Coal Handling Control System

输煤控制系统
 Introduction介绍
 Coal handling Control system of Qasim 卡西姆的煤炭处理
控制系统
 PLC
 Port Qasim Power Project Control and Automation,
Problems and Solutions. 卡西姆港电力项目控制和自动化，
问题和解决方案。
 Control System Structure 控制系统结构
 The project main process system data: 项目主要过
程系统数据：
 List of main equipment of Profi bus: 现场总线主要设备清
单：
Summary 概要
 The project in Qasim Pakistan includes not only the coal
handling system part of the plant but also the coal handling
system of the terminal, The entire engineering process
system is huge, the process requirements are complex, the
number of third-party equipment is varied, the number of
coal conveying belts is large, and the length of a single belt is
long, which brings great difficulty to the implementation of
the coal conveying control system of this project.
 At the beginning of construction, through the in-depth
analysis and field investigation on the latest status quo of the
technical development of the coal transportation control
system in China, the Profi bus technology was decided to be
selected, especially the control of the coal handling system of
the thermal power plant by the power line Profi bus
technology. The project brings technical and economic
benefits.
 巴基斯坦卡西姆项目不仅包括工厂的输煤系统部分，还
包括终端的输煤系统，整个工程过程系统庞大，工艺要
求复杂，第三方设备数量多样， 输煤带数量多，单带
长度长，给本项目输煤控制系统的实施带来很大困难

。
 在建设之初，通过对中国煤炭运输控制系统技术发展的
最新现状进行深入的分析和现场调查，决定选择现场总
线技术，特别是煤炭运输控制 火力发电厂的系统由电
力线现场总线技术。 该项目带来技术和经济效益。
 In Qasim coal fired project, Coal Handling control system is
much differ than other control systems such as Chemical Control
system, Ash Handling control system etc
 Because other control systems uses only PLC for automation
purposes. But Coal handling system is controlled with the help
of power line Profi bus technology.
 It include Allen Bradley (AB) PLC in series connected with
Master Controller and section vise microcontrollers and so on.
 在卡西姆煤炭项目中，煤炭处理控制系统与其他控制系统如化
学控制系统，除灰控制系统等有很大不同
 因为其他控制系统仅将PLC用于自动化目的。 但煤炭处理系统
是借助电力线现场总线技术来控制的。
 它包括与主控制器和部分钳位微控制器串联的Allen Bradley
（AB）PLC等。
 “一种数字化操作的电子设备，它通过实现诸如逻
辑排序，定时，计数和算术等特定功能来通过数
字或模拟输入/输出模块控制各种类型的机器或过
程，使用可编程存储器来存储指令的内部存储 。
用于执行可编程控制器功能的数字计算机被认为
是在此范围内，不包括鼓和其他类似的机械顺序
控制器。“
 "A digitally operating electronic apparatus which
uses a programmable memory for the internal
storage of instructions by implementing specific
functions such as logic sequencing, timing,
counting, and arithmetic to control, through
digital or analog input/output modules, various
types of machines or processes. The digital
computer which is used to perform the functions
of a programmable controller is considered to be
within this scope. Excluded are drum and other
similar mechanical sequencing controllers."
 If we want to perform any operation in coal handling system, we
give command from Coal Handling Control Room. Which
transfer this instruction to PLC. CPU process it and send it to
particular Master Controller, which further transfer it to sub-
controller installed at Site, which process it and execute the
given command. After executing command it gives signal to
master controller which convey the signal to PLC and display this
signal at the computer screen of Operator.
 Each Control box have particular I.P and NUCID. Instruction is
transferred according to these ID’s.
 如果我们想在煤炭处理系统中进行任何操作，我们会向煤炭处
理控制室发出指令。 它将这条指令传送给PLC。 CPU对其进行
处理并将其发送给特定的主控制器，然后再将其传送给安装在
Site上的子控制器，后者对其进行处理并执行给定的命令。 执
行命令后，它向主控制器发出信号，将信号传送给PLC，并在操
作员的计算机屏幕上显示该信号。
 每个控制盒都有特定的I.P和NUCID。 指令根据这些ID传送。
 设备布置分散，距离长，干扰问题严重：
equipment layout scattered, long distance, interference problem.
