Honeywell-DCS操作-培訓(xùn)

1、HoneywellDCS 操作培訓(xùn)目錄緒論從一個(gè)完整的Shutdown 上裝載系統(tǒng) Honeywell 組合鍵盤 使用本地窗口狀態(tài)工具條 操作入門 操作On Off 控制點(diǎn)GUS R600 報(bào)警器報(bào)警 系統(tǒng)狀態(tài)使用Trend 顯示工藝報(bào)警響應(yīng) 操作HPM 程序 (可選)其它· 工具· 命令· JP/SOP附錄X_Plant 縮寫列表同Merlion 的接口 邏輯符號(hào)Honeywell 縮寫描述Honeywell 手冊(cè)報(bào)警和狀態(tài)指示 HPM參數(shù)參考緒論· HoneywellTPS 綜述· HPM 控制功能概觀· X6 DCS ·

2、; DCS 設(shè)備布局圖· DCS 標(biāo)簽編號(hào)系統(tǒng)· 點(diǎn)類型· Honeywell DCS系統(tǒng)操作簡(jiǎn)介 (參考 : HP12500)· X6 Honeywell DCS 系統(tǒng)操作· 工藝操作 Honeywell TPS 綜述 · 全球用戶工作站 (GUS)* DCS 操作控制臺(tái)* IS Merlion控制臺(tái)* Windows NT* 通過(guò) LCNP 處理機(jī)同LCN通信* 本地 window Þ 操作者和工程師職責(zé)(報(bào)警系統(tǒng)/控制臺(tái)狀態(tài)等等) Þ 每個(gè) GUS都有一個(gè)* 其它windows (顯示, 微軟官能度)* 顯示

3、創(chuàng)建者, 站點(diǎn)創(chuàng)建者, 安全綜述 (工程功能)* 遙控功能· 高性能工藝管理(HPM)* M68040 平臺(tái)Þ 通信/控制處理器(冗余)Þ I/O 接口處理器(冗余)* 獲取數(shù)據(jù)和控制功能, 對(duì)等通信* 點(diǎn)數(shù)據(jù)* 順序控制語(yǔ)言(CL), 聯(lián)鎖操作* 每秒鐘800個(gè)處理單元 (PU) (控制，離散邏輯，次序組等等)。 1個(gè)PID 控制器使用1個(gè) PU。* 培訓(xùn)系統(tǒng)I/O 模擬。· 通信網(wǎng)絡(luò)* 本地控制網(wǎng)絡(luò)(LCN)Þ 操作網(wǎng)絡(luò)(歷史紀(jì)錄,軟件裝載,訪問(wèn)硬盤等等)Þ 5兆/秒 Þ 令牌轉(zhuǎn)交接受協(xié)議，每個(gè)節(jié)點(diǎn)令牌的通過(guò)時(shí)間大約為3

4、0秒。Þ A和B 電纜線上同時(shí)廣播。Þ 最多支持64 個(gè)節(jié)點(diǎn)，網(wǎng)絡(luò)最遠(yuǎn)距離為300米。Þ 用于 GUS/PLNM/AM/AxM/HM/NIM/APPNODE* 全球控制網(wǎng)絡(luò)(UCN)Þ 工藝網(wǎng)絡(luò) (SP, OP, PV, range, alarm generation)Þ 5兆/秒 Þ 令牌總線網(wǎng)絡(luò)Þ 用于HPM· 網(wǎng)絡(luò)接口模塊(NIM)* UCN 接到LCN* 冗余* 使LCN 和 UCN同步* 最多支持 32 冗余設(shè)備· 工廠網(wǎng)絡(luò)模塊 (AppNode)* LCN和以太網(wǎng) (PIN)的接口* 為了下載

