现场总线技术在闪速冶炼中的应用 Fieldbus Technology Application in

Flash Smelting

刘志强Mr. Liu Zhiqiang计控车间生产副主任Deputy Director, Control Workshop江铜贵溪冶炼厂Guixi Smelter of Jiangxi Copper Corporation

成立于１９７９年的江西铜业集团公司，为目前中国最大的阴极铜生产商，世界铜行业第二大企业。公司在铜以及相关有色金属领域，拥有勘探、采矿、冶炼、加工为一体的完整产业链。江铜为国内铜精矿自给率最高的公司，是国内最大、最现代化的铜生产和加工基地，黄金、白银、硒、碲、铼等稀贵金属和硫化工的重要生产基地。Established in 1979, Jiangxi Copper Corporation (JCC) has gone through 30 years development, and is now the largest copper producer and copper fabricator in China, also a fundamental supplier for gold, silver, selenium, tellurium, rhenium, as well as sulphide chemicals.

江铜贵溪冶炼厂始建于 1979 年，是世界上产能最大的单个铜冶炼工厂，中国最大的硫化工、稀贵金属产品生产基地。工厂拥有两台闪速炉，两套铜酸生产系统，年产阴极铜 100 万吨以上。Guixi Smelter is the largest single copper smelting factory capacity in the world, China's largest sulfur chemicals, precious metal products production base. The factory has two flash furnace, two sets of copper acid production system, more than one million tons annual output of copper cathodes

为了应对国内外铜市场的需求和竞争，贵溪冶炼厂扩建了一套 30 万吨级铜冶炼系统，采用世界上最先进的闪速炼铜工艺技术。整个工程于2005 年 12 月 2 日开工建设， 2007 年 8 月 1 日建成投产。闪速炉、硫酸主工艺流程选用艾默生公司的 Deltav Ff 总线控制系统，主要的配套装置空分系统选用横河公司的 CS3000 Ff 总线控制系统。自动化仪表控制系统投运至今，运行稳定、可靠。这也标志着 Ff 现场总线控制技术在江铜 30 万吨级铜冶炼应用获得了成功。In response to market demand and competition in domestic and overseas market, Guixi Smelter expanded a 300KT/a copper smelting project with most advanced copper flash smelting technology. The entire project started construction on December 2, 2005, put into operation on August 1, 2007. Emerson’s DeltaV Fieldbus control system was chose in Flash furnace and sulfuric process units. And Yokogawa’s CS3000 fieldbus control system was chose in air separation unit. Till now, the a control systems are stable and reliable running. This also marks the Ff fieldbus control technology in JCC 300KT/a copper smelting applications have been successful.

系统总体要求与选择 Overall System Requirements

系统总体设计关键在于： 现场总线选择及布线实现方式； 基于多现场总线的控制系统设计（系统需要和

一些 Profibus 设备连接）； 基于多现场总线控制系统的安全联锁技术等。 选择综合性价比高，适于对象过程控制与设备

管理的系统。

The key points of overall system design ： Fieldbus selection and wiring

implementations ； Based on multi-fieldbus control system design

(Ff for process monitor and control, Profibus for electric device communication);

Safety interlock technology based on multi-fieldbus control system

• Select the system with high performance / price ratio and suitable for the process control and device management system.

考虑的要素 Keys to be Considered 系统规模大小； 整体经济性或长期成本：设备投资和运行维护费用； 适应性：所适用的控制对象类型、可挂接设备的种类； 施工便利性：布线方式与现场配置，组态与调试等； 系统运行的可靠性与稳定性； 互联的开放性： 冗余与可扩展性： 易维护性与操作性： 技术先进性

结合企业内部仪表控制的机构设置、人员水平、地域分布、设备类型等多状况，考虑到控制分散风险、管理信息集中的要求，设计应用了美国 Emerson 公司采用 PlantWeb 结构的 Delta V 系统。

System size ； The long term cost: equipment investment and operation, maintenance Adaptability: the type of control objects, the type of device can be hooked up; Construction convenience ： wiring, field configuration, staging etc. Reliability, stability; Interconnected openness; Redundancy and scalability; Ease of maintenance and operability; Advance of technology

Plus, considering combined with the internal instrument settings, staffing levels, geographical distribution, device type and other multi-situation, taking into account the control of risk diversification requirements, centralized management information, we chose Emerson's PlantWeb DeltaV system.

控制系统的选择： Ff 总线方案 Choice of Control System: Ff Solution

采用现场总线技术可以促进现场仪表的智能化、控制功能分散化、控制系统开放化，符合工业控制系统领域的技术发展趋势。Fieldbus technology can promote intelligent field instrumentation, control functions decentralized and control system to open up, in line with the trends of the technology in the field of industrial control systems.

