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现代火力发电企业是什么样的?当您进入火力发电厂时,看不到人来人往的情形,而机组的发电与现代化的管理正在悄然进行。调度会上,主管生产的副总经理正与各生产部门经理在大屏幕投影前查看机组运行情况和电网负荷,制定新的竞价电价和设备检修计划;财务部正在打印财务报表和预测新的发电成本;材供部正在查阅材料消耗情况和设备损耗情况,根据库存制订备品配件购买计划,并在Internet上发布采购信息;检修班组正在网上填写工作票,申请对设备进行检修;出差在外的总经理正用笔记本电脑在网上查看公司各部门的数据,并根据分析系统得出的结论作出正确的决策。这就是现代化火力发电企业的情景,与以往的热火朝天形成了鲜明对比,但却产生了数倍的经济效益。员工虽少,效益却高,企业每部分都能产生最大的效能。这是任何一个火电厂企业领导人的梦想,而这可通过实施管控一体化DCS(分布式控制系统)工程实现。
现代火力发电企业是什么样的?当您进入火力发电厂时,看不到人来人往的情形,而机组的发电与现代化的管理正在悄然进行。调度会上,主管生产的副总经理正与各生产部门经理在大屏幕投影前查看机组运行情况和电网负荷,制定新的竞价电价和设备检修计划;财务部正在打印财务报表和预测新的发电成本;材供部正在查阅材料消耗情况和设备损耗情况,根据库存制订备品配件购买计划,并在Internet上发布采购信息;检修班组正在网上填写工作票,申请对设备进行检修;出差在外的总经理正用笔记本电脑在网上查看公司各部门的数据,并根据分析系统得出的结论作出正确的决策。这就是现代化火力发电企业的情景,与以往的热火朝天形成了鲜明对比,但却产生了数倍的经济效益。员工虽少,效益却高,企业每部分都能产生最大的效能。这是任何一个火电厂企业领导人的梦想,而这可通过实施管控一体化DCS(分布式控制系统)工程实现。
什么是管控一体化DCS工程呢?首先,管控一体化系统总体技术路线为:系统采用WINDOWS NT和QNX操作系统平台,采用现场总线技术,形成DCS系统对火电机组的生产全过程至每个环节进行监视和控制。在此基础上,火电厂企业资源计划(ERP)的功能通过实时信息系统接口集成到DCS中,形成管理和控制一体化的计算机系统。系统从体系结构上应充分采用现场总线技术和开放式计算机与网络技术。系统结构示意图如图1。
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在火电企业中,利用管控一体化系统实现什么目标呢?首先,利用计算机集成制造的哲理,使火电企业的人、财、物、时间等各种资源得以充分利用,使发电生产过程和企业的经营得到优化,使企业在"厂网分开、竞价上网"的市场竞争中取得优势。通过实施管控一体化DCS工程,整合企业资源,实现对企业进行有效的经营管理,充分发挥企业核心竞争力的优势,降低发电成本,满足电网需求。企业以安全经济的电能质量和高效、优质的检修服务质量,实现长期的经济效益。实施管控一体化DCS工程的效益主要体现在: (1)降低发电生产成本;(2)降低管理成本;(3)提高企业利润;(4)提高企业综合经济效益;(5)提高企业核心竞争力、顾客满意率。
火电企业要实现以上目标,管控一体化系统应具有什么功能呢?在管控一体化DCS工程思想统一下,综合自动化技术、计算机技术、网络技术、信息技术、智能技术和有关工艺(包括发电、检修等工艺)技术,建立火电企业集成化的经营决策系统、管理信息系统、生产计划与调度系统、车间管理、现场控制与数据采集系统。在计算机网络和数据库管理的支持下,不仅把发电企业的全部生产活动,包括市场分析(如:电网负荷分析、发电成本分析等)、经营管理、生产(包括主业及三产),集成起来,也把人-机集成起来,建立一个经营决策、生产调度、车间管理、生产过程优化控制的集成生产自动化系统。因此,系统应具有以下主要功能:(1)常规检测功能;(2)自动控制功能;(3)高级检测功能;(4)一体化的ERP功能。从而可以实现满意的经营决策、信息管理、优化企业生产调度、优化发电工艺的操作和控制,达到节能降耗、降低成本,以安全经济的电能质量满足电网要求,全方位提高火电企业的能力水平。这就是为什么在火电厂实施管控一体化方案的原因。
二、管控一体化系统体系结构及功能
管控一体化系统体系结构怎样且如何实施呢?我们发现火电企业存在两类信息,即管理数据和现场数据。管理数据可采用分布式数据库管理,现场数据由DCS管理。管理所需要的现场数据,以及现场控制需要的管理数据,可相互获取和传送。为此,应将系统分为控制网络、系统网络和管理网络三层。控制网络应采用国际上最流行的现场总线网络技术(如Profibus-DP和CAN等),用来连接现场控制站主控制器和I/O单元;系统网络用于连接现场控制站和操作员站及系统服务器,用于完成现场控制站与操作员站及服务器的通信和数据交换;管理网络用于DCS与ERP的数据交换以及和外部的数据交换。
1.系统硬件体系结构
系统硬件体系应由DCS系统硬件、ERP系统硬件和网关构成。DCS系统硬件包括I/0站、操作员站、工程师站、服务器、电源柜、接地柜、集成器等。ERP系统硬件包括2~3个服务器、1OOMbps交换机、集成器、电脑终端等。
2.系统软件体系结构
(1)体系结构
NEW SICK OPTIC ELECTRONIC PHOTOELECTRIC WT27-R610 (WL40-2)
