stations, programmable controllers, operator stations in
common Ethernet network is used.
The Siemens SCALANCE X-208 Ethernet switches are using as an active network
Original inv. no. Signature and date
equipment. Optical media converters SCALANCE X-101LD series are using for connections
between optical and electrical parts of networks.
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5. SYSTEM SOFTWARE
Base software refers to specialized software developed by third parties and used to set
up, program and configure applications, objects, devices and networks of an automation
system.
The application software includes all programs and algorithms developed for this
project of pressure control for each single coke ovens for:
Process sequences.
Human-machine interface;
6. FUNCTIONAL DESCRIPTION
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The main functional description of pressure control system for each single coke oven is
given in document 1339063-ТХ.Z made by GIPROKOKS.
Local mode:
When local mode is selected, control is carried out from the local control posts LCP
that are located inside the HYDAC cabinet for each separate standpipe. In this case,
the local mode indicator lights up at the post. The service personnel are then able to
operate the ascending pipe cover and poppet (disk) valve. In case of an unforeseen
situation, an emergency indicator is additionally installed at the post. When the
hydraulic cylinders are directly servicing in manual mode, it is necessary to
prohibit the operation of the automation system by emergency stop button located
at the posts.
Control posts for each ascending pipe are provide the following:
Remote mode:
In the remote mode, the operator carries out control directly from the operator
station separately for each ascending pipe. When calling up the pipe control in
remote mode, the following control buttons are available:
Original inv. no. Signature and date
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close the pipe.
Automatic mode:
There are the following software interlocks are intended for ascending pipe control:
prohibition of opening the pipe cover until the pipe poppet (disk) is
closed;
prohibition of opening the pipe poppet (disk) until the pipe cover is
closed;
This software interlocks are used for all control modes operated by logic
controllers.
The choice of the mode is carried out from the operator stations. The possibility of
individual selection of the mode is provided for each ascending pipe.
There is also a manual control mode without any participation of the PLC, which is
described in the assignment for the hydraulic drives control.
The operation of the hydroinjection system and the control of the hydroinjection pumps
are controlled by the AB_PLC1 controller. The controller, receiving data on the start of
Original inv. no. Signature and date
charging, sends a command in advance to accelerate the pump to the required power,
maintains pressure in the system due to feedback, and when the injection is turned off, it stops
the pumps in advance to avoid water hammer. Additional information about the operation of
hydraulic pumps is transmitted by this controller to the GIPRO system. The use of a separate
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AB_PLC1 controller will allow, if necessary, to control such parameters as overpressure,
operating currents, temperature of pump bearings, and control vibration of motors. In addition,
since the GIPRO system uses the redundant controllers of S7-1500H series, in order to provide
communication between the existing control system and two H-systems, the AB_PLC1
controller is used as a communication controller that acts as a bridge.
The preliminary list of data exchange signals between existing system and “GIPRO”
system is shown in Appendix 1.
The following equipment in automation system of pressure control for each single oven
is used:
Local control cabinet HYDAC with LCP post and HY-TTC CAN bus adapter,
which are designed for local control of each ascending pipe and allow the pipe to
be controlled (open/close pipe’ cover, open/close poppet (disk) valve) in local
mode. The total number of control cabinets is equal to the number of coke ovens in
two blocks A and B of the coke oven battery (55 units of each cabinet);
A_PLC1 and B_PLC1 logic controllers that control the pressure in the coke ovens
of blocks A and B, accordingly. Each controller is designed to control the
ascending pipes of 55 ovens;
Controller AB_PLC1, which controls the operation of the hydroinjection system for
blocks A and B, and interconnects redundant and non-redundant system controllers.
control 28 pipes. Ascending pipes 1-28 controlled by remote I/O stations located
into A_PLC1 cabinet inside coke oven battery electric room. Ascending pipes 29-
55 and gas bleeders controlled by remote I/O stations located into A_RIO1 cabinet
at block A end bench;
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55 and gas bleeders controlled by remote I/O stations located into B_RIO1 cabinet
at block B end bench;
Operator stations OS1 and OS2 designed for visualization, monitoring and control
of the pressure control in each single coke oven;
Portable field programmer PG1 used for maintenance and modification of GIPRO
application software;
Network Ethernet switches SW1 and SW2, located into a network equipment
cabinet NEC1;
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1. ВВЕДЕНИЕ
2. НАЗНАЧЕНИЕ СИСТЕМЫ
позволяет исключить газование печей в первые часы после загрузки и подсос воздуха в
камеры коксования в конце периода коксования.
