I. INTRODUCTION In today's highly developed information technology, the petrochemical industry as a traditional industry is still an important pillar of the country's economic development.
For decades, the automation technology of the petrochemical industry has developed along with the continuous development of process and equipment technology. From the initial simple manual operation to the continuous process and the continuous increase of load, the requirements for production stability have become higher and higher, and the requirements for control have been increasing. And the level of automation is getting higher and higher, and the use of meters is becoming more and more common. From the closed-loop control of simple loops to the complete automation of the unit devices, the control tools used are also widely applied from the pneumatic unit combination meter to the DCS. The level of control also extends from single-parameter simple control loops to multivariable complex control loops. Advanced control systems and optimized control systems are examples of successful applications in various applications.
With the further promotion of industrial scale, the successful development of rapid reaction, critical stable process, and energy comprehensive balance has raised higher requirements for automation. In addition, fierce market competition also puts forward new goals and requirements for automation. At the same time, information technology has also injected new vitality into the development of petrochemical automation technology.
Second, the application of fieldbus will gradually promote the fieldbus (fieldbus) is applied to the production site, in the field instrument (including transmitters, actuators, recorders, single loop regulators, programmable logic controllers, etc.), The network interconnection technology that realizes all-digital, serial, bi-directional and multi-variable digital communication between field instruments and control devices. Its appearance has had a very big influence on the field of industrial control technology.
Although the fieldbus international standard IEC61158 contains eight types (now added to ten types) of fieldbus including FF, Profibus, ControlNet, WorldFIP, P-NET, etc., its original "single field bus" was not implemented. The goal, at the same time, also announced the existence of a variety of field bus coexistence. But compared with existing DCS and PLC, FCS fieldbus control system is still a petrochemical industry due to its all-digital multi-point communication, controllable on-site equipment status, openness, mutual operation, and decentralized control. The development trend of the industry basic automation system.
However, in the near future, the promotion and application of FCS will exhibit the following characteristics:
(1) FCS will coexist with DCS Since its introduction in the 1970s, DCS has experienced several stages of development, maturity, and large-scale application, and has adopted a large number of advanced and mature technologies. DCS technology is mature, reliable performance, rich software, perfect functions, has gained the trust of users, has become the main means of industrial production process control. While FCS is still in the development stage, the technology itself is not yet mature, (such as network redundancy has not yet been well resolved) reliability has not been fully verified, the function is not as good as DCS. Therefore, although users are concerned about the development of FCS, they still have doubts and tend to be cautious.
In addition, for the occasions where the system is small in scale, where the distribution of control objects is relatively concentrated, and where there is no need to expand the equipment's intelligent diagnosis and management requirements, the superiority of the field bus cannot be fully reflected. Large-scale replacement of existing DCS equipment will inevitably cause great The waste.
Fieldbus-based on-site smart device management has also been used as a hot selling point for fieldbus. However, after careful analysis of equipment management products provided by major companies in the world, there is no new idea. For example, equipment fault diagnosis is a complex science. It needs to combine mechanical, electronic, computer and other multi-disciplinary knowledge to establish a fault model of the equipment, and after collecting a large number of equipment operating status information, conduct detailed analysis in order to make accurate and Judgment of meaning has real guiding significance for the maintenance of equipment. Unfortunately, the current device management software products basically do not do this.
In short, DCS has been developed quite maturely and practically, and it is still the mainstream of current industrial automation system application and selection. It will not withdraw from the stage of history as soon as the appearance and development of FCS. On the contrary, for a long time to come, DCS will coexist with FCS.