NEW DONGAN SINGLE PHASE GENERAL PURPOSE TRANSFORMER 35-1030 .750 KVA (X6)
Reliance Electric P18G4900 Energy Efficient AC Motor 3 HP 3520 RPM (Z5)
AT&T LUCENT TN742 V10 ANALOG LINE CARD REFURBISHED? GOOD USED (165)
ACTION INSTRUMENTS V560 LOOP POWERED INDICATOR LR-42272 (I6-5)
LOT OF 16 SWAGELOK? 2 MICRON ELEMENT FILTER? (BIN65)
USED BAILEY TRANSMITTER BCN12611380 15PSI 12-42VDC (Q4)
NEW YARWAY INSTRUMENT 8110 3-WAY VALVE MANIFOLD 1500/5000 PSI 250/850°F (YY2)
NEW CUTLER HAMMER 200A PANEL 120/240VAC 36x20A BREAKERS (67)
FEDERAL MOGUL BCA BEARING 13685 NEW NIB BOWER (108-1)
NEW NO BOX AMPHENOL 18-10PF CONNECTOR (180-1)
SCIENTIFIC COLUMBUS POWER FACTOR TRANSDUCER PF-1A4 USED NO BOX (CC6)
NEW NIP HUBBELL CORD CABLE ASSEMBLY YELLOW C504P24J4DESN 0194 (B6-1)
AMERICAN BOSCH CORP. PULSE-TRONIC100 IGNITION SYSTEM (K2)
NEW IN FACTORY SEALED BOX TIMKEN 388DA ROLLER BEARINGS (132-5)
SET OF 2 INMOTION CONTROLS REMOTE CONTROL FOR AUTOMATION 260 SERIES TX (N2)
GE FANUC IC693PWR321U GOOD USED POWER SUPPLY PLC MODULE (D5-2)
ALLEN BRADLEY SZ 3 MCC MOTOR CONTROL 2112B-E475513/1?-3A (76)
NEW* 2AK41H BROWNING SHEAVE PULLEY (F3-1)
NEW AMPHENOL AEROSPACE 97-3106B-20 CIRCULAR MIL SPEC CONNECTOR (156-1)
NEW MCLEAN FAN APW 1RBB0M115V NIB (LL2)
NEW NIB BROWNING VF4S-235 2 3/16" SET SCREW STANDARD BEARING (VV5)
LOT OF 5 NEW IN PKG HYSTER CLAMP 241878 (DR1F-2)
NIP AMPHENOL 97-60-36 SIZE 36 SHELL METAL PROTECTIVE CAP WITH CHAIN (W2-1)
SYSTECON S9072 RELAY WHITE WITH BASE ST11-PC 300V 10A USED (TT4-3)
LOT OF 3 SETS OF 4 NEW RIDGID PIPE DIES 1/2" 1/2 (181-1)
USED MAGNETEK GPD333 DS042 1.5HP 380-460V 2.9A VFD AC DRIVE (R8)
NEW FENWAL 9828 THERMOSWITCH THERMOSTAT CONTROL 01-018023-000 (Y5)
NEW IN BOX ALEMITE GASKET FILTER ELEMENT KIT 393339-42 9612 40 MICRON (120-2)
HYDRO-LINE CYLINDER R5F-2.5X7 N-.63-2-N-N-N-1?-1-X (L7)
HYDRO-LINE CYLINDER R5F-3.25X9 N-1-2-N-V-V-1-1?-X 192082416-1 (CC4)
NEW IN BOX GE REPLACEMENT COIL 55-B38H 24V 50/60 HZ (286-1)
NEW, Amphenol Cable & Connector CA-A421-0222-A 9948 (X3-1)
LOT OF 6 NEW SMC CQ2B80-PS REPAIR KIT (147-1)
NEW MODICON 990NAD23000 MB + T CONNECTOR (S4)
NEW ALLEN BRADLEY 195-FA40 TYPE F SER A ADD ON CONTACTOR BLOCK (BIN5)
MITSUBISHI FREQROL FR-A044-0.4K-UL 400V INVERTER DRIVE (28/25)
NEW IN PACKAGE OIL AIR OILAIR 5 GAL ACCUMULATOR BLADDER R5-101 (113)
