CN106444678B - Energy management system and method for metallurgical enterprises - Google Patents
Energy management system and method for metallurgical enterprises Download PDFInfo
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- CN106444678B CN106444678B CN201610928601.8A CN201610928601A CN106444678B CN 106444678 B CN106444678 B CN 106444678B CN 201610928601 A CN201610928601 A CN 201610928601A CN 106444678 B CN106444678 B CN 106444678B
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
- G05B19/41845—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by system universality, reconfigurability, modularity
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/33—Director till display
- G05B2219/33273—DCS distributed, decentralised controlsystem, multiprocessor
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Abstract
The utility model discloses a metallurgical enterprise energy management system and a method, which belong to the field of automatic control, wherein the system is based on an EMS system and comprises a central network system, an industrial Ethernet and an Oracle database server, and a switch is additionally arranged between the central network system and the industrial Ethernet; and an application server, an industrial gateway IGS server, a real-time database server and an Oracle database server are additionally arranged on the switch. The method comprises the steps of adding an application server, an industrial gateway IGS server and a real-time database server on a switch; installing an IGS hardware dog and an IGS driver in the industrial gateway IGS server; configuring communication connected with a PLC and a DCS in software of an industrial gateway IGS server; the industrial gateway IGS server reads and stores real-time data of the site PLC and DCS; the effects of fine management, data feedback accuracy improvement, equipment system simplification and compression improvement cost are achieved.
Description
Technical Field
The utility model belongs to the field of automatic control, and particularly relates to an energy management system and method for a metallurgical enterprise.
Background
Ma Gangdi the existing EMS system of the two-energy general plant is divided into 2 parts: the trend data in the monitoring system cannot be stored for a long time, the basic energy management system only counts the accumulated data, and the minimum data unit is 1 hour. In order to further mine energy management potential and expand energy management functions, it is proposed to save trend data displayed by the existing SCADA monitoring system, and develop corresponding management functions, such as instantaneous data historical trend query, customized trend analysis, medium and house alarm query analysis, and key energy equipment management, on the basis of long-term classified saving of all the data.
The utility model discloses an improved industrial control redundancy system, which comprises a server, an operation station, a PLC control system, a DCS system, an RTU system, a network security system, an industrial Ethernet, a firewall, an engineer station, a manager, a printer, a GPS system, a magnetic disc library, a large screen system and a main communication line, wherein all the components are connected with the main communication line. However, the basic goals of energy production management are: safe and stable, economic balance, high quality and environmental protection. By constructing the data management system, the functions of archiving, inquiring, analyzing and the like for a large amount of instantaneous data of the EMS system for a long time are realized, and the functions of improving production of steel enterprises, working of equipment systems, reducing energy consumption and improving energy management level and equipment management level are promoted. Therefore, the technical scheme also has the following technical problems:
1. the trend data in the monitoring system is stored in a local hard disk, the communication load of an IO server is considered during storage, the time limit for storing the data is 20 days for electric power and 30 days for power/water, and long-term storage cannot be achieved;
2. the basic energy management system only counts the accumulated data, the minimum data unit is 1 hour, and the query of the instantaneous data cannot be satisfied;
3. different groups of IO servers in the EMS system cannot generate trend groups (such as a group of power and power trends) of different media;
4. the statistics, comparison and inquiry of the alarm quantity cannot be achieved in the EMS system;
5. the EMS cannot perform fine management on the key energy use device.
At present, there may be a plurality of technical solutions for solving the above technical problem (one) in the prior art, but they have a common technical problem (two): the data feedback precision is low, the error rate is high, the equipment is redundant, and the improvement cost is high
Disclosure of Invention
1. Problems to be solved
Aiming at the technical problem (I), the utility model provides an energy management system for metallurgical enterprises, which further digs the potential of the existing EMS system, shifts the functions such as instantaneous data, trend graphs and the like which are only concerned by an SCADA online monitoring system to the system, saves massive instantaneous data, can read and retrieve the massive data at any time, analyzes and filters out needed information, classifies the information for statistics, realizes a series of functions such as long-term storage of the data, flexible comparison of trend, visual alarm statistics, fine management on important energy utilization equipment, effectively combines the EMS system with the data management system, promotes the development and application of independent intellectual property systems of the EMS system of steel factories, and improves the energy management level of new areas of the steel factories;
aiming at the technical problem (II), the utility model provides the energy management method for the metallurgical enterprises, which can realize fine management through manual intervention setting on the basis of the system of the utility model, improves the accuracy of data feedback, simplifies the equipment system and maximally compresses the improvement cost.