3. СТРУКТУРА СИСТЕМЫ
Уровень 0
исполнительными механизмами;
Уровень 1
Instead inv. no.
Для связи между элементами системы используются сети Profinet/CAN bus (для
подключения удаленной периферии), Industrial Ethernet (для подключения
программируемых контроллеров к рабочим станциям) и Basic Communication Ethernet
(для рабочих станций).
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4. ТЕХНИЧЕСКОЕ ОБЕСПЕЧЕНИЕ СИСТЕМЫ
Входные:
Дискретные сигналы.
Выходные:
следующих чертежах:
Регулирование:
Original inv. no. Signature and date
Дистанционный контроль:
Регулирование:
Дистанционный контроль:
Сигнализация:
Местный контроль:
Местный контроль:
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давление аммиачной воды на гидроинжекцию и гидросмыв (4 точки
измерения).
Местный контроль:
Внимание:
Местный контроль:
Внимание:
Местный контроль:
Местный контроль:
Регулирование:
Дистанционный контроль:
Местный контроль:
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просмотра архивных данных по истории процесса, сообщений о состоянии объекта,
генерации технологических отчётов. Текущую информацию о ходе технологического
процесса операторские станции получают от контроллеров Уровня 1 по сети Industrial
Ethernet.
4.5. Программатор
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на инжиниринговых станциях или программаторах, входящих в общую систему
автоматизации коксовой батареи (при их наличии).
Технологические программы.
Алгоритмы регулирования.
ГИПРОКОКСа 1339063-ТХ.Z.
Местный:
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При выборе местного режима управление осуществляется с локального поста
управления LCP, расположенного в шкафу управления системой HYDAC для
каждого отдельного стояка. При этом на посту загорается индикатор
местного режима. После этого обслуживающий персонал имеет возможность
управлять крышкой стояка и тарельчатым клапаном. В случае
непредвиденной ситуации дополнительно на посту установлен индикатор
аварии. При непосредственном обслуживании гидроцилиндров (ручной
режим) необходимо запретить работу системы управления аварийной
стоповой кнопкой, расположенной на постах.
o открыть крышку;
o закрыть крышку;
Дистанционный:
открыть крышку;
закрыть крышку;
Original inv. no. Signature and date
открыть стояк;
закрыть стояк.
Автоматический:
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При выборе автоматического режима управление стояком осуществляется по
определенному алгоритму программой контроллера A_PLC1 для блока A
(B_PLC1 для блока В). Этот режим работы предусматривает автоматическое
открытие/закрытие стояка по команде от коксовых машин. Автоматическое
регулирование давления в печи возможно только в автоматическом режиме
работы стояка.
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Appendix 1. List of data exchange signals between existing equipment (coke machines
coordination PLC) and “GIPRO” system.
Specified signals are necessary for normal operation of the GIPRO system. Customer
must quarantee the stable tramsmission of these signals.
№ Name/Наименование Type/Тип
Input signals/Входные сигналы
SCPM. Operations on the oven / ТЗВМ. Операции над печью
1 Push ram target/actual position. Includes block serial number / Int
Целевая/текущая позиция, относительно выталкивающей штанги.
Включает порядковый номер блока
2 Сharging plate actual position. Includes block serial number / Текущая Int
позиция, относительно загрузочной плиты. Включает порядковый
номер блока
3 Actual coordinate of charging plate [mm] / Актуальная координата Real
загрузочной плиты [мм]
4 Sequence of operations for pushing / Выполняется Bool
последовательность операция по выдаче
5 Ready for pushing / Готовность к выдаче кокса Bool
6 Pushing / Выдача кокса Bool
7 Sequence of operations for charging / Выполняется Bool
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обслуживаемой печи
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2 Ready for coal cake charging into the oven / Готовность к загрузке Bool
угольного пирога в печь
3 Installed gas bypass elbows on the chambers N+2 and N-1 / Bool
Установлены газоперепускные колена на камеры N+2 и N-1
4 Valve covers on gas bypass elbows opened / Открыты крышки Bool
клапанов на газоперепускных коленах
5 Removed gas bypass elbows on the chambers N+2 and N-1 / Сняты Bool
газоперепускные колена на камеры N+2 и N-1
Battery/Батарея
1 Pressure in gas collecting main /Давление в газосборнике Real
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BE