LAYERZERO EPOD SIGNAL ACQUISITION BOARD 40-11-10120103 (J3)
SQUARE D 8501 KPD12 2PDT 24VDC RELAY 2 POLE SER D USED NO BOX (BB5-3)
POTTER & BRUMFIELD KRPA-11AG-120 RELAY W/BASE AB 700-HN125 USED NO BOX (Z3-2)
GETTYS AEG PS3005-A00 AC SERVO POWER SUPPLY INPUT VOLTS 230 USED NO BOX (SS5-1)
AIR LOGIC WIRE HARNESS F-5100-5FT-3C NEW IN BAG (DD5-1)
NEW IN PKG HYSTER FORKLIFT TRANSMISSON PUMP GASKET 0346686 (TT1)
GRAYMILLS DOUBLE DIAPHRAGM PUMP 1" MODEL DDPT-100 NEW IN BOX (RR6)
FOXBORO P0900HS FBM 22 I/A Series Card w/ cables (TT5)
SMC CYLINDER CQ2B80-50DM-XC1 DUAL SRTOKE? (158)
NIB GENUINE PANASONIC TONER CARTRIDGE KX-FA76A (XX3) 3721
NEW EATON HYDROLINE HYDRAULIC CYLINDER N5R2.5X1-N-1 4-NV-R-1-4 (164)
T&B CONDUIT SPACER 1-1/4"-1-1/2" & 2" CONDUIT BOX OF 19 NEW IN BOX (UU5)
NEW PNEUMATIC NORGREN CYLINDER CONEC 41" STROKE 250PSI B04-UM SPUSR/010G0240 (36
NEW IN BOX NDH BEARING DELCO Z993L02 BALL BEARING GM PRODUCT (280-10)
USED FIREYE 60-2204-2 60-2207-1 60-2301 FLAME AMPLIFIER MODULE (UU2)
NEW IN BOX NDH BEARING DELCO 87606 BALL BEARING GM PRODUCT (217-1)
NEW IN BOX TIMKEN ROLLER BEARING 52401 3H000 H000 4” 5 3/4" (296-1)
FISHER CONTROLS ACTUATOR SIZE 30 TYPE 667 3/4HP W/ POSITION SWITCH (FF6)
NIB CATERPILLAR 153-6559 1536559 HORN AS 24VD W/ PLUG KIT 155-2270 1552270 (G4)
NEW TRERICE THERMOMETER A00504WWG BX91403-1/2 0/160 DEG F NIB (283)
CUTLER-HAMMER C340FNG KVA .200 .200KVA TRANSFORMER USED NO BOX (P6)
MORSE 322435 40-3 O/L STRAND RIVETED ROLLER CHAIN LINK S 2 NEW IN PACKAGE (L6-2)
NEW TELEMECANIQUE ZB2BW37 CLEAR PUSHBUTTON (CC5-1)
BULLETIN 700 TYPE N AC RELAY SER B 700-N200A1 700-NA20 (JJ2)
NEW IN BOX CUTLER-HAMMER 10250T197L INDICATING LIGHT S11004 (BIN7)
SIECOR OPTICAL CABLE 09/98 62.5/125 MICRON TBII OFNR (UL)FT4 (CSA) (BIN67)
RELIANCE ELEC AC MOTOR NEW 1/2 HP NEW P56H1302G FB56 (DD4)
**NIB** SIEMENS MODULE PTS DIG SIMATIC PLC 505-4232A 110 VAC (AA2)
NEW Precision 017535 R08 35/64 Twist Drill (BIN56)
NEW MCGILL MR 32 S NEEDLE PRECISION BEARING USED (BIN55)
HELI-COIL 5-40 STI NC GH2 HSS A 05-CSA HAND TAP LOT OF 10 NEW NO BOX (WL29-1)
CEL-CHK BATTERY MONITOR X-180 MANUAL/ 4 HR PRINT-OUT/BATTE?RY DISCHARGE USE (XX3)
NEW HUBBELL MCMA2417 MICRO-QUICK FEMALE R/A PLUG CABLE ASSEMBLY (YY2)
LGF MOISTURE REGISTER MOISTURE METER W/CARRYING CASE T8 USED LOT 2(P7)