2. Technical proposal
In order to solve the problems, the utility model adopts the following technical scheme.
An energy management system of a metallurgical enterprise is based on an EMS system, and comprises a central network system, an industrial Ethernet and an Oracle database server, wherein a switch is additionally arranged between the central network system and the industrial Ethernet; an application server, an industrial gateway IGS server and a real-time database server are additionally arranged on the switch.
Preferably, the central network system and the industrial Ethernet are connected by a star-type twisted pair; the communication lines between the central network system and the industrial Ethernet comprise a main communication line and a standby communication line.
Preferably, the application server comprises a first application server and a second application server; the first application server is connected with the main communication line and the standby communication line at the same time; the second application server is only connected to the standby communication line.
Preferably, the real-time database server comprises a second real-time database server; the Oracle number
The database server is connected with the main communication line and the standby communication line at the same time; industrial gateway IGS service
The server and the second real-time database server are connected only to the standby communication line.
Preferably, the central network system is connected with a server in the EMS system in a hanging mode.
Preferably, the industrial gateway IGS server directly reads and connects to the industry through OPC UA mode
On the ethernet.
A metallurgical enterprise energy management method comprises the following steps:
s1, setting a switch in a central network system and an industrial Ethernet based on an EMS system;
s2, an application server, an industrial gateway IGS server, a real-time database server and an Oracle database server are additionally arranged on the switch in the step S1;
s3, installing an IGS hardware dog and an IGS driver in the industrial gateway IGS server;
s4, configuring communication connected with the PLC and the DCS in software of an industrial gateway IGS server;
s5, the industrial gateway IGS server reads and stores real-time data of the site PLC and DCS;
s6, newly adding an alarm information point table in the ORACLE database server;
and S7, developing corresponding management functions on the application server.
Preferably, the industrial gateway IGS server in step S5 directly reads and stores real-time data of the PLC/DCS in the field in OPC UA mode.
Preferably, the alarm information point table in step S6 includes alarm point codes, alarm point names, units, normal values, alarm interlock values (H value, HH value, L value, LL value, interlock value), notes.
Preferably, the corresponding management functions described in step S7 include a history storage application, an alarm management application, a trend management module application, and an important energy device parameter statistics query application.
3. Advantageous effects
Compared with the prior art, the utility model has the beneficial effects that:
(1) The data management realizes long-time storage of the historical data, and is divided into 1 year, 2 years and permanent storage according to different categories;
(2) The data management realizes the comparison of online duration trends, and improves the comparison of gas data influencing the normal operation of an energy system;
(3) The data management realizes macroscopic alarm management, the total alarm quantity of house/medium can be counted in the system, and the comparison of day, month and year is carried out, the important tracking can be carried out on the frequent alarm area through the alarm management, and the frequent alarm area can be eliminated in time
Hidden trouble;
(4) In the data management, the key energy-saving equipment is managed, so that the equipment manager can grasp the whole condition of the equipment more conveniently. The fault occurrence rate of the equipment is known through the fault times and the tripping times, whether the equipment correctly executes an equipment switching system is known through the longest uninterrupted running time, how long the equipment is overhauled next time can be known through the overhauling countdown function, the overhauling preparation work can be carried out in advance, and the degradation trend is analyzed.
Drawings
FIG. 1 is a connection diagram of a metallurgical enterprise energy management system of the present utility model;
FIG. 2 is a comparative analysis diagram of an energy medium;
FIG. 3 is a graph of media alarm trend analysis;
fig. 4 is an analysis diagram of the important equipment.
In the figure: 1. to an ERP system; 2. a firewall; 3. a first application server; 4. a trend server; 5. a second application server; 6. an industrial gateway IGS server; 7. a second real-time database server; 8. a main communication line; 9. a spare communication line; 10. a first real-time database server; 11. a backup server; 12. an I/O server; 13. a magnetic disc library; 14. a first DCS system; 15. a first PLC; 16. a second PLC; 17. a second DCS system; 18. an industrial ethernet; 19. a network security system; 20. oracle database server.