(2) Combining field bus and DCS to integrate field bus technology into existing control systems, connecting field bus smart meters to DCS, making use of DCS rich and mature control functions and software and hardware products to promote the popularization and application of field bus . In general, there are mainly three ways to integrate fieldbus and traditional control systems: one is the integration of fieldbus at the I/O level of DCS and PLC, and the fieldbus device is integrated into DCS and PLC as I/O cards. The second is the fieldbus integrated in the DCS, PLC network, fieldbus devices through the gateway integrated into the DCS, PLC, unified configuration, monitoring and management; the third is the integration of information between the independent FCS and DCS, PLC That is, FCS and DCS and PLC work independently, and the information mapping and mutual visit between the two are realized through the gateway. In the current situation where traditional control systems are still in heavy use, the above methods can not only make use of the mature technologies and experiences of DCS and PLC, but also give full play to the advantages of field buses.
At the same time, on the basis of the promotion and application of fieldbus, the functions of management and control integration will be gradually improved. Utilize field bus's all-digital communication function to collect a large amount of non-control information provided by on-site smart devices, establish on-site smart device database, establish and improve remote control, fault diagnosis, preventive maintenance, on-line adjustment and remote management of on-site smart devices. Functions to realize integrated management and control of field devices.
(3) Multi-bus integration and "islands of automation"
The fieldbus international standard IEC61158 does not have the ability to unify all fieldbuses. In addition to the factors of market interest, because different fieldbuses are developed for a specific application field, they have technically distinctive characteristics, so there is no one so far. The bus can replace all other fieldbuses. For example, FF and HART have certain characteristics in the processing of continuous signals, and PROFIBUS and INTERBUS have certain advantages in the processing of switch signals.
Therefore, in the coming period of time, no matter what form of basic automation control system, will have a variety of fieldbus interconnection and information integration capabilities.
No matter what kind of control system is adopted, the problem of “automation island†between different field buses and different types of control systems must be solved. Each manufacturer’s DCS, PLC and other smart devices are connected to a unified database platform. Unified scheduling and sharing.
(4) Ethernet field bus With the development and popularization of Internet technology, Ethernet has the characteristics of wide application, low cost, high communication speed, rich hardware and software resources, and great potential for sustainable development. It is gradually penetrating from the field of commercial communications. The field of control, and is widely used in the communication between the control layer and management equipment of industrial enterprises.
To this end, international multinational companies have launched fieldbus technologies based on Ethernet, such as EPA of the Zhejiang University, Siemens ProfiNet I/O, EOACAT and PowerLink of the European Open Network Consortium IAONA. These real-time Ethernet protocols have been listed in the IEC 61784-2, an international standard for real-time Ethernet applications that is being drafted by the IEC.
Because the real-time Ethernet fieldbus not only combines the features of the existing fieldbus, but also combines with the mature technologies in the field of information, it will be widely used in the field of petrochemical automation control.
Third, the combination of information technology and automation technology - industrial IT
As the Internet continues to mature, the Internet has bonded two separate areas of computers and communications together. This not only enables computers running on a stand-alone computer to fully enter the Internet era, but also rapidly promotes the development of the computer industry and communications industry.
On the other hand, with the wide application of information technology, microelectronics technology in automated instrumentation and control systems, and the integrated development of industrial control networks and information management networks, the data collection, regulation control, and monitoring of the company’s production processes are digitized. Configuration and design, equipment maintenance, production management, and business decision-making are integrated into a complete integrated automation information system through an integrated network communication platform to realize the digitization of field devices, the intelligent control of production processes, and the management of enterprises. Informatization and networking of consulting services. According to experts' predictions, in this kind of automated control integrated information system, traditional control information will be reduced from the original 85% to 40%. The management information will rise to 60%. Therefore, the field of industrial control already has the contemporary IT technology and industrial characteristics, namely the so-called industrial "IT" (IndustrialIT), in which "intelligent" industrial automation instruments and industrial control networks constitute the technical basis of the industrial "IT" And hardware platform.
On this basis, it adopts some real-time database technologies, soft measurement technologies, data fusion and data processing technologies, advanced control and process optimization technologies, ERP technologies, etc., and adopts information network IT technologies, such as network technology, communication technology, and information. Processing technology, etc., to achieve remote monitoring, fault diagnosis and maintenance of industrial production processes, to achieve the integration of management and control of the entire industrial plant.
