摘要
仿真训练装置原是燕山仿真中心1994年建成的培训技术人员和操作工人培训装置,其工艺流程是以某二甲苯装置中异构化反应的分离工段为参照对象,结合仿真实现的实际需要而设计的。由于数字仿真技术的发展及训练装置运行成本较高等原因,于1998年停运。北京石油化工学院面对目前社会需要加强大学生工程实践能力的需求,与燕山仿真中心共同改造了该仿真训练装置。改造后现场设备装置中运行的物料为水和氮气,替代实际装置中相应的液相和气相物料,本文利用GPRES通用过程工业严格模型开发系统设计了该装置的仿真模型以实时模拟其中各种化工过程的动态特性,并使用ECS-100集散系统对现场装置、仿真模型的对象进行控制和集中操作管理。在实际运行过程中,ECS-100集散系统与仿真模型之间通过OPC技术进行数据交换。
在分析训练装置的工艺流程和系统构成的基础上,本文结合实际系统控制方案,进行了以下研究:
1、分析训练装置仿真模型的建立方法以及仿真模型的功能;研究ECS-100系统构成及其OPC服务器,并探讨仿真模型与集散系统的OPC通讯方法。
2、利用浙大中控ECS-100软硬件资源,根据训练装置的I/O点统计和功能需求,进行集散系统的选型和控制系统设计,并完成了集散控制的系统组态、控制组态和操作组态等。
3、对目前在石化行业中广泛应用的先进控制技术进行了研究,结合仿真装置的使用特点,以管式加热炉为对象,设计了几种实用、易于培训和掌握的先进控制方案,包括IMC-PID控制器设计和控制器的参数整定、加热炉出口温度的预测函数控制,提升了仿真装置的培训层次。
改造后的仿真装置已用于本校大学生的实习和企业员工培训,实际运行效果良好。
The Simulation Equipment for Training, which was set up by YanShan Simulation Center in 1994, was used for training technician and operator. Refer to the separation work segment of the reaction in the xylene equipment, the Simulation Equipment technology flow was designed according to the simulation demand. The equipment had to stop working in 1998 because of the rapid development of digital simulation technology and the high cost to run it. Now to meet the demand that the engineering faculty of university students should be strengthened, the BIPT and YanShan Simulation Center reformed the simulation equipment. After reformed, the equipment takes the water and nitrogen as the medium in replace of the liquid and gaseous materials in the past. Utilizing the GPRES development system, the paper designs the simulation model of the equipment to real-time simulate the dynastic characteristics of the chemical process. The paper presents the control and concentration operation management of the practical equipment and simulation model using the ECS-100 system. And based on OPC technology, the paper designs a kind of data exchange technology for practical control system between the ECS-100 system and the simulation model.
On the basis of analyzing the equipment's technical flow and system structure, the paper, combining with the practical system control scheme, does the following researches.
1. The paper analyzes the method to construct the simulation model of training equipment and its function, researches on ECS-100 system structure and its OPC server, and probes into the OPC data exchange method between the simulation model and DCS.
2. Based on the SUPCON's ECS-100 DCS, the paper carries out the DCS system selection and design according to the training equipment's IO number and functional demand and completes the DCS system configuration, control configuration, and operation configuration, etc.
3. After researching on the advanced control technology widely used in the petrol-chemical industrial, the paper designs some kinds of advanced and practical control system, which is suitable for operator training and easy to grasp, for the tube heater. The designed control system, including the IMC-PID controller and its parameter tuning, the predictive Functional control to the heater's outlet temperature, etc, improve on the simulation equipment greatly.
The reformed simulation equipment is proved to be excellent by applied to the BIPT student practice and operator training,.
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