Detailed Description
As shown in fig. 1, the existing EMS system includes a central network system and an industrial ethernet 18, the central network system is connected to all servers in the EMS system in a hanging manner; the central network system and the industrial Ethernet 18 are connected by a star-shaped twisted pair mode; the communication lines between the central network system and the industrial Ethernet 18 comprise a main communication line 8 and a standby communication line 9; the industrial Ethernet 18 is connected with a PLC and DCS system on site; the PLC and DCS systems on site comprise a first DCS system 14, a first PLC15, a second PLC16 and a second DCS system 17; wherein:
the first DCS system 14 is a comprehensive automation system of the on-site substation, and plays roles of controlling on-site equipment of the substation, collecting relevant signals of the substation and communicating with the EMS system;
the first PLC15 is used for controlling the field equipment, collecting signals related to the substation and communicating with the EMS system, and comprises a field gas system, an air compression station system, a water system and an oxygen generation system;
the second PLC16 plays roles in remotely collecting and monitoring the signals of the main process equipment operation signals, key energy consumption signals and factory metering signals of each main process on site, and timely grasping the production and quick distribution conditions of the energy system on the energy, so that the energy can be conveniently and timely adjusted;
the second DCS system 17 is a comprehensive automation system of the on-site substation, and plays roles of controlling on-site equipment of the substation, collecting relevant signals of the substation and communicating with the EMS system;
four groups of I/O servers 12 are included between the central network system and the industrial Ethernet 18, each group of I/O servers 12 including a primary and a backup; the system also comprises a trend server 4, a second real-time database server 7, a backup server 11, a disk library 13, a network security system 19 and an Orcales database server 20; the backup server 11 and the disk library 13 are connected with the backup communication line 9 only, the network security system 19 is connected between the industrial Ethernet 18 and the main communication line 8, and the rest is connected with the main communication line 8 and the backup communication line 9 simultaneously.
The working process of the existing EMS system comprises the following steps: the method comprises the steps that field data in the PLC/DCS are transmitted to an IO main and standby server through an industrial Ethernet, the IO server collects the data and then transmits the data to a dispatching terminal to provide control and monitoring on field unattended equipment, a first real-time database server receives the field data collected by the IO server and transmits the data to a company LES system, a input-output platform, a metering system, a daily cost management system and a data management system, meanwhile, the collected factory metering data are transmitted to an application server and then are processed through the application server and then are stored in an Oracle database server to form an energy report, and a disk library is responsible for storing the factory metering data after archiving processing; the data processed by the application server is transmitted to the ERP system 1 through the firewall 2, so that statistics, calling and query are convenient;
in order to ensure that the dispatching terminal controls and monitors the on-site unattended equipment, IO servers and trend servers related to production are used as main and standby redundancies in the system, and meanwhile, communication lines are also used as main and standby redundancies, so that when the main IO servers, the main trend servers and the main communication lines are faulty, the system can be switched to the standby IO servers, the standby trend servers and the standby communication lines, and the safe and effective energy production is ensured. The existing EMS system has limited data storage capability, and cannot store a large amount of various data, especially some instantaneous data such as pressure and flow information, for a long time. Along with the requirement of energy management refinement, historical data (such as instantaneous data of flow, pressure, temperature, vibration, liquid level, valve opening, heat value, current, active, reactive, power and the like displayed by an EMS monitoring system and all heavy faults and light fault alarms) in a longer time range need to be searched, compared and analyzed, and the data has two characteristics, namely, the data is large in quantity and high in frequency, so that if the data is kept for a longer time, the data is quite large, and the data management system is required to store the existing data for a long time, so that on the basis of the existing EMS system, the utility model is improved as follows:
example 1
As shown in fig. 1, a metallurgical enterprise energy management system is based on the existing EMS system, and a switch is added between the central network system and the industrial ethernet 18; an application server, an industrial gateway IGS server 6, a real-time database server and an Oracle database server 20 are additionally arranged on the switch; the application servers comprise two first application servers 3 and a second application server 5; the first application server 3 is connected with the main communication line 8 and is also connected with the standby communication line 9; the second application server 5 is only connected to the standby communication line 9;
the real-time database server comprises a first real-time database server 10 and a second real-time database server 7; the Oracle database server 20 is connected with the main communication line 8 and the standby communication line 9; the industrial gateway IGS server 6 and the second real-time database server 7 are connected with the standby communication line 9 only; the industrial gateway IGS server 6 is connected to the industrial ethernet 18 in an OPC UA mode via a central ethernet switch.
An improved energy management system for metallurgical enterprises is characterized in that an IGS industrial gateway server is responsible for acquiring field data in an OPC mode and storing the field real-time data into a second real-time database server 7; the second real-time database server 7 counts the archived data and stores the data into the Oracle database server 20 of the EMS system; and reading the real-time data in the second real-time database server 7 and the offline data in the Oracle database server 20 on the second application server 5, developing an application, and combining to meet the application requirements.
The technical problem (I) mentioned in the background art is solved by the improved scheme, but the problems in terms of data accuracy and stability still remain, and the method can realize fine management, improve data feedback accuracy, simplify equipment systems and maximally compress improvement cost.