In fact, automation technology has been closely integrated with information technology since the invention of the computer. The development of information technology has provided more and more means and more and more convenient tools for automation technology, making the past a lot of sophisticated techniques in automation technology (such as a variety of complex PID algorithms and such as uniform control, decoupling control, Advanced algorithms such as fuzzy control become software codes that are easier to implement in a segment. It is also because of IT technology that many of the ideas that remain in theory in automation technology become reality.
At present, with the rapid development of IT technology, how to better, faster, and more apply IT technology to automation products is a common topic facing suppliers of automation products. The ability to apply IT technology as much as possible to automation technology has gradually become an important factor in determining the competitiveness of the company.
The first is how to better apply IT technology, and secondly, how to generate benefits through optimization, combine specific processes and equipment, tap potentials of equipment and technology, promote production increase, reduce consumption, and make production process more secure. In short: "To control and optimize for efficiency."
In addition, how to transform an “automated island†in a company into a unified platform and realize “process visualization†while expanding information sharing, improving information utilization rate, and improving enterprise’s decision-making level and effectiveness, and achieve management and control integration. "Management and information systems need to be effective" is also a major issue.
In general, industrial "IT" has the following characteristics: digital intelligence of field instruments, digitization of production process, design digitization, management digitization and informationization. Specifically:
(1) A new type of industrial automation network system technology based on modern computers, networks, communications and modern control technologies, serving the process industries and manufacturing industries, has strengthened the information on the basis of further improving the information collection function. The network transmission technology of processing and processing, especially measurement and control information of industrial production processes, is more open and has been rapidly developed.
(2) The traditional automation instrument goes digital and intelligent, has an open network communication interface, and becomes a node of the networked control system. Distributed industrial control networks will become the dominant technology for future control systems.
(3) Using field bus, industrial Ethernet and other industrial control networks as platforms to utilize the software and hardware resources (such as functional modules) of field devices to achieve full decentralized control, while also enabling remote access, monitoring and calibration of field instruments. , diagnosis, maintenance and other management functions.
(4) The control system and information system achieve smooth connection and multi-network integration. Industrial Ethernet technology will be more widely promoted in the field of control. Real-time control information can be shared, detected, controlled and managed via Intranet/Internet.
(5) The industrial control system software and various application software development and system integration technologies have become core technologies and have become high value-added carriers instead of system hardware. Through advanced control and optimization software, advanced intelligent control such as predictive control, fuzzy control, neural network control, and expert system control can be realized, as well as data correction, process simulation, quality monitoring, scheduling and scheduling, fault diagnosis, and safety management. The optimal management of the production process.
(6) The company's business management uses ERP-Enterprise Resource Planning (ERP) software and Supply Chain Management (Supply Chain Management) software as its platform to implement bill of material, routing, inventory management, production planning, material requirements planning, and capabilities. Requirements planning, cost management, financial management, sales management, product data management, quality management, equipment maintenance management, laboratory management, transportation management, formula management, human resources management, strategic management, customer service management, development and research management, etc. Integrated management.
(7) Dedicated IC chips, communication modules of various industrial control networks, bridges, repeaters, gateways, remote I/O nodes, and functional modules have become the key products in the new generation of distributed network control systems, and have been associated with network information. The technology is developing at the same time.
IV. Comprehensive enterprise automation will become an effective means for enterprises to improve their core competitiveness. After 50 years of development in China's petroleum and chemical automation industries, the level of automation has achieved significant progress through technology introduction, digestion and absorption, and continuous innovation. With the rapid development of China's economic construction, China's petrochemical industry has encountered unprecedented opportunities for development, but it is also facing more and more severe challenges. Compared with advanced countries, China's petrochemical industry still has problems such as large energy consumption, poor product quality, backward production process, low automation level, low management level, low information integration, and weak comprehensive competitiveness. The integrated enterprise automation system integrates advanced process equipment technology, modern management technology, and information technology represented by advanced control and optimization technologies, and controls the production process control, optimization, operation, planning, and management as a whole. With management, providing a total solution to achieve the company's optimal operation, optimization control and optimization management, thus becoming the core high technology to improve the competitiveness of enterprises.