5、 SOC 等等· 應(yīng)用模塊 (AM / AxM)* 運(yùn)算控制器的補(bǔ)充* 管理控制* 更先進(jìn)的計(jì)算和控制策略 * 控制SOC下載語(yǔ)言程序等等 c· 歷史模塊 (HM)* 存儲(chǔ)系統(tǒng)軟件和應(yīng)用文件（例如硬盤）* 存儲(chǔ)連續(xù)的工藝歷史和事件日志 * 存儲(chǔ)圖表，節(jié)點(diǎn)操作軟件，CL 程序 HPM 控制功能概觀典型的控制回路 :FirewallIP.21APPNODEDCS 標(biāo)簽編號(hào)系統(tǒng)8 個(gè)特征P1*: polymer POF line 1 tag (P2* : polymer POF line 2 tag)C1*: polymer, common areaSA01*TC: spinni

6、ng machine A cell 01 temperature controller, * loop no.S1*: spinning common area (e.g. aspiration gas)R1*: solvent recovery areaP19*: site specific, polymer areaC19*: site specific, polymer common areaR19*: site specific, solvent recovery area*G*Tanalog input (FULL point form)模擬全點(diǎn)analog input (COMPO

7、NENT point form) 模擬半點(diǎn)*V*X*R*Zanalog output (control valve)模擬輸出(控制閥)analog output (micro-motion flow control valve) 模擬輸出(流量控制閥)analog output (heater control output) 模擬輸出(熱量控制輸出)analog output (drive control output) 模擬輸出(熱量控制輸出)*Ccontrol (控制)FQtotaling (累加器)HChand controlSCspeed control (速度控制)XGAnalyze

8、r (分析器)*Adigital alarm (數(shù)字警報(bào))PBRCratio control (比率控制)Dig CDOECEDOcalculated value (計(jì)算值)digital input (數(shù)字輸入)digital output (數(shù)字輸出)PBdigital composite / device control數(shù)字組合/設(shè)備控制點(diǎn)HSHSdigital composite / device control數(shù)字組合/設(shè)備控制點(diǎn)DO¬SolonidDIE2SVE1Dig C­第 21 頁(yè)P(yáng)oint Type (點(diǎn)的類型)Point Type點(diǎn)的類型Descrip

9、tor(描述)Tag Name點(diǎn)名Tag Descriptor點(diǎn)的描述ANALOG INPUT 模擬輸入Perform input processing on all field I/O.(P10312PG)MDI SUPP TK VNT PRESSANALOG OUTPUT 模擬輸出Perform output processing on all field I/O.(P10319PV)MDI SUPP PRESS CTRL VLVDIGITAL INPUT 數(shù)字輸入Perform input processing on all field I/O.(P10315E)MDI SUPP PMP

10、 START/STOPDIGITAL OUTPUT數(shù)字輸出Perform output processing on all field I/O.(P10315DO)MDI SUPP PMP RUNREGULATORY PV 常規(guī)PVProvide an easy to use configurable approach for implementing PV calculations and compensation functions.(P10317PG)MDI FLTR DPREGULATORY CONTROL常規(guī)控制Perform standard control functions b

11、y executing the algorithms that have been configured.(P10319PC)MDI SUPP PRESS CTRLDIGITAL COMPOSITE 數(shù)字組合A multi-input/multi-output point provides an interface to discrete devices such as motors, pumps, solenoid valves, and motor-operated valves. It provides built-in structures for handling interlock

12、s, and supports display of the interlock conditions in group, detail, and graphic displays. (P10321HS)MDI ONL/RECIRC VLVDEVICE CONTROL 設(shè)備控制Provide a way to manipulate a device (e.g. motor) and to view the strategy through a single point (help the operator to graphically trace the source of an interl

13、ock condition. (P10315PB)MDI SUPP PMPFLAG 狀態(tài)點(diǎn)A 2 state (On and Off) point is used for storing a Boolean value. The value can be supplied by the operator, sequence program, another point output, etc.(P10322FL)MDI/GLY ONL/RECIRCNUMERIC 數(shù)值點(diǎn)Data point used to store numeric values that can be used for ba

14、tch/recipe operations, or to store the intermediate results of calculations.(P1CPRCLM)CP RATE CHANGE +/-PROCESS MODULE 過(guò)程模塊The resource for execution of user-created programs (CL). (P1CPRTCH)CAPPING RATE CHANGEARRAY 數(shù)組點(diǎn)Provide access to HPM box global variables, or external data from/to serial inter