 整个输煤系统需监视控制的设备成百近千，设备之间基本呈线性
分布，点多面广，战线极长。由于工程建设中的好多实际问题，
现场控制电缆基本与动力电缆紧靠敷设，如果采用PLC方案，控
制系统极易受强电系统干扰。如对本工程#7A\7B带，皮带长度近
400米，从输煤程控室距最远端设备电缆单根长度就达六七百米；
如此长的电缆，按常规PLC技术系统很难正常可靠工作。
 The entire coal handling system to be monitored and controlled by
the equipment nearly a thousand, the basic linear distribution
between devices, point wide and broad, the battle line is extremely
long. Due to a lot of practical problems in the construction of the
project, the on-site control cables are basically laid close to the
power cables. If the PLC scheme is adopted, the control system will
be easily disturbed by the strong power system. If the project # 7A
\ 7B belt, the belt length of nearly 400 meters, from the coal
control room away from the most remote device cable length of a
single up to 6700 meters; such a long cable, according to
conventional PLC technology system is difficult to normal and
reliable jobs.
 当本工程采用现场总线技术后，干扰、
距离都得以解决。
 When the project uses fieldbus
technology, interference, distance
problem resolved.
 庞大的控制电缆用量：
huge amount of control cables:
 由于输煤系统距离长，设备分散的原因，使输煤程控
系统对控制电缆的消耗极大，总线技术，对整个输煤
工程，包括主厂区和码头两部分，实际控制电缆用量
大大降低。缩短施工工期。
 Due to the long distance of the coal conveying system
and the reasons for the scattered equipment, the coal
consumption control system consumes a great amount
of control cables. The bus technology greatly reduces
the actual amount of control cables used for the entire
coal transportation project, including the main plant
area and the wharf. Shorten the construction period.
 输煤系统粉尘污染问题，是每一个电厂的顽症，再加
上几乎每班运行后水冲洗，使输煤系统控制设备长期
处于大灰尘、高潮湿的环境中。总线装置所有布置于
现场的电控设备全按IP67防护等级要求。
 The problem of dust pollution in the coal handling
system is a chronic problem in every power plant.
Coupled with the water flushing after almost every
shift, the coal handling system control equipment is
kept in a large dusty and humid environment for a
long time. All bus devices arranged in the field of
electronic control equipment in full accordance with
IP67 protection level requirements.
 电缆防火，是输煤程控系统最大的故障隐患：
Prevent Control Cable form Fire damage.
 常规系统电缆量极大，电缆积灰是该系统的顽疾。电缆长
期堆积在电缆外表、设备外表、电缆桥架等处，现场电缆
不可避免发热，煤粉极易燃烧，从而给输煤系统的安全运
行带来不可估量的损失。特别是对巴基斯坦卡西姆项目，
夏季外界气温长期在40多度以上，系统长期运行时火灾危
险将是本系统最大的安全隐患。
 The amount of conventional system cables is huge and the
fouling of the cables is a stubborn problem for the system.
Long-term accumulation of cables in the cable appearance,
the appearance of the equipment, cable tray, etc., on-site
cables inevitably fever, coal extremely easy to burn, thus
bringing the inevitable loss of the safe operation of coal
transportation system. Especially for Pakistan's Qasim
project, the outside temperature in summer has long been
more than 40 degrees and the fire hazard in the long-term
operation of the system will be the biggest potential safety
hazard of the system.