Foreign large-scale process companies, especially petrochemical companies, attach great importance to the application of information integration technology and have organized plant-level, company-level, or even super-corporate information integration systems with great enthusiasm and energy. In 1995, more than 100 refining and chemical companies in the United States, Japan, Western Europe and other countries have implemented the CIMS program, which has promoted the application of integrated process automation technology in actual production, such as Japan Mitsui Petrochemical Industry Co., Ltd. Chemical companies such as GOL have successively established integrated automation systems.
In general, the requirements of the process automation industry for integrated automation technology mainly focus on four issues. (1) Security: The need to use high-reliability control systems, inspection and enforcement agencies to provide guarantees for the operation of equipment and devices, and then the fault diagnosis and health maintenance of key devices. (2) Low cost: Through advanced technology and process parameters to reduce energy consumption and raw material consumption, and through advanced modeling technology, control technology and real-time optimization technology to improve product qualification rate and conversion rate. (3) High efficiency: Improve equipment utilization and labor productivity through advanced planning, scheduling and scheduling technologies and process simulation technologies. (4) Improve competitiveness: Through the integrated integration of data and information, such as advanced management technologies (including ERP, CRM, SCM, etc.), e-commerce, and value chain analysis technologies, etc. Comprehensive Competitiveness.
According to the development trend of integrated automation technology at home and abroad and the development status of network technology, the overall structure of the process industry integrated automation technology can be divided into three layers, as shown in Figure 1.
Fig. 1 The overall structure of the process industry integrated automation technology (1) The basic automation layer represented by the PCS (Process Control System). The main contents include advanced control software, soft measurement technology, real-time database technology, reliability technology, data fusion and data processing technology, distributed control system (DCS), field control system (FCS), multi-bus networked control system, based on high-speed Ethernet On-site control equipment, sensor technology, special actuators, etc.
(2) The optimization layer of the production process represented by MES (Production Process Manufacturing Execution System). The main contents include Advanced Modeling Technologies (AMT), Advanced Planning and Scheduling (APS), Real-time Optimization (RTO), Fault Diagnosis and Health Maintenance Technology, Data Mining and Data Correction. Technology, Dynamic Quality Control and Management Technology, Dynamic Cost Control and Management Technology, and more.
(3) The optimized production and management layer represented by ERP (Enterprise Resource Management). The main contents include enterprise resource management (ERP), supply chain management (SCM), customer relationship management (CRM), product quality data management (PqDM), data warehouse technology, equipment resource management, enterprise e-commerce platform and so on.
By studying the production process manufacturing execution system (MES) and related technologies, online cost prediction, control and feedback correction can be realized to form a production cost control center to ensure the optimal operation of the production process; the entire production process can be optimized and unified Command to form a production command center to ensure the optimal control of the production process; to achieve quality tracking and safety monitoring of the production process to form a quality management system and equipment health protection system to ensure the optimal management of the production process.
The key technologies that enterprises need to solve in integrated automation are:
(1) Information integration, mining, and value-added information integration is the core of integrated automation, and database management systems are the foundation of information integration. Due to the characteristics of the process industry, there are a large number of real-time mass data that reflect the status of the production process needs to be processed, managed, and effectively applied. Therefore, the real-time database management system uses real-time data to supervise and control the production process, and analyzes and evaluates the production status. Foundation. Therefore, the process industry information integration environment needs to set up a relational database and a real-time database system at the same time as the distribution center of the entire system information. These two databases can operate independently and cooperatively, processing all kinds of information from the whole plant in parallel or in a timely manner, and truly integrate and share information.
The purpose of information mining and value-added is to fully and effectively use information.
