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　煤气在使用过程中容易产生管网压力波动，存在不安全因素。煤气柜作为调剂煤气供应、减缓管道波动的有效方法，在冶金和化工等行业得到了广泛的应用。煤气柜可以有效回收放散煤气，充分合理利用企业内部的附产煤气，调节管网压力。作为煤气这个危险性气体的“归宿”，煤气柜的安全运行对于全厂的生产安全具有重要意义。
　　山东金能科技股份有限公司是一家综合性化工企业。多年来，公司秉承 “资源高效、绿色低碳”的循环发展理念，以技术创新为驱动、以资源高效利用为导向，打造了区别业内其他企业的循环经济产业链，构建了资源利用、产品结构、技术装备、环保模式四大差异化的盈利模式，实现了煤化工与精细化工的科学整合，做到了资源利用最大化与资源利用价值最大化。
　　由于金能科技现有的30000m2煤气柜控制系统在设计时不具备硬件的冗余、容错和复杂逻辑判断等功能，当现场仪表出现显性故障时，极易造成工艺事故。为提高全厂的安全水平，金能科技决定利用冗余控制技术，升级现有的煤气柜监控系统。
　　挑战
　　煤气柜监控系统是智能自动化仪表技术、自动化控制系统、计算机技术和网络技术等多种技术的结合，涉及到多方面的知识。新系统的设计需要重点解决现有系统面临的以下三方面问题：
　　 故障安全：原有系统配置不能够排除当现场仪表出现故障或假液位造成的显性故障，易造成工艺事故。
　　 传感器的独立设置：对参与联锁的各个传感器(如活塞高度、气柜内压力等值)配置为单台测量，未使用不同的测量方式，不符合传感器冗余设置三选二的原则。
　　 硬件的冗余、容错：模块前期设计时，未考虑PLC模块的冗余、容错设计，如发生仪表的损坏、模块损坏、电源异常断电等故障时，极易造成工艺事故。
　　解决方案
　　针对金能科技干式煤气柜实际情况，基于罗克韦尔自动化组态技术和人机界面检测技术，金能科技构建了现代化的煤气柜监控系统，并与原有控制系统实现了无缝的融合与兼容。
　　项目总体实施过程包括五个步骤：气柜监控监测系统总体的方案设计;气柜监测系统逻辑关系模型的建立;冗余、容错目的的达成，及数学模型的建立;完成气柜监测系统软件部分的组态设计与开发;最终系统的联调联试以及持续改进。
　　新系统采用由罗克韦尔自动化PLC冗余控制系统结构，基于ContrlNet协议、工业以太网协议等通信方式，实现了传感器、电源、控制单元以及通信的冗余设置，控制精度达到毫秒级，保证系统安全可靠运行。可以完成对现场活塞高度、气柜内部压力、油槽液位、顶部泄漏量的数据的采集和进出口阀门等阀门的过程控制。对于输入、输出模拟量信号通过加装防爆安全栅(一入两出)进行现场与控制系统的安全有效隔离，现场检测信号一分为二，一路进原有系统显示报警，另一路进本系统参与联锁控制，双重保证检测信号的稳定性和安全性。系统所有开关量输入、输出信号都通过隔离继电器隔离，保证测点的干接点输入和输出。

Texas Instruments 500-5030

Mercedes C230/C240/C300 Sablite Radio Universal Media Interface Module OEM

Yamato EV211F-R6 I/O Board

Siemens 6ES7 151-1BA02-0AB0 6ES71511BA020AB0

SIEMENS LOGO 6ED1055-1FB00-0BA0 Exsion Module

Modicon AS-S491-100

Schneider Modicon AS-H827-209 984 Series 11 Slot Rack ASH827209

Schneider Modicon AEG/GOULD/MODICON/ AS-B571-001/B571-001 INPUT MODULE XLNT

Schneider Modicon AS-B239-001 NSFP ASB239001

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Schneider Modicon AS-B556-101 OUTPUT MODULE 5V TTL

Modicon MPCST52NDJ10T Telemecanique Magelis Smart iPC

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SIEMENS 6ES5-482-7LA11 USPP 6ES54827LA11