 纵观采用完全的PLC设备实现的输煤程控系统，一般
性设置为：输煤程控室设置集中的双机热（冷）备
CPU，执行整个系统的控制逻辑，再以转运站为单位，
设置多个远程站，在远程站配置大量的DI、DO、AI、
AO模块，设置大量的I/O隔离继电器，以及外接大量
的至现场设备的电缆所实现。其典型的程控系统配置
图如附图方案一。
 根据本工程的实际情况，本项目采用基于PLC框架的
现场总线系统网络结构，具体的说就是：从输煤程控
室内的上位机系统、PLC CPU系统、及与电力线现场
总线主控装置之间的网络结构和设备，采用PLC技术
实现。本工程PLC选用AB系列PLC，PLC CPU与主控
装置之间采用AB公司的EtherNet IP工业以太网技术，
环网通讯。
 Throughout the use of complete PLC equipment to achieve coal
control system, the general set to: coal control room set
centralized dual thermal (cold) standby CPU, the
implementation of the entire system control logic, and then to
the transfer station as a unit, set Multiple remote stations, a large
number of DI, DO, AI, AO modules at the remote station, a large
number of I / O isolation relays, and a large number of external
cables to the field devices. The typical program configuration of
the program as shown in Figure a program.
 According to the actual situation of this project, this project
adopts the network structure of fieldbus system based on PLC
framework. Specifically speaking, it is from the upper computer
system, PLC CPU system and the main control device Network
structure and equipment, using PLC technology. This project
PLC selects AB series PLC, between PLC CPU and the main
control installment uses AB Corporation EtherNet IP industry
ethernet technology, the ring network communication.
 本工程不设常规的PLC I/O模块，现场层全部采用分
布式布置的直接布置于被控对象旁边的现场总线设备
（智能模块、智能控制箱、智能电控箱）实现，从而
起到节省电缆，节省投资、方便施工的目的。
 The project does not set conventional PLC I / O
modules, the scene layer all distributed directly
arranged in the controlled object next to the Profi bus
device (smart module, intelligent control box,
intelligent control box) to achieve savings Cable, save
investment, convenient construction purposes.
 完全的现场总线技术方案是指取消输煤程控室的PLC CPU，
将原来由PLC CPU完成的控制功能交由现场总线模块自身
的CPU和位于程控室的FPU一起协调完成。输煤程控室内
设置上位机、FPU挂墙箱、以太网交换机，主控装置视情
况布置于程控室或现场转运站内。从FPU到主控装置之间
采用100M工业以太网连接。此方案本工程未选用。
 The complete Profi bus technology scheme is to cancel the
PLC CPU of the coal conveying control room, and the
control function originally completed by the PLC CPU is
handed over to the Profi bus module's own CPU and the
FPU located in the program-controlled room to coordinate
and complete. PC program control indoor PC, FPU wall
box, Ethernet switch, the main control device is placed in
the program-controlled room or on-site transfer station.
100M Industrial Ethernet connection from FPU to main
control unit. This program is not selected for this project.
项目名称： 巴基斯坦卡西姆2X660MWR燃煤电
站
工程设计单位： 河北省电力设计院
电厂规模： 2x660MW机组
数据来源： 工程施工图
煤仓层长度： 164.5米
原煤仓数量： 12个；
煤仓层犁煤器数量： 22个；
电动三通数量： 5个；
除尘器数量： 18个；
高料位计数量： 24个；
煤场数量： 3个；
煤场长度： 408 米；
煤场喷头数量： 96个；
煤场刮水器数量： 2个；
煤场犁煤器数量： 2个；
电力线现场总线产品提供及现场实施单位：西安博恒智能技术有限
公司
 Project Name: Pakistan Qassim 2X660MWR coal-fired power station
 Engineering design unit: Hebei Electric Power Design Institute
 Power plant size: 2x660MW unit
 Data source: Construction drawings
 Coal warehouse length: 164.5 meters
 The original coal warehouse number: 12;
 Coal warehouse plow number: 22;
 Electric three links Quantity: 5
 Number of precipitators: 18
 High material level count: 24;
 Number of coal yard: 3
 Coal yard length: 408 meters;
 Coal field nozzle number: 96;
 Coal yard wipers: 2;
 Coal field plow number: 2;
 Power line Profi bus products provide and on-site implementation units: Xi'an
Bo Heng Intelligent Technology Co., Ltd.