在系统中，现场总线使自控系统与设备加入工厂信息网络，成为企业信息网络底层，是支撑现场级与车间级信息集成的技术基础，使企业信息沟通的覆盖范围一直延伸到生产现场。Fieldbus system make automatic control systems and equipment to join the plant information network, to be the base of enterprise information network. It’s the technical foundation to support field level workshop level information integration, coverage has been extended to the production site of the enterprise information communication.

基金会现场总线下的设备管理系统还有如下优点：Foundation Fieldbus device management system also has the following advantages: 全分布式，智能化与自诊断 Fully distributed, intelligent and self-diagnosis 多功能仪表 Multifunction Meters 易操作和维护 Easy operation and maintenance 开放性 Open 经济性 Economy 全数字化，双向传输 All-digital, two-way transmission 节省布线及控制室空间 Wiring and control room space savings 开放性与互操作性 Openness and interoperability 扩展方便 Expansion is convenient

系统概况 System Architecture

系统概况 System Overview

现场总线控制卡采用 30 对冗余总线控制卡和5块非冗余总线控制卡。

使用的网段中平均每条带有 6 台 Ff 设备，配置最少的一条网段为 4 台 Ff 设备，配置最多的一条网段为 8 台 Ff 设备。

网段辅助设备全部采用 P+F 公司的产品。

30 pairs of redundant H1 card and 5 simplex H1 cards.

Average 6 Ff devices each segment, least 4 Ff devices in a segment, and most 8 Ff device in a segment

Segment auxiliary equipment used P+F products

系统概况 Device Summary

Yokogawa Emerson ABB E+H Honeywell Invensys

温度变送器 Temperature Transmitter   7 4      

流量变送器Flowmeter Transmitter   9   2    

压力变送器 Pressure Transmitter 15 70 3 2 15  

多参量变送器Multi-parameter Transmitter   1        

多路温度变送器 Multi-channel Temperature transmitter

  99        

阀门定位器 Valve Positioner   39       1

电导率变送器 Conductivity Transmitter 3          

仪表类型Device Type

数量Quantity

厂商Supplier

Ff 现场仪表的连接与配置 Conductivity Transmitter

采用 P&F 总线电源调节器和分线箱 270 台 Ff 设备

- Rosemount 3051压力变送器- Rosemount 848T 8路输入转换器- MicroMotion 2700质量流量计- Fisher DVC6000阀门定位器

… 40 个控制回路中 , 大部分以单回路为主 ,其控制

作用 (PID) 放在阀门定位器中执行

Use P&F power regulator and splitter box 270 FF devices

- Rosemount 3051 pressure transmitter- Rosemount 848T 8-input converter- MicroMotion 2700 mass flowmeter- Fisher DVC6000 Valve positioner

… 40 control loop, majority is single-loop whic PID

is executed in valve postioner

Ff 实际应用概况－节省 Ff Application Overview - Saving

模拟量信号电缆减少 75%,I/O卡件和底板也有了相应的减少省去中间端子 , 相比一系统的控制系统减少了一半机柜 Analog signal cable reduce by 75%, has also been a corresponding reduction in the I / O card and

backplane Eliminating the need for intermediate terminal, cabinet reduction by half compared to a system

control system cabinet

Ff 仪表的现场安装和常规仪表一样 , 对施工人员毋需特别培训

Ff meter on-site installation has no difference with traditional instruments. Construction workers do not need special training

Ff 实际应用概况－简便易用Ff Application Overview – Easy to Use

现场增加测控点简单省时： 比如设备部门根据需要安装新增一台压缩机时，机上的 8点温度需引入控制系统。这时只需从现场总线接线盒的分支上增添一个 848T就实现了。

It’s easy and simple to add monitoring and control points in the field: For example, if the equipment

department need to install a new compressor, 8 temperature signal should be connected to system, we only need to add a 848T to fieldbus junction box.

848T

Ff电缆去控制室Ff wiring to control room

Ff 实际应用概况－简便易用Ff Application Overview – Easy to Use

控制策略组态中功能块调用和常规组态很类似 , 所见即所得

Ff Function block used in control strategy configuration is similar to conventional configuration.

控制在现场

Ff 实际应用概况－简便易用Ff Application Overview – Easy to Use

利用 Ff 仪表的唯一性的 ID 标识来作回路测试，快捷准确

Use Ff instrument unique ID to identify for the loop test, fast and accurate

Ff 实际应用概况－调试Ff Application Overview – Loop Test

控制回路下放到现场分散执行，在提高控制安全的同时降低了控制器的内存使用和运行负荷

Decentralize the control loop to execute in field, to improve the security control at the same time reduce the memory usage and load of controller.

Ff 实际应用概况－提高性能Ff Application Overview – Improving Performance

80% 空余内存80% free memory

70% 空闲时间70% idle time

使用 AMS 设备管理软件 , 实现仪表远程调试、组态与故障诊断，可以让仪表人员足不出户就能解决许多疑难杂诊。

AMS Device Manager, realize remote debugging, configuration and fault diagnosis, it allows maintainance engineer to solve miscellaneous issues from control room.