Siemens SCD 1597 K Control Panel 6AV8100-1BC00-0AA1 Looks

SIEMENS 6DD1681-0AJ1 CONVERTER SU12 SIMADYN

SIEMENS SINUMERIK 800 6FX1151-1BD01 6FX11511BD01

SIEMENS 6SN1111-0AA01-1BA1 LINE FILTER FOR INFEED (5KW) GOOD TAKEOUT

SIEMENS Simodrive 6RB2000-0GB01 Power Control Board

SIEMENS 6FC9348-7HX NSFP 6FC93487HX

Advantech ECM-3610 REV.A1.2

ALLEN-BRADLEY 1771-OGD TTL OUTPUT MODULE

ABB ACS600 MULTIDRIVE MODULE # ACN6340255500000300902

ACUMETER DIVISION MAY COATING TECHNOLOGIES PTC-8 PN77-0902 TEMPERATURE CONTROL

6ES7467-5GJ01-0AB0 6ES7467-5GJ02-0AB0 Brand , Factory Sealed,

900' Rust 250MCM 250 MCM 3/0 Rust Aluminum Cable Wire URD 600 volt

SQUARE D MEL36800LSG USPP MEL36800LSG

COMPUMOTOR DR-1400A60 USPP DR1400A60

BAUMULLER BUM60-VC-AE-1024 USPP BUM60VCAE1024

MODICON S975-000 USPP S975000

MAGNETEK 53SHC000-0003 USPP 53SHC0000003

ELECTRO CRAFT 9101-1131 NSPP 91011131

Siemens 6ES5 103-8MA03 6ES51038MA03

Siemens 6ES5-465-3AA13 USPP 6ES54653AA13

SIEMENS 6ES5 982-3UA11 6ES59823UA11

SIEMENS S5 6ES5-318-8MC12 ET200U

Siemens /PLC 6ES5-101-8RW11/6ES51018RW11

Siemens 6ES7331-7KB02-0AB0 6ES7 331-7KB02-0AB0

SIEMENS SINUMERIK 6FC5203-0AF02-0AA1 Membrane Keypad

Siemens 6ES5314-3UA11

ICD UNI-002 UNI002 Network Interface Module No Box

Xpresskit XK510 interface module by Directed Electronics Viper Python Avital

Siemens 6ES5441-8MA11 6ES54418MA11

Siemens MP270 6AV6 542-0AH10-0AX0 Membrane Keypad

Omron E3N2-D2Y4B-US

Schneider Modicon AS-BDAP-210 DISCRETE OUTPUT MODULE

Schneider Modicon AS-506P-002 USPP AS506P002

Schneider Modicon AS-J890-101 I/O INTERFACE PROCESSOR ASJ890101

Schneider Modicon AS-516P-006 Processor Board Rev C21 (UEX)

Schneider Modicon EK-489 DTA201 RACK W/CARDS 2EA DAP 210/AS-BDA

Schneider Modicon -AS-5540-000

SIEMENS/TI/CTI 505-4216A INPUT MODULE 110VAC 16PTXLNT

SCHNEIDER TSXSUP1051 POWER SUPPLY

Siemens Sinumerik Verteiler Box 6FX2006-1BC01 _ $$

SIEMENS 505-4532 OUTPUT MODULE 5054532

SIEMENS SINUMERIK 810 BOARD 6FX1120-7B

Corbco Millennium DBCS-16 Digital Telecom Communications Chassis Module LOADED

SIEMENS SIMODRIVE C98043-A1086-L11 07 C98040-A1086--P11-05-86

SIEMENS SIMODRIVE 6SN1145-1AA01-0AA1SINUMETIK 840D NCU-BOX 6FC52476FC5357 OP

Advantech CompactPCI MIC-3961-A

Allen-Bradley 6185-DACABBZ Series A Touchscreen A4

ABB 3HAA0001-XH IRB6000 Robot Servo Motor Axis 1 (complete with pinion)