(2) Scientific decision-making Supporting production and business decision-making is an important part of the company's production and operation activities. However, the traditional production management model is still in the experience of decision-making, with a greater degree of randomness, and scientific decision-making support is the key to business success.
The cost-benefit analysis refers to the process of applying the financial analysis method to the production and business activities of an enterprise for analysis and evaluation to obtain the comprehensive economic indicators of the entire enterprise. In the comprehensive automation of refinery enterprises, cost-benefit analysis is an important part in the production management of refineries, and it is also a necessary step in the production and operation decisions of refiners.
Cost-benefit analysis aims to achieve the maximum profit for the company. A cost-benefit analysis of the company's production and operation, and a profit and loss analysis of the production program on the basis of this, provide business leaders with economic indicators of the actual production and operation process and production plans, in order to improve the level of enterprise decision-making and strengthen the competitiveness of enterprises in the market .
In order to achieve the company's pre-established profit target, it is necessary to coordinate the work of various departments of the company, namely, crude oil procurement, production planning, production scheduling, and product sales. Since crude oil is the main raw material for refinery production, the cost of crude oil accounts for 80-90% of the total cost of the product. Therefore, in order to achieve the profit target, it is necessary to first control the cost of crude oil, that is, to control the purchase price of crude oil.
The break-even analysis refers to the use of financial analysis methods and mathematical tools to analyze the production and management plans or plans, and to obtain the maximum purchase price of crude oil (poly points) and non-destructive operations (profits of 0) that achieve the profit target. Price (maintenance point). The break-even analysis has important reference value for crude oil procurement, control of costs, and improvement of economic efficiency. It is an important link in the development of a reasonable production plan. It controls production costs, expands profits, and thus guarantees the realization of profit targets, and guides the production and operation of the whole company. , has a very important significance.
(3) Perform process simulation, establish process model, realize process optimization, perform process simulation, establish process model, and realize process optimization. This is another key technology of process automation.
The scientificization of production planning/scheduling is the key to achieve a certain degree of production flexibility in the refining production process, and it is a research topic that has been highly valued by the academic community and industry. Because of the highly complex nature of refining production, it is necessary to closely integrate the modeling of the production process mechanism with the system engineering theory to find a solution to this problem. The practical results show that a computer-aided production planning/scheduling system based on full-process simulation combined with the application of linear programming, nonlinear programming or dynamic programming is an effective way to achieve optimal scheduling/optimization scheduling.
The optimization of process operations is another key to the flexibility of production in the refining industry to adapt to changes in the market for raw materials and product requirements. The technical difficulty first is to establish a steady state mathematical model of the process. Due to the complexity of process technology and different device mechanisms, some complex reaction process mechanisms are still unclear. Moreover, modeling involves process mechanisms and information processing technologies and is interdisciplinary. Therefore, it is extremely difficult to establish industrial application models.
In addition, there are soft measurement technology, new process fault diagnosis technology, safety protection technology of the production process, and data adjustment technology for processing data measured in real time, which are urgent problems to be solved in the automation field.
V. Concluding remarks Applying field bus technology and information technology to petrochemical industry, developing comprehensive integrated automation solutions and integrated technologies can improve product quality, increase product output, reduce production costs, achieve significant economic and social benefits, and strengthen enterprises. The competitiveness is the trend of the development and application of automation technology in the petrochemical industry in the future.
For decades, the automation technology of the petrochemical industry has developed along with the continuous development of process and equipment technology. From the initial simple manual operation to the continuous process and the continuous increase of load, the requirements for production stability have become higher and higher, and the requirements for control have been increasing. And the level of automation is getting higher and higher, and the use of meters is becoming more and more common. From the closed-loop control of simple loops to the complete automation of the unit devices, the control tools used are also widely applied from the pneumatic unit combination meter to the DCS. The level of control also extends from single-parameter simple control loops to multivariable complex control loops. Advanced control systems and optimized control systems are examples of successful applications in various applications.