A metallurgical enterprise energy management method comprises the following steps:
s1, setting a switch in a central network system and an industrial Ethernet based on the existing EMS system;
s2, adding an application server, an industrial gateway IGS server and real-time data on the switch in the step S1
A library server and an Oracle database server;
s3, installing an IGS hardware dog and an IGS driver in the industrial gateway IGS server;
s4, configuring communication connected with the PLC and the DCS in software of an industrial gateway IGS server; the specific configuration method comprises the following steps: adding a communication channel (channel 1 … n) in the Configuration in the software of the industrial gateway IGS server, adding communication equipment (emS 1 … n) in the communication channel, configuring equipment I P addresses, port numbers, communication modes (mailbox, modbus, etc.), connection timeout time, etc. in equipment Configuration, and finally adding numbers, names, addresses, data types (long, float, dword, string, etc.), scanning periods and access types (read only, read/write) of communication points in the communication equipment;
s5, the industrial gateway IGS server directly reads and stores real-time data of the site PLC and DCS in an OPC UA mode;
s6, newly adding an alarm information point table in the ORACLE database server; the alarm information point table (shown in table one) comprises alarm point codes, alarm point names, units, normal values, alarm interlocking values (H value, HH value, L value, LL value and interlocking value) and remarks;
form one, newly added alarm information point list in ORACLE database server
S7, developing corresponding management functions on the application server; the system comprises a history storage application, an alarm management application, a trend management module application and an important energy utilization device parameter statistics query application; the specific implementation mode is as follows:
1. history storage application: the functions such as instantaneous data, trend graphs and the like which are only concerned by the original SCADA on-line monitoring system are shifted into the system, massive instantaneous data are saved, the massive data can be read and searched at any time, needed information is analyzed and filtered, and statistics is carried out according to classification.
2. Alarm management application: designing a data classification information definition table (shown as a table II), storing classification information of the data points in an ORACLE database, developing a user editing interface and a query interface for providing data, and searching data according to various query modes such as different time granularities, custom time intervals, alarm classification, fuzzy query of alarm names and the like;
TABLE II, design data class information definition TABLE
And developing a data reading program, and combining classification information in the ORCALE library with corresponding specific data in the IHIS real-time library during reading. Designing and writing a graphic control, and displaying an alarm result in a graph mode, for example, using a pie chart to represent the proportion of different types of alarms to the total alarm quantity, using a curve to represent the trend of the alarm quantity and the like;
as shown in fig. 2, the system alarms and counts the transverse comparison analysis of the occurrence times of faults of certain media on the basis of time granularity taking a day as a unit, can effectively and intuitively display the occurrence frequency of faults of each energy medium and house, and can enable equipment and operators to finely manage the operation of the equipment by combining fault analysis reports, thereby playing an instructive role in reducing the occurrence of faults.
As shown in fig. 3, the system alarms to analyze month, year and general trend, counts the occurrence times of faults of certain medium in month (year), can effectively and intuitively display the high and low trend of faults, and can lead equipment and operators to finely manage the operation of the equipment in combination with fault analysis reports, thereby playing a guiding role in reducing the occurrence rate of faults.
3. Trend management module application: a transient trend data classification information definition table (shown in table three) is designed and the classification information of the data points is stored in an ORACLE database. The user editing interface is developed, and classification, addition and deletion can be flexibly filed according to the actual data point addition or change condition so as to maintain the timeliness of the data. And developing and providing a query interface, and searching data according to various query modes such as different time granularities, custom time intervals, data classification, name fuzzy query and the like.
Table III, transient trend data classification information definition table
And designing a graphic control, displaying trend in a curve mode, and simultaneously displaying specific information of peak data.
And designing a functional page, filling quaternary analysis comments for each data point, uploading the accessory, and attaching related accessories for reference.
And designing a graphic control, and displaying trend in a curve mode. Associated data points can be selected, and the trend curve can be displayed in a comparison mode on the same picture. Besides the comparison and display of the related data preset by the system, the trend query also provides the user-defined comparison of the related data, so that the user can freely select the data points considered to be related by the user for comparison and display, analysis opinions of month, season and year can be filled in for each data point, and related accessories can be attached for reference.
4. Important energy device parameter statistics query application: corresponding information maintenance interfaces are developed, and the information can be compiled. And developing a recording interface, and recording equipment parameters of important energy utilization equipment, such as rated voltage, current, maximum running time, maintenance interval time and the like. Recording various operation data of important energy utilization equipment from a real-time database, carrying out induction analysis statistics on massive real-time data, carrying out background logic processing judgment, and storing relevant statistical information into an ORACLE database for query and reference;
and providing a query interface, and searching data according to various query modes such as different time granularities, custom time intervals, equipment classification, name fuzzy query and the like. And the trend is displayed in a curve mode, the associated equipment data information can be selected, and the data comparison analysis, such as the comparison, the ring comparison data comparison and the like, can be performed on the same picture.