ACCURAY 082157-002 NSPP 082157002

A06B-6102-H206#H520 FANUC CONTROLLERS REMANUFACTURED

8030-CRM565 SYMAX INTERFACE MODULE POWER LOGIC CIRCUIT

SIEMENS 6ES5-246-4UA31 NSFP 6ES52464UA31

APC SYCF40KF USPP SYCF40KF

ALLEN BRADLEY 6181P-15TPXPH USPP 6181P15TPXPH

KONE KM781380G01 NSFP KM781380G01

GRACO 236-930 NSFP 236930

PEPPERL & FUCHS IVI-KHA6-4HRX NSPP IVIKHA64HRX

Siemens 6ES5-340-3KB21/6ES5340-3KB21 COMM./INTERFACE MODULE XLNT

SIEMENS 6ES5 440-8MA21 DIGITAL OUTPUT MODULE IN BOX

SIEMENS S5 6ES5-5524-3UA13 Interface Module 6ES555243UA13

Siemens MEMORY CARD 5V FLASH 128KB 6ES5-374-2KG21 6ES5374-2KG21

Siemens 6ES7 223-1PL22-0XA0 6ES7223-1PL22-0XA0 FreeShip

SIEMENS OP7 6AV3 607-1JC30-0AX1 Membrane Keypad ping Worldwide

Qlogic QLE8142-SR 10Gb CNA Dual Port PCIe HBA FCoE with 10Gb optical SFP

GM TECH 1 OBD 2 VEHICLE INTERFACE MODULE 14 PIN DLC SELF TEST ADAPTER AND CABLE

TOTAL CONTROL "QPI21100C2P serA" OPERATOR INTERFACE WITH COMMUNICATION MODULE

Siemens 3RK1903-1CB00 3RK19031CB00

SIEMENS FLASHING PULSE GENERATOR 6DS1922-8AA IN BOX, Seal opened,

Modicon PC-L984-785

Schneider Modicon GOULD B374 ANALOG OUTPUT MODULE AS-B374-001

Schneider Modicon AS-BVIC-224 TESTED 4 Ch Ctr IN ASBVIC224

Schneider Modicon AS-D004-030 USPP ASD004030

Schneider Modicon AS-P180-010

Schneider Modicon AS-BDEP-220 TSX Compact Discrete Input

Schneider Modicon Micro 84 Controller AS-M84A-002 Programmer P370P371 Program Pack

Schneider TELEMECANIQUE XBT-GT-2110 XBTGT2110 with cable

Schneider Lexium 23 AC Servo Driver LXM23CU01M3X 100W

Promise Removable Device PR401US Pegasus R4 4TB RAID System 4x1TB SATA

SIEMENS 6ES5 454-7LA12 OUTPUT MODULE

SIEMENS 6DD3-470-0AD0/6DD3470-0AD0 BOARD XLNT

HONEYWELL MEASUREX DIGITAL 05366901 SERIAL LINE COMMUNICATION MODULE 62759

SIEMENS SIMODRIVE 6SN1145-1BA01-0DA1 6SN11451BA010DA1

SIEMENS SINUMERIK 810D/840DPCU20 6FC5210-0DF00-1AA1

SIEMENS MOORE ACM ADVANCED 39ACM24BDN CONTROL MODULE APACS 24V 21196

ALLEN-BRADLEY Panelview 300 24VDC 2711-B5A1L1 Series F

553VIC10100 MODICON MONITORS CRT REMANUFACTURED

ABB Teach Pendant 3HAB-5386-1/1 #34232

A06B-0153-B077#7076 FANUC SERVO MOTORS REMANUFACTURED

715-031752-206 CAP LOWER ELECTRODE 6"

RELIANCE ELECTRIC 19C401 USPP 19C401

ALLEN BRADLEY 1785-L40L USPP 1785L40L

ALLEN BRADLEY 1398-DDM-020 NSPP 1398DDM020

GENERAL ELECTRIC DS3800NPSE1E1G USPP DS3800NPSE1E1G

TOSHIBA VT130H1U-4220-B0H USPP VT130H1U4220B0H

SYMAX 8030-CRM-510 NSFP 8030CRM510

FISHER ROSEMOUNT 1151AP8S52B1M3 USPP 1151AP8S52B1M3

Siemens 6ES5-095-8MD02 USPP 6ES50958MD02

SIEMENS 6ES5 318-8MB12 INTERFACE ET200U MODULE

SIEMENS 6ES5-930-7AA22/6ES5930-7AA22 POWER SUPPLY XLNT

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Siemens 6ED1055-1FB00-0BA1 ping