With the further promotion of industrial scale, the successful development of rapid reaction, critical stable process, and energy comprehensive balance has raised higher requirements for automation. In addition, fierce market competition also puts forward new goals and requirements for automation. At the same time, information technology has also injected new vitality into the development of petrochemical automation technology.
Second, the application of fieldbus will gradually promote the fieldbus (fieldbus) is applied to the production site, in the field instrument (including transmitters, actuators, recorders, single loop regulators, programmable logic controllers, etc.), The network interconnection technology that realizes all-digital, serial, bi-directional and multi-variable digital communication between field instruments and control devices. Its appearance has had a very big influence on the field of industrial control technology.
Although the fieldbus international standard IEC61158 contains eight types (now added to ten types) of fieldbus including FF, Profibus, ControlNet, WorldFIP, P-NET, etc., its original "single field bus" was not implemented. The goal, at the same time, also announced the existence of a variety of field bus coexistence. But compared with existing DCS and PLC, FCS fieldbus control system is still a petrochemical industry due to its all-digital multi-point communication, controllable on-site equipment status, openness, mutual operation, and decentralized control. The development trend of the industry basic automation system.
However, in the near future, the promotion and application of FCS will exhibit the following characteristics:
(1) FCS will coexist with DCS Since its introduction in the 1970s, DCS has experienced several stages of development, maturity, and large-scale application, and has adopted a large number of advanced and mature technologies. DCS technology is mature, reliable performance, rich software, perfect functions, has gained the trust of users, has become the main means of industrial production process control. While FCS is still in the development stage, the technology itself is not yet mature, (such as network redundancy has not yet been well resolved) reliability has not been fully verified, the function is not as good as DCS. Therefore, although users are concerned about the development of FCS, they still have doubts and tend to be cautious.
In addition, for the occasions where the system is small in scale, where the distribution of control objects is relatively concentrated, and where there is no need to expand the equipment's intelligent diagnosis and management requirements, the superiority of the field bus cannot be fully reflected. Large-scale replacement of existing DCS equipment will inevitably cause great The waste.
Fieldbus-based on-site smart device management has also been used as a hot selling point for fieldbus. However, after careful analysis of equipment management products provided by major companies in the world, there is no new idea. For example, equipment fault diagnosis is a complex science. It needs to combine mechanical, electronic, computer and other multi-disciplinary knowledge to establish a fault model of the equipment, and after collecting a large number of equipment operating status information, conduct detailed analysis in order to make accurate and Judgment of meaning has real guiding significance for the maintenance of equipment. Unfortunately, the current device management software products basically do not do this.
In short, DCS has been developed quite maturely and practically, and it is still the mainstream of current industrial automation system application and selection. It will not withdraw from the stage of history as soon as the appearance and development of FCS. On the contrary, for a long time to come, DCS will coexist with FCS.
(2) Combining field bus and DCS to integrate field bus technology into existing control systems, connecting field bus smart meters to DCS, making use of DCS rich and mature control functions and software and hardware products to promote the popularization and application of field bus . In general, there are mainly three ways to integrate fieldbus and traditional control systems: one is the integration of fieldbus at the I/O level of DCS and PLC, and the fieldbus device is integrated into DCS and PLC as I/O cards. The second is the fieldbus integrated in the DCS, PLC network, fieldbus devices through the gateway integrated into the DCS, PLC, unified configuration, monitoring and management; the third is the integration of information between the independent FCS and DCS, PLC That is, FCS and DCS and PLC work independently, and the information mapping and mutual visit between the two are realized through the gateway. In the current situation where traditional control systems are still in heavy use, the above methods can not only make use of the mature technologies and experiences of DCS and PLC, but also give full play to the advantages of field buses.
At the same time, on the basis of the promotion and application of fieldbus, the functions of management and control integration will be gradually improved. Utilize field bus's all-digital communication function to collect a large amount of non-control information provided by on-site smart devices, establish on-site smart device database, establish and improve remote control, fault diagnosis, preventive maintenance, on-line adjustment and remote management of on-site smart devices. Functions to realize integrated management and control of field devices.