15、face devices.(P1MWTOP)TOP MW ONL DATATIMER 時(shí)間點(diǎn)Timer data point allows the operator and the sequence program to time the process events.(P1MWRCTM)MW SILO RATE CHANGE TMRLOGIC 邏輯點(diǎn)Provide a configurable mix of logic capability that provides the basis for integrated logic functions. (P1LOGA)MDI/GLY DIVE

16、RT VALVESSTRING 字符串點(diǎn)Store descriptive text data, such as the brand name or model etc.-平臺(tái) (Point Form)"Full" point form includes alarm-related parameters and sometimes, some other miscellaneous parameters. This information is needed when the point is to be used as the primary operator inter

17、face to the point's data."Component" point form should be used for points that provide inputs to the "Full" point, and also for those points that handle the outputs from the "Full" points. Component" points should be used as part of the "Full" point t

18、hat has been designated a primary operator interface point.NOTE: Full-point form cannot be assigned to DO (digital output) points; they are always component points. Stand-alone digital output pointsrequire using a digital composite point that has 0 (zero) inputs and 1 output.Example : Single-Loop Ex

19、ample :Mass FlowExample : Motor Control Honeywell DCS 系統(tǒng)操作簡(jiǎn)介(參考： HP12500)登錄· Alt-Ctl_+Del組合鍵用戶名: gus密碼 : 鍵操作· 工程鍵盤· 功能鍵· 操作鍵· 通過(guò)工程鍵盤(用于紡絲層)操作鍵 · 鍵鎖· 其它：* 主菜單 (Poly/Spin/Recovery)* Recall tag/schematic name key .* 清屏* 故障* Schematic Tagname Toggle* 調(diào)出最新的圖表 * 相關(guān)的顯示* 組

20、* 詳述* 示意圖* 標(biāo)準(zhǔn)* 系統(tǒng)狀態(tài)* CONS 狀態(tài) (單元顯示 / 單元分配 /控制臺(tái)報(bào)警狀態(tài)/ 系統(tǒng)報(bào)警狀態(tài))* 報(bào)警SUMM / UNIT ALM SUMM* MSG SUMM / MSG CONFM / MSG CLEAR* 系統(tǒng)菜單Þ 概要菜單Þ 事件歷史Þ 組編輯顯示 (391400)顯示· 改變區(qū)域· 節(jié)點(diǎn)描述· 組· 圖表· 詳述· 趨勢(shì)改變方式· 手動(dòng)· 自動(dòng)· 串聯(lián)· 程序, 包括CL 程序 (例如用于SOC, .)信號(hào)處理· 指示

21、或調(diào)整控制(帶有運(yùn)算器)模擬/靈敏傳感器· 用于聯(lián)鎖和順序控制的數(shù)字傳感器 · 驅(qū)動(dòng)通信的串行接口 · PV 源選項(xiàng)* 所有Þ 自動(dòng)Þ 手動(dòng)Þ SUB, 從程序輸入Þ 追蹤* 僅自動(dòng)PointExecState· Active · Inactive X6Honeywell DCS 系統(tǒng)操作控制臺(tái)體系結(jié)構(gòu)· GUS* Deskside GUS 用于紡絲層, ICR, 紡絲 3rd層和培訓(xùn)系統(tǒng)。* 控制臺(tái) GUS用于 OCR。* 在 CE/Slurry 和Capping系統(tǒng)中為GUS清除附件