Siemens LOGO! 6EP1 322-1SH41 6EP1322-1SH41

Rigol Function/Arbitrary Waveb Generator DG2041A 40M

Telemecanique ZB2-BW031

Smema Interface Module 60.009.037

VWIC-2MFT-E1 CISCO 2-PORT RJ-48 MULTIFLEX TRUNK E1

Siemens C7-626 6ES7 626-1DG03-0AE3 Membrane Keypad ping worldwide

Modicon AS-T584-101

Schneider Modicon Automation Inc DAP 216N/AS-BDAP-216N DAP216NASBDAP216N Module

Schneider Modicon AEG/GOULD// AS-B550-101 OUTPUT MODULE 115VAC XLNT

Schneider Modicon AS-B885-100 ASB885100 Motion Module

Schneider Modicon ASB248 ASB248501 Output Module AS-B248-501

Schneider Modicon PC-0984-381 CPU Module AS-9584-000 w/AS-M380-004 & AS-E381-902 NICE

Schneider Modicon AS-P890-000

Schneider Automation / Modicon PanelMate Plus MM-PMC2-200 WARRANTY

SIEMENS TI30525N INPUT MODULE

RELIANCE ELECTRIC 0-57405-E USPP 057405E

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Omron C500-LK003 3G2A5-LK003 Communication Module