NEW NEW CHESTERTON 221-28 SPLIT SEAL SPARE KIT SHAFT SIZE 3.500 VITON (183)
HUBBELL TWIST LOCK CONNECTOR USED NO BOX 20A 125/250V (L6-1)
AT&T 631DA1 POWER UNIT SERIES 1:5 120V 60HZ (T5)
41-09-629291 REV A02 CYBEREX MICRO CONTROL I/O INTERFACE (HH5-1)
LOT OF 2 NEW AMPHENOL 97-283-18 97 SERIES CIRCULAR CONNECTOR (130-2)
NEW Precision 51056 R51 7/8 Twist Drill (S42D)
NEW NIB NACHI DOUBLE ROW BALL BEARING 5307 D (BIN22)
CYBEREX AC/ST/SW GATE DRIVE 41-09-655761 REV E00 USED (HH5-1)
ALLEN-BRADLEY SELECTOR SWITCH 800MR-H31B SER A/800M-XA SER B NEW (CC6-3)
MARATHON WEINMAN MOTOR M306 4VH145TTDR5346A?D TYPE-TDR 60 HZ 3 PH (or44)
NIB BALDOR MOTOR VJMM3211T 3HP 3PH,230/460 V 60HZ 1725 RPM, FRAME 182JM (294)
LAMBDA LUS-10-5 DC POWER SUPPLY MAX D10A NEW IN BOX (173-1) 3721
NEW IN BOX, FRAM C1174PL Fuel Filter (I4)
NEW SW-50 1000131 REFLECTOR 60MM DIAMETER (156-1)
LOT OF 3 NEW IN PKG FISHER 1U225705092 2 IN PISTON RING 0509 PTFE/CARB (204-2)
USED FIREYE 60-2204-2 60-2207-1 60-2205 DISPLAY FLAME AMPLIFIER MODULE (UU2)
NEW NIB Parker 07F21AB Filter 3/8" (BB3)
NEW IN BOX FMC BEARING 75SLB22L-C 2215LBK 75SLB22K-3 (145-1)
LOT OF 10000 +/- NEW ON REEL DIODE ZENER 1N5230B 4.7V (316)
NEW Cleveland Twist Drill MT-5221-B2 REV. R (323)
FAG 22228E SK 22228ESK C3 SPHERICAL ROLLER BEARING 140x250x68MM (PP5)
SVF COMPACT 15-R64466TT-SE ACTUATOR H25 SR 20 (M4)
Precision 33605 D888S0 5/16x4 Masonry Drill (BIN56)
LOT OF 5 ALLEN BRADLEY COIL OA86P 0A86P 120V 60CY 110V 50CY (155)
HONEYWELL SZR-LY4-N1 MAGNET RELAY 10A @ 250VAC 20A 24VDC NEW NO BOX (Z4-1)
AT&T LUCENT TN754B V4 DIGITAL LINE CARD (157)
NEW ALLEN BRADLEY AUXILIARY CONTACT SERIES A 140M-C-ASA02 (R2)
NEW SIGNODE BANDING STEEL STRAPPING 19MM X .64MM ? X .025 076310 (trailer)
NIB DIXON BOSS GL 130 GL-130 ABS STANDARD DRY GAUGE GAGE 0-160 PSI (BIN26)
USED RELIANCE P56H3665M DUTY MASTER AC MOTOR TYPE P 3PH 1725 RPM (34)
NEW EATON HYDROLINE CYLINDER R5C-2.5X8 B-.63-2-N-N-N-1?-1 (166)
MIXED LOT OF 13 HAND TAPS USED/NEW (DR1G-1)
NEW DODGE V RTL PIPE GROMMET KIT 315-407 SL 132646 (YY2)
NEW IN BOX ALLEN BRADLEY 32A06 COIL 220V/60CY 208V/60CY (131-3)
LOT OF 11 NEW RANCO SOLENOID COIL LDK-31 120V 50/60HZ 5W/4W (189-1)
LOT OF 10 NEW IN BOX SYLVANIA MINIATURE LAMP BULBS 736 (238-1)
NEW IN PKG HYSTER FORKLIFT VALVE COVER GASKET 1390147 (TT1)