 智能电控箱数量： 56台
 智能接口箱数量： 128台
 跑偏开关： 48台
 拉绳开关： 82台
 速度开关： 10台
 撕裂开关 ： 10台；
 低压馈线： 18回；
 电流信号接口箱： 3台；
 煤水处理系统接口箱： 15台；
 intelligent control box number: 56 Taiwan
 intelligent interface box number: 128 units
 deviation switch: 48 units
 rope switch: 82 units
 speed switch: 10 units
 tear switch: 10 units;
 Low-voltage feeder: 18 times;
 current signal interface box: 3 sets;
 coal handling system interface box: 15;
 按照输煤程控系统技术协议及巴基斯坦国家电压标准，
外部系统供给输煤 400V PC母线的电源“标称电压”应
为AC230V，实际“运行电压”取上限+5% 应为AC240V，
母线上的最大电机启动时允许最大压降20%，即
230x0.8=184V， 按此标准，我方设计的液力耦合器控
制箱的工作电压范围为AC250V~AC180V， 应该说满
足技术协议要求的，供货没有问题。但现场实测，在
全厂最大的电动机 (电动给水泵）启动瞬时，输煤低
压变高压侧母线电压直接下降了 28%，若再 计及低压
侧电缆和变压器抽头的调整，现场的电压已低到了
AC170V 以下甚至更低，由此导致布置于现场的智能电
控箱内的CPU在大功率电机启动瞬间工作异常。
 According to the technical agreement of coal conveying control
system and Pakistan national voltage standard, the nominal
voltage of the power supply of 400V PC bus supplied by external
system should be AC230V, the upper limit of actual operating
voltage + 5% should be AC240V, and the maximum on bus When
the motor starts to allow the maximum pressure drop of 20%,
that is, 230x0.8 = 184V, according to this standard, we designed
hydraulic coupler control box operating voltage range AC250V ~
AC180V, it should be said that meet the technical requirements
of the agreement, the supply no problem. However, on the spot,
when the maximum motor (electric water pump) of the whole
plant was started, the busbar voltage of low voltage and high
voltage side of coal conveying dropped directly by 28%. If the
adjustment of the low voltage side cable and transformer taps
were taken into consideration, the voltage of the site was already
low AC170V even below the even lower, resulting in the
deployment of the intelligent control box in the field of CPU
power in the moment of high-power motors start working
abnormal.
 1.使用试验调压器确认CPU可靠工作电压及接触器线圈
可靠工作电压。
 2.改变液力耦合器就地控制箱控制回路供电方式，将
之前从动力回路供电改为由总线直接提供控制电源。
 3.适当调整输煤系统电压，使电压保持在可靠工作电
压范围内。
 4.将油泵接触器控制回路增加自保持接点，当CPU死
机时，油泵合闸回路不会断开。
 5.重新设计调整控制箱的最低极限工作电压至AC165V。
 在经过现场调试人员和技术人员的共同努力下，液力
耦合器油泵跳闸及信号误动作的问题基本解决，后续
几次卸煤系统工作正常，但还需长期运行验证。
 1. Use test voltage regulator to confirm CPU reliable working
voltage and contactor coil reliable working voltage.
 2. Change the local control box power coupling fluid control
circuit, the power supply from the power circuit will be replaced
by the bus directly to provide control power.
 3. Properly adjust the voltage of the coal handling system to keep
the voltage within the reliable working voltage range.
 4. The pump contactor control loop to increase self-holding
contacts, when the CPU crashes, the pump closing circuit will
not disconnect.
 5. Redesign and adjust the control box minimum operating
voltage to AC165V.
 With the joint efforts of on-site commissioning personnel and
technical staff, the problem of hydraulic coupler pump trip and
signal malfunctioning basically solved. The following several
unloading systems work normally, but long-term operation
verification is needed.