Ff 实际应用概况－设备管理Ff Application Overview –Device Management

40 个调节阀远程调校 ,减少近 80%的时间

40 remote control valves remote adjustment in control room, which can reduce nearly 80% time

Ff 实际应用概况－设备管理Ff Application Overview –Device Management

使用 DeltaV Inspect 、 ValveLink 等软件 ,快速了解现场设备健康状况

Use DeltaV Inspect, AMS,ValveLink etc. to quickly understand the health status of field devices

Ff 实际应用概况－设备管理Ff Application Overview –Device Management

使用现场总线带来了…With Ff Technology, We Can…

便于操作，提高效率

减少不必要的现场巡检次数，减少维护成本，人员减少80% 。

Easy to operate, improve efficiency

Reduce unnecessary on-site inspection, reduce maintenance costs, and 80% reduction in man hour.

使用现场总线带来了…With Ff Technology, We Can…

设备自诊断功能 , 在故障发生之前就能预先侦察到 设备在线增加更容易，节约施工量 控制系统检修不影响现场控制2012 年度大修，在控制系统由 8.4.1英文版升级到 10.1 中文版过程中，现场炉体保温相关设备保持正常控制运行。

Device self-diagnostic function, before a failure occurs will be able to pre-detected

Easier to add equipment online, saving implementation cost The control system maintainence does not affect the on-site control

Among 2012 annual overhaul, we upgrade the control system from V8.4.1 to V10.1 online without plant shutdown, the process equipment field furnace insulation to maintain a normal running.

经济性分析 ( 定性 )Benefit Analysis (Qualitative)

系统投资：由于 Ff 总线系统采用的模块数量相对减少，节省了机柜、控制室的空间，故其系统投资与按常规 DCS 系统设计的系统投资相差不大。

仪表及安装费用： Ff 总线型变送器和阀门定位器等仪表设备的投资目前虽较常规 /带 HART协议变送器的投资多 10%~30% ，但由于 Ff 总线系统使用的安装材料（电缆、桥架等）大大节省，安装工作量明显减少，而且随着点数增多 , 这方面的优越性会体现得越是明显。在通常的大型装置中， I/O 总点数一般总是成百上千安装费用和时间通常可减少三到四成，所以这项费用不仅不会增加，实际还会有所减少。

调试费用：由于采用总线技术给调试带来的诸多便利，调试的工期缩短，投入的人工成本大大降低，故可节约投资在 50% 以上。

维护费用：由于采用 AMS 和嵌入诊断功能的 Ff 现场仪表设备，可节省 50~70% 的维护时间和费用。

System investment: Because the Ff system uses relatively less modules which can save cabinets, control room space. So the investment is near with conventional DCS system .

Instruments and installation costs: Ff transmitters and valve positioners costs are 10% to 30% higher compared with conventional / HART transmitters , but since there are huge saving in the Ff bus system installation materials ( cables, bridge, etc.) ,man-hours, the total cost does not increase, even can decrease, especially in large projects.

Commissioning costs: As a result of the intelligent bus technology, it’s easy to commission, shorten the commission duration greatly, reduce the labor costs of the investment, and finally save more than 50% of the investment.

Maintenance costs: As a result of the AMS and embedded diagnostic function in Ff field instrumentation, we can save 50 to 70% of maintenance time and costs.

总结 Summary

通过现场总线技术的运用，实现了真正的集中管理、分散控制，提高了管理效率，为实现预防维修打下了坚实的基础。至今， Ff 现场总线技术已经有了大量的成功应用案例，它在提升工厂的运行管理水平上发挥着举足轻重的作用。在满足装置测量控制要求的同时，现场总线控制系统还具有很好的性能价格比，在初期投资、安装调试和日后维护等各个方面都能节省不少的费用开支及人力资本。这一切都决定了 Ff 现场总线技术将在未来的工程项目建设与装置扩产改造中被得到进一步的推广和应用。在今年实施的 1# 闪速炉工艺优化改造中，我们也采用了现场总线技术。

Through the use of fieldbus technology, We can realize a truly centralized management, decentralized control, and improve the management efficiency, and laid a solid foundation for preventive maintenance.

So far, Ff fieldbus technology has a lot of successful application cases, it has played an important role in enhancing plant operation and management level. Fieldbus control system also has a very good performance / cost ratio while meet the control requirements of the device measurement. There’s lots of saving in initial investment, installation and commissioning and future maintenance expense and human capital. All these determine that Ff fieldbus technology will be further promoted in the future.

During the #1 flash furnace process optimization, we continue to use the fieldbus technology.

报告完毕 谢谢 !

Thank you