OGDEN HEATER HEATING ELEMENT 1250W HS2514 4-1 LOT OF 2 (M5)
GE Auxiliary Relay 12HGA111J2 125VDC (DD4)
USED** 5 TON JET HOIST DOUBLE DROP CHAIN 6FT OPER 10FT LIFT CHAIN. 7630121 (16)
JOHNSON CONTROLS X-200-181 MULTI RANGE TEMPERATURE CONTROLLER (K4-1)
USED* CUTLER-HAMMER DRY-TYPE TRANSFORMER 2KVA S48G11S02SSCU 120/240 V 1PH (Q4)
GOOD USED FANUC PLC MODULE IC693MDL240E INPUT 120 VAC 16PT DOOR MISSING (WL9)
USED MICRO SWITCH SNAP/BASIC ACTION SWITCHES BZ-2RD-P1 (X2-2)
REFURBISHED LUCENT 120A3 CSU MODULE ALARM CONTACTS NETWORK 106606536 (195-2)
NEW IN BOX TRIAD EC-100-A TOROID MOLDED 100 MH (195-2)
NEW LOT OF 4 DIODES R 16RIA60 8901 BN BK DIODE (bin20)
MAGNETEK LOUIS ALLIS HYDRAULIC PUMP W/ PACEMAKER MOTOR .50HP 208V 865 RPM (68)
YOKOGAWA ANALOG INPUT MODULE GOOD USED AAV141 AAV141-S00 S2 (306)
NEW VEEDER-ROOT 744096-221 MECHANICAL COUNTER 6 DIGIT (BIN14)
LOT OF 4 NEW RECTIFIERS SK3683 RCA H 8245 SCR RECTIFIER 5A? (BIN32)
ALLEN-BRADLEY SWITCH BOX 800H-NP14X CAT NO 800H-2HYX7 (WL13)
**NEW** LOT OF 11 SURPLUS L-COM ETHERNET CABLE TRDU45SCR-5 (H5)
CM LODESTAR XL 5 TON PNEUMATIC CHAIN OPERATED HOIST TROLLEY 24 FT 53425 (30)
NEW LOT OF 14 GOULD SHAWMUT FUSE NEW TRS2 ? FSR-R 2 1/2 R FUSES (BIN41
NEW IN BOX ALLEN BRADLEY 800 QK10 PILOT LIGHT 110V AC or DC (286-1)
NEW IN BOX HYSTER FORKLIFT HOUR METER 275648 1/10 (G3-3)
NEW IN BOX STANDARD POWER SLS 32-24 115/230V 47-440 HZ 24V 1.2A (132-3)
HERTNER BATTERY CHARGER 3TF12-450 WH 12 CELL L-A (39)
SIEMENS SITRANS P 7MF4032-1BC10-1?QC6-Z TRANSMITTER (171)
GOOD USED ALLEN BRADLEY 500FEOD930 SIZE 4 CONTACTOR SER C (41)
NEW SICK OPTIC CONNECTION MODULE AMS10-012A02 (WL40-3)
NIB NEW FMC LINK -BELT BALL AND ROLLER BEARING 1-7/16" P3U223H P3-U223H (WW2)
PANAMETRICS AT 868 AquaTrans Flowmeter AT868W-1-1-1-1 w/ Transducers (229)
LOT OF 4 NEW IN PKG SQUARE D SK-5666 (140-2)
NEW NIB SOLENOID COIL ITT GENERAL CONTROLS CS4AMO2A24 CLASS M (309-1)
TORSION BALANCE CO SCALE DLM2 171439 120G CAP W/2 OHAUS ANALYTACAL SCOOPS (II1)
BBC Brown Q101C Glow Lamp 13,800 volts High Volt Indicator Bulb (309-5)
LOT OF 3 NEW ALLEN BRADLEY CONTACTS 800M-XAS 1NO 1 NC CONTACT SER B (123-1)
BROWNING 50 S/C C/L PK 25 CONNECTING CHAIN LINK LOT OF 5 NEW (L6-3)
NEW EATON HYDROLINE HYDRAULIC CYLINDER R5A-2.5X2 193060595-2 (159)
MALLORY VWIK P4 CONTROL 1 K OHM 5 WATT NEW IN BOX (BB1-1)