As shown in fig. 4, the management of the heavy point energy utilization equipment in the factory, such as an air compressor of an air compression station, a gas pressurizing machine and other rotary equipment, is also in a self-built equipment maintenance form, the operation time of the pressurizing machine, the failure times and the vehicle skip times are counted manually, the maintenance time cannot be counted down automatically according to the requirements on the equipment specification, and in order to strengthen the management and maintenance of the heavy point energy utilization equipment in the factory, a management module of the equipment is specially provided in a data management system; the module comprises:
1. real-time display of important measuring points of the rotating equipment (such as vibration, temperature and the like),
2. the statistics of the times of fault tripping are carried out,
3. the statistics of the number of the alarm times,
4. statistics of the longest uninterrupted run time,
5. the overhauling is counted down, the time is counted down,
6. display function of device parameters.
The beneficial effects of this embodiment include: 1. important production data are saved, and a data platform is provided for production application. 2. The alarm management can effectively improve the equipment management capability of equipment and operators on the production and use of field energy, reduce equipment faults, improve the control capability 3 of equipment degradation trend and compare custom trend, and can effectively improve the analysis capability of operators. 4. The equipment system is monitored continuously on line, so that the equipment maintenance management level 5 of the steel mill can be improved, the independent construction work of the energy data platform can be realized for the first time, the development and application of an independent intellectual property system of the steel mill on an EMS system are improved, and the energy management level of the steel mill is improved.
Claims (2)
1. An energy management system for metallurgical enterprises, based on an EMS system, comprising a central network system, an industrial ethernet (18), an Oracle database server (20), characterized in that: a switch is additionally arranged between the central network system and the industrial Ethernet (18); an application server, an industrial gateway IGS server (6) and a real-time database server are additionally arranged on the switch;
the central network system is connected with the industrial Ethernet (18) through a star-type twisted pair mode; the communication line between the central network system and the industrial Ethernet (18) comprises a main communication line (8) and a standby communication line (9);
the application server comprises a first application server (3) and a second application server (5); the first application server (3) is connected with the main communication line (8) and is also connected with the standby communication line (9); the second application server (5) is only connected to the standby communication line (9);
the real-time database server comprises a second real-time database server (7); the Oracle database server (20) is connected with the main communication line (8) and the standby communication line (9); the industrial gateway IGS server (6) and the second real-time database server (7) are only connected with the standby communication line (9);
the central network system is connected with a server in the EMS system in a hanging mode;
the industrial gateway IGS server (6) is directly read and connected to the industrial Ethernet (18) in an OPC UA mode.
2. A metallurgical enterprise energy management method, using the metallurgical enterprise energy management system of claim 1, characterized in that: the method comprises the following steps:
s1, setting a switch in a central network system and an industrial Ethernet based on an EMS system;
s2, an application server, an industrial gateway IGS server, a real-time database server and an Oracle database server are additionally arranged on the switch in the step S1;
s3, installing an IGS hardware dog and an IGS driver in the industrial gateway IGS server;
s4, configuring communication connected with the PLC and the DCS in software of an industrial gateway IGS server;
s5, the industrial gateway IGS server reads and stores real-time data of the site PLC and DCS in an OPC UA mode;
s6, newly adding an alarm information point table in the Oracle database server; the alarm information point table comprises alarm point codes, alarm point names, units, normal values, alarm interlocking values and remarks; the alarm interlocking value comprises an H value, an HH value, an L value, an LL value and an interlocking value;
and S7, developing corresponding management functions on the application server, wherein the management functions comprise a history storage application, an alarm management application, a trend management module application and an important energy device parameter statistics query application.
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| CN107357272A (en) * | 2017-07-03 | 2017-11-17 | 燕山大学 | A kind of DCS mobile remote monitoring systems and method based on OPC UA |
| CN109145000B (en) * | 2018-08-13 | 2022-03-18 | 上海电气集团股份有限公司 | Industrial real-time database OPC UA data interface implementation method |
| CN109032064B (en) * | 2018-09-10 | 2024-02-27 | 江门市崖门新财富环保工业有限公司 | Online monitoring system for waste gas treatment facilities |
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| CN112000031B (en) * | 2020-08-26 | 2021-09-14 | 安徽华创环保设备科技有限公司 | Equipment remote maintenance pipe system based on regenerated metal smelting |
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