22、3; 遠(yuǎn)程 GUS :* GUS 客戶端有原理圖軟件，只要輸入動(dòng)態(tài)信息。* 全部的操作功能 (本地窗口, 操作顯示, PC 應(yīng)用等等), 遠(yuǎn)程控制（兩端顯示相同）。軟件· 所有的GUS 都有相同的軟件報(bào)警策略· P1, C1, S1, SASL, R1單元· 聚合體低優(yōu)先級(jí), 頁(yè)面調(diào)度系統(tǒng)發(fā)出一聲蜂鳴。· aspiration系統(tǒng)高優(yōu)先級(jí), 報(bào)警頁(yè)面調(diào)度系統(tǒng)發(fā)出一聲蜂鳴。· 溶劑回收塔低優(yōu)先級(jí)。· 紡絲過(guò)程中, “藍(lán)燈”報(bào)警組顯示· Group Display 1-390 is configurable, while 391

23、-400 is operator definable.· NAX, only 1 group is defined.1100200300390400POF 1ßPoly/Asp. Gas àßspinningàßOperator definable· X6, 2 groups are defined. * polymer/aspiration gas system/solvent recovery1100200300390400Poly/AG/SRß Poly/Asp. Gas àßUtilit

24、y àß S/R àßOperator & site spec. definable* 紡絲1100200300390400紡絲ß Asp. Gasàß紡絲àß操作者definable區(qū)域和控制· NAX, 一個(gè)區(qū)域* POF_1 包括所有單元· 新的POF, 定義兩個(gè)區(qū)域：* OCR1: P1, C1, S1, R1* SPINFLR1: SA, SB,SC, SD, SE, SF, SG, SH, SI, SJ, SK, SL, S1, C1· X6, 定義兩個(gè)區(qū)

25、域 * OCR1:在開(kāi)啟時(shí)所有單元all units at startup* SPINFLR1: SA, SB,SC, SD, SE, SF, SG, SH, SI, SJ, SK, SL, S1, C1圖像· 所有的GUS圖像都一樣· 顏色:* 紅紫色: 工藝線* 白色: 設(shè)備* 青色: 水 / 冷凝物* 紅色: 蒸汽· 工藝線連接 :* 黃色: 不可以進(jìn)入下一個(gè)圖像, 例如僅僅用于描述* 藍(lán)色: 連到下一個(gè)相關(guān)的圖像c· 泵 / 閥:* 綠色: 運(yùn)行 / 打開(kāi)* 紅色: 停止 / 關(guān)閉* 紅色背景: ?· PBP :* 主菜單* SOC檢查

26、報(bào)警* CL程序運(yùn)行失敗* VAX 問(wèn)題聯(lián)系DP· 其它：* 控制器背景為白色，說(shuō)明控制器不在正常模式 * 如果泵聯(lián)鎖繞過(guò)旁路，泵旁邊有一個(gè)小的黃色指示。* 如果控制器處于MAN 模式則%OP為黃色 ; 如果聯(lián)鎖生效則為紅色。追蹤· The long term historian is being done in Infoplus· Honeywell 在DCS上的追蹤為1分鐘代表1個(gè)月。工藝操作紡絲· 當(dāng)正在下載SOC 時(shí)不要開(kāi)/關(guān)氣源 · DCS噴絲板聯(lián)鎖加熱1小時(shí) · Merlion 系統(tǒng)上沒(méi)有跟DCS聯(lián)鎖的噴絲板從而保證使用正

27、確的噴絲板· 紡絲機(jī)器 :* 循環(huán)的氣流和溫度控制 * headwater t溫度控制，無(wú)流量控制· 上進(jìn)風(fēng)加熱器控制溫度來(lái)補(bǔ)償粘度 · 噴絲板的舉起時(shí)間依賴于甬道頂?shù)拈_(kāi)/關(guān)。· For heating up state, spinneret expired time is a SOC item; and bypass mode is available.· O2 display in the condenser for the aspiration gas system will be the mid value of the three a

28、nalysers.· Logic A : cell heater; Logic B : metering pump open/start; Logic C : cell balance; Logic D : interlock bypass recycle gas heater.PBP· Graphic display :* green: normal (PVLOTP < PV < PVHITP)* yellow: outside of control limit, (PVLLTP < PV < PVLOTP or PVHITP < PV &l