SIEMENS SIMODRIVE 462018.7925.1150A6SN1123-1AA00-0CA1 BOARD

SIEMENS SINUMERIK PCU 50 6FC5210-0DF20-0AA0

SIEMENS Marble Products International Fossil Coaster Set of 6 FC101

AllenBradley1771-ODDPLC-5Isolated120VACOutputModule

Allen Bradley SLC-500 Output Mod. 16-Point 1746-OA16

ABB PCB BOARD DSQC 328A 3HAC 17970-1

Zygo 7003A & 7015 & 7012

, factory sealed SIEMENS 6FX1132-0BA01

MODICON AM-S980-810 USPP AMS980810

ALLEN BRADLEY 1394C-SJT10-D USPP 1394CSJT10D

GETTYS 110-0134 NSFP 1100134

GE FANUC 44A398722-G03 USPP 44A398722G03

SIEMENS 6SC9111-2AF2 USPP 6SC91112AF2

SICK OPTIC ELECTRONIC PLS101-112 USPP PLS101112

ACCURAY 725782 USPP 725782

Siemens 6ES5 900-7AA11 6ES59007AA11

Siemens S5 6ES5 385-8MB11 High Speed Counter Module

SIEMENS 6ES5-464-8ME11/6ES5464-8ME11 ANALOG INPUT MODULE NIB

Siemens 6ES5 430-4UA12/6ES54304UA12 FACTORY SEALED

Siemens S5 Power Supply Module S5-110A 6ES5 930-7AA21 WARRANTY

Siemens CUVC 6ES7 090-0XX84-0AB0

SFP-10G-LR LONGLINE 10GBASE-LR SFP MODULE FOR CISCO

Square D 8030 RRK-200

Siemens 6ES5 318-8MA12 Simatic S5 Interface Module

WE SHIP SAME CISCO WS-C3750X-24S-E SWITCH 1 YR 3750X-24S

Siemens 6GK7 243-2AX01-0XA0

SIEMENS TP177B 6AV6 642-0BA01-1AX1 Touch Glass + Protective film

Schneider Modicon AS-BDEP-210 Discrete Input NIB

Schneider Modicon ASBDEP210 8 Pt 120VAC Input Module AS-BDEP-210 Electric

Schneider Modicon AS-B806-032 NSFP ASB806032

Schneider Modicon Panelmate plus MM-PMC3-100 110/230 V As Is Parts Or Repair

Schneider Modicon AS-MBPL-001 USPP ASMBPL001

Schneider Modicon AS-B885-002 ASCII Basic Module

Schneider/Modicon PLC Output Module TSXDSZ32R5 NIB

Siemens 6ES7 321-1FF01-0AA0 DIGITAL INPUT MODULE PART TYPE SM 321 8 POINT

SANS DIGITAL MR4UT 4-bay hot-swap hardware RAID storage

Siemens Handwheel Sinumerik 6FC9320-5DC00 5V nice

SIEMENS Sinumerik 802S 802C Mechanical Keypad 2 month warranty

SIEMENS 6DD1661-0AB0 COMMUNICATION MODULE

SIEMENS 6SN1145-1AA01-0AA2 SIMODRIVE 611 INFEED MODULE 10 25kW UNREGULATED

SIEMENS 6SN1114-0NB01-0AA0 Simodrive 611U Option- Profibus DP3 Version B

SIEMENS 6FC5130-0CA01-0AA0 USPP 6FC51300CA010AA0

AllenBradleyPanelview2711-B6C2X/A2711B6C2X

ALLEN BRADLEY X-51343 NSFP X51343

ABB DRIVES,INDUSTRY OY CONVERTER UNIT ACS504-100-5,CONTROL UNIT ACS50Y-YYY-Y-00P

AdeptSix 300 Robot

(8538) 1 ALLEN BRADLEY 803-B6 ROTARY CAM LIMIT SWITCH

INDRAMAT TRANS-01.00 USPP TRANS0100

WINSMITH 4CV USPP 4CV

FANUC A16B-0160-0950 NSPP A16B01600950

ELME MSS0004000 USPP MSS0004000

RELIANCE ELECTRIC 86466-26R USPP 8646626R

OMRON C500-NC211 USPP C500NC211

OMRON CVM1-CPU01-EV2 USPP CVM1CPU01EV2

Siemens 6ES5 441-4UA14 -FS- 6ES54414UA14

Siemens 6ES5-921-3WB11 USPP 6ES59213WB11

SIEMENS 6ES5-400-7AA13 USPP 6ES54007AA13

Siemens 6ES5 441-7LA11 Digital Output Clip Broken

Siemens S5 6ES5 420-7LA11

Siemens 6SE7090-0XX84-0FF5 DP Communication Card

Siemens 6ES7 331-7SF00-0AB0 SIMATIC SM 331 ANALOG INPUT

Square D 8010 CC-100

RV LP INTERFACE MODULE PN 38030057

WE SHIP SAME CISCO SFP-10G-SR 10GBASE-SR SFP MODULE

Siemens CP5613 Card 6GK1561-3AA01 , opened box,

Siemens RWD62 Controller

Reliance 0-57412

Schneider Modicon Kodak Retina Reflex III with -Kreuznach Retina-Xenon f1.9/50mm AS-IS

Schneider Modicon AS-B258-101 NSPP ASB258101

Schneider Modicon AS-P964-000 NSFP ASP964000

Schneider Modicon AS-B838-032 OUTPUT MODULE 32POINT DISCRETE .5AMP 24VDC

Schneider Modicon AS-B804-000/ASB804000 Output

Modicon MM-PMA2-200 PanelMate Plus Operator Interface

Siemens Simatic 505-4108 Low VDC Input Module

SIEMENS 6ES5-305-7LB11 NSFP 6ES53057LB11

SIEMENS S5 6ES5 470-7LC12 Analog Output Module

SIEMENS 6DD2920-0AC0 LIGHT INTERFACE MODULE IN BOX

SIEMENS SINUMERIK 840C/840CE MMC CPU 6FC5110-0DB03-0AA4 NIB

SIEMENS 6SN1112-1AC01-0AA1 SIMODRIVE 6SN11121AC010AA1

SIEMENS SIMODRIVE 611 SERVO DRIVE 6SN1145-1BA01-0DAI IN BOX

SIEMENS 6FC9348-5XC FNFP 6FC93485XC

Advantech Motherboard PCA-6104 NIB

ALLEN-BRADLEY 1771-OD16 120V AC Isolated Output Module

ABB ACS60101205000B1200000

ADDIDATA PA8000 NSPP PA8000

6ES7614-1AH00-0AB3 6ES7614-1AH03-0AB3 Brand , Factory Sealed,

90pcs LSI Agere 2650B Broadband Photodiode For CATV, Video Transportation, EDFA

SQUARE D PHF2036 NSPP PHF2036