 高压电动机温度监控箱温度跳变严重，对设备的安全
运行构成威胁，具体现象有，2017年8月17日 7A皮带
启动过程中头部电机A相绕组温度跳变达到80度，尾
部电机B相绕组温度最高达到178度，导致电机启动过
程中温度保护动作跳闸等。电机在运行过程中温度跳
变频繁，不能准确反映电机实时温度，对监控造成干
扰，造成设备运行的安全隐患
 分析其跳变原因主要有以下几点；
 High voltage motor temperature monitoring box
temperature jump serious threat to the safe operation
of the equipment, the specific phenomenon, August
17, 2017 7A belt start the first phase of the motor
winding temperature jump to 80 degrees, the tail of
the motor phase B Winding temperature up to 178
degrees, resulting in the motor starts the process of
tripping the temperature protection action. During
the operation of the motor, the temperature jumps
frequently, which can not accurately reflect the real-
time temperature of the motor and interfere with the
monitoring, thus causing potential safety hazard of
the equipment operation
 对从高压电机本体测温信号接线盒到总线测温箱之间
的测温电缆的选型，以及此段测温电缆所引入的外部
干扰对温度测量值的影响进行了测试性试验，实际测
试表明，从高压电机到总线测温箱之间的信号电缆是
引入外部信号 干扰跳动的另一个及其重要的环节和因
素。考虑到现场更换测温电缆、重新施工电缆的难度，
我方从软件角度出发，在就地总线测温箱内增加了数
字滤波功能，不再要求施工方更换电缆，此问题得以
彻底解决。
 The test from the high-voltage motor body temperature
signal junction box to the temperature measurement box
between the bus thermometer cable selection and the
temperature measurement of external interference
introduced by this section of the temperature
measurement cable conducted a test, the actual test This
shows that the signal cable from the high-voltage motor to
the bus thermometer is another important factor in the
introduction of external signal disturbances. Taking into
account the scene to replace the temperature cable, the
difficulty of rebuilding the cable, we from the software
point of view, in the local bus thermometer added digital
filtering, no longer require the construction side to replace
the cable, this problem can be completely solved.
 大大降低工程电缆造价：
 greatly reduce the construction cost of cable:
 简化的输煤系统电缆通道：
 simplified coal system cable channel:
 更高的系统智能化功能：
 higher system intelligence function:
 工程施工周期短：
 short construction period:
 系统调试时间短：
 The system debugging time is short:
 极简单方便的系统功能扩充能力：
 very simple and convenient system capabilities to expand capacity:

 降低的电缆防火工作应对难度：
 reduce the difficulty of the cable fire work to deal with:
 卡西姆燃煤电站现场的总线技术，虽然在调试及试用
阶段，突出表现出如液力耦合器死机和温度跳变的问
题，但经过厂家技术人员对相关设备的改进，解决了
相关问题。总线技术从根本上改变了输煤系统的施工
方案及控制方式，总线设备采用了IP67防护等级的就
地智能电控箱，提高了系统的防护等级，杜绝了由于
现场的防护问题带来的一系列安全问题，简化了输煤
程控系统；极大限度的减少了现场的电缆用量，为输
煤程控室提供了更多就地设备的信息，提高了系统的
自动化水平。将煤仓层与程控室之间 的通讯改为光纤，
提高通讯可靠性，增加抗干扰能力，明显的降低整个
工程的一次性投资，提高系统的运行稳定性和系统的
自动化水平，加快工程的建设周期，对整个工程具有
实质性的意义。
 Although the bus technology at the site of Qasim coal-fired
power plant has shown problems such as crash of hydraulic
coupler and temperature jump during debugging and trial phase,
the related problems have been solved after improvement of
relevant equipment by factory technicians. Bus technology
fundamentally changed the coal handling system construction
programs and control methods, the bus equipment uses IP67
protection level intelligent control box on the ground to improve
the system's protection level, eliminating the protection of the
scene as a result of a Series of safety issues, simplifying the coal
control system; greatly reduce the amount of cable at the scene
for the coal handling room to provide more information on the
location of equipment and improve the system's automation
level. Change the communication between coal warehouse and
program control room to optical fiber to improve
communication reliability and increase anti-interference ability,
significantly reduce one-time investment of the whole project,
improve system operation stability and system automation, and
speed up the construction of Construction cycle, the entire
project has a substantive significance.