29、t; PVHHTP)* blinking yellow: outside of waste limit, (PV < PVLLTP or PV > PVHHTP)* red: outside of waste limits for the compliance delay time. (process should be put to waste)SOC· Limit* control limit (high/low) :PVHITP/PVLOTP* Segregation limit (high/low) : PVHHTPPVLLTP· SOC checks

30、:* in Merlion, from VAX to PLNM * in DCS, from PLNM to AM to HPM· SOC feature :* R_AIM: ratio, P1ALMCL1 to calculate absolute* B_AIM: bias, P1ALMCAL to calculate absolute* DEV_FLG: Þ if DEVFLG is ON, P1ALMCL1 and P1ALMCAL calculate absolute alarm for Hi/Lo limit.Þ if DEVFLG is OFF, Hi

31、/Lo limits are the control limit.· Polymer and aspiration gas system watchdog is used to test whether the interlocks (S1LOGA, S1LOGB, S1LOGC, S1LOGD) are working.· Bypass SOC· SOC downloading option for spinning cell :* immediate* after doffOthers· Polymer : watch-dog, etc.·

32、 SR : purge control, etc.OTHERSTools· Doc tool * Query à Build à UCN à Proc Net List : 1 à Device List : 3 5 à Parameter value to show : pt desc* Output à pathname : net > temp > promods.*Commands· To retrieve point detail from database, select ctl-help/

33、 Builder Command/ Reconstitute/ Enter tag name into the Entity.JP/SOP· System Menu (Event history . Etc.)· Find Name .APPENDICESX_PLANT ABBREVIATIONS LISTINGREDIENTSEQUIPMENTEDA - EthylenediamineR1 - Capping reactorDEA - DiethylamineR2 - Chain extension reactorDYTEK- DytekSILO - Silo LRD3

34、- LRD3MW - MicrowaveGLY - GlycolAPP - ApplicatorMDI - DiisocyanatePR - Pre-reactorA519 - A519PM - Pre-mixerDMAC - DimethylacetamideDM - Dilution mixer47H2O - 47 degree waterVNT - VentEXT - ExtenderPMP - PumpCOEXT- Coextender CLR - CoolerSTPR - StopperHX - Heat exchangerTER - TerminatorTK - TankSLR1-

35、 Slurry system oneTK JKT- Tank JacketSLR2 - Slurry system twoJKT - JacketCG - Capped glycolVLV - ValveVP - Virgin polymerSM - Spinning machineSOLN - SolutionCOND - CondenserPOL SOLN- Polymer solution after SAMRFLTR - Rotary filterYR SOLN- Yarn recycle solutionANLY - AnalyzerYR - Yarn recycleHTR - He

36、aterDCG - Dilute capped glycolMIX - Mixer25GLY - 25% glycolDRV - Drive45GLY - 45% glycolMTR - MotorFIN - FinishAGIT - AgitatorLRD32 - LRD32COMPRESS - CompressorCYAN - CyanoxGEN - GeneratorMETH - MethacrolMP - Metering pumpCW - Chilled waterHDR - HeaderCTW - Cooling tower waterFLTR - FilterO2 - Oxyge

37、nSTRNR - StrainerHW - HeadwaterSYS - SystemAG - Aspiration gasSAM - Static additive mixerVG - Vacuum gasBP - Booster pumpN2 - NitrogenHSM - High Shear MixerINST AIR - Instrument airTUR - Turbine (agitator)CP - CappingCOLL TK- Collection TankCE - Chain ExtensionYSB - Yarn recycle batchREAG - Reagents

38、STAB - StabalizerSTM- SteamH2O - WaterPOSITION / ACTION or PROCESS PARAMETERSXFER - TransferSUPP - SupplyRECIRC - RecirculationONL - OnlineVAC - VacuumBAL - BalanceCTRL - ControlPWR - PowerCLN - CleanIN - InletOUT - OutletMID - MiddleBOT - BottomDP - Delta pressureRTRN - ReturnDT - Delta temperature

39、SEL - SelectorHI - HighPOS - PositionMAX - MaximumAVG - AverageAUTO - AutomaticSTAT - StatusCIRC - CirculatingSTRT - StartSTOP - StopPRESS- PressureTEMP - TemperatureVISC - ViscosityLVL - LevelKG/HR - Kilograms per hourDEGC - Degrees celsiusRPM - Revolutions per minuteMIN - MinuteKG/SQCM- Kilograms

40、per square centimeterPCT - PercentMM H20 - Millimeters waterSP - SetpointNUM - NumericTM - TimeSPD - SpeedTMR - TimerERR - ErrorSEC - SecondHR - HourINTERFACING WITH MERLION· Activate by :* ACIDP: DCS activates the PLNM point.* EIP: HPM activates the *.PPS of AM or PLNM point.* *.PPS: HPM proce

41、ss module point runs the attached program in AM or CG.· SOC Downloading, from VAX through AppNode to AM, data transfer are done the same way; however* All the spinning data downloading to controller are done directly from AM (but not HPM).* All the polymer and solvent recovery data downloading

42、to controller are done by HPM. Prior to that, the data are transferred from AM to HPM.VAX will check the data stored in the CDS.SOC Write data to CDS Trigger AM point by setting *.pps = ON.SnSOC (AM point)This CL block is triggered to run by the host setting *.PPS = ON. S_SOC (AM/CL block) SOC_DATA

43、(CDS)Cell load porgram will be triggered to run again from the doff control program, SnDOFF by setting flag SnccDEFL after the cell has doffed so that the remaining cell values may be loaded. Write new SOC value to PM numerics Write deviation and return delay times to the compliance monitoring CDS,

44、CMPLDATA On AM point SnccRG, AM/CL : ALMHANDL and CMPLCHK. Trigger cell load program (one for each cell), SnccSOC Trigger machine load program (one for each machine), Sn00SOC· Event reporting, from DCS to VAX, are done in the same way for all areas (spinning, polymer and solvent recovery). PM/A

45、M programs will notify Event Collector (in AM) to gather the event; and collector program will send to the PLNM. Collector also inform VAX to get the information from the PLNM. VAX program is supposed to run periodically. Write message data to buffer (i.e. CDS : S_MESSG1/2) and process point (XXMESS

46、AG)Read new messageSnccCKFL.PVFLSnccSCFL.PVFLSnccDEFL.PVFLSnccCSFL.PVFLAMHPMSn01SCCK-Sn06SCCKSn00SCCKSn01SOC-Sn06SOCSn00SOCSn01RG-Sn06RGXXCELSTSXXDOFFXXEVENTCL : XXEVENT1 XXEVENT2 XXEVENTRCDS : S_EVTSTRDetect event from flag status generated by programs.PLNMxxMESSAGCDS : S_MESSG1 S_MESSG2XXEVENT tri

47、ggers XXMESSAG to process after writing new meassage to the buffer (defined in CDS, S_MESSG1/2)VAXSnccCMFL.PVFLLOGIC SYMBOLSMAXPULSEThis will give out a logic 1 for a predetermined amount of time Or gateAnd gateThis will delay the output signal after receiving the input for a predetermined amount of

48、 timeONOELNot gateFlagSwitch, the flag will determine the selection.Less than or equal to.=>Greater than or equal to.CHKBADThis will check for a bad PV and will give a logic 1 if true.Greater than<Less thanInvertedXXLogic gate number in the block.Flag :Twelve flags, FL(1) to FL(12), are provid

49、ed for each logic point. The states of flags FL(1) to FL(6) are controlled by the HPM and cannot be changed by the user. Flags FL(7) to FL(12) are assigned by the user for controlling the path of the logic in the respective logic point. The flags are described in the following listing:Flag Descripti

50、onFL(1) Always Off (but see 5.2.5 when used for logic output enable).FL(2) Always On.FL(3) On only if this logic point is processing for the first time after becoming active.FL(4) On only if this point is processing for the first time after the HPMM box state has transitioned from Idle to Run, or the HPMM has gone into the Run state following a power-up.FL(5) On if at least one of the logic input connections was unsuccessful in fetching the specified source par