(3) Multi-bus integration and "islands of automation"
The fieldbus international standard IEC61158 does not have the ability to unify all fieldbuses. In addition to the factors of market interest, because different fieldbuses are developed for a specific application field, they have technically distinctive characteristics, so there is no one so far. The bus can replace all other fieldbuses. For example, FF and HART have certain characteristics in the processing of continuous signals, and PROFIBUS and INTERBUS have certain advantages in the processing of switch signals.
Therefore, in the coming period of time, no matter what form of basic automation control system, will have a variety of fieldbus interconnection and information integration capabilities.
No matter what kind of control system is adopted, the problem of “automation island†between different field buses and different types of control systems must be solved. Each manufacturer’s DCS, PLC and other smart devices are connected to a unified database platform. Unified scheduling and sharing.
(4) Ethernet field bus With the development and popularization of Internet technology, Ethernet has the characteristics of wide application, low cost, high communication speed, rich hardware and software resources, and great potential for sustainable development. It is gradually penetrating from the field of commercial communications. The field of control, and is widely used in the communication between the control layer and management equipment of industrial enterprises.
To this end, international multinational companies have launched fieldbus technologies based on Ethernet, such as EPA of the Zhejiang University, Siemens ProfiNet I/O, EOACAT and PowerLink of the European Open Network Consortium IAONA. These real-time Ethernet protocols have been listed in the IEC 61784-2, an international standard for real-time Ethernet applications that is being drafted by the IEC.
Because the real-time Ethernet fieldbus not only combines the features of the existing fieldbus, but also combines with the mature technologies in the field of information, it will be widely used in the field of petrochemical automation control.
Third, the combination of information technology and automation technology - industrial IT
As the Internet continues to mature, the Internet has bonded two separate areas of computers and communications together. This not only enables computers running on a stand-alone computer to fully enter the Internet era, but also rapidly promotes the development of the computer industry and communications industry.
On the other hand, with the wide application of information technology, microelectronics technology in automated instrumentation and control systems, and the integrated development of industrial control networks and information management networks, the data collection, regulation control, and monitoring of the company’s production processes are digitized. Configuration and design, equipment maintenance, production management, and business decision-making are integrated into a complete integrated automation information system through an integrated network communication platform to realize the digitization of field devices, the intelligent control of production processes, and the management of enterprises. Informatization and networking of consulting services. According to experts' predictions, in this kind of automated control integrated information system, traditional control information will be reduced from the original 85% to 40%. The management information will rise to 60%. Therefore, the field of industrial control already has the contemporary IT technology and industrial characteristics, namely the so-called industrial "IT" (IndustrialIT), in which "intelligent" industrial automation instruments and industrial control networks constitute the technical basis of the industrial "IT" And hardware platform.
On this basis, it adopts some real-time database technologies, soft measurement technologies, data fusion and data processing technologies, advanced control and process optimization technologies, ERP technologies, etc., and adopts information network IT technologies, such as network technology, communication technology, and information. Processing technology, etc., to achieve remote monitoring, fault diagnosis and maintenance of industrial production processes, to achieve the integration of management and control of the entire industrial plant.
In fact, automation technology has been closely integrated with information technology since the invention of the computer. The development of information technology has provided more and more means and more and more convenient tools for automation technology, making the past a lot of sophisticated techniques in automation technology (such as a variety of complex PID algorithms and such as uniform control, decoupling control, Advanced algorithms such as fuzzy control become software codes that are easier to implement in a segment. It is also because of IT technology that many of the ideas that remain in theory in automation technology become reality.
At present, with the rapid development of IT technology, how to better, faster, and more apply IT technology to automation products is a common topic facing suppliers of automation products. The ability to apply IT technology as much as possible to automation technology has gradually become an important factor in determining the competitiveness of the company.
The first is how to better apply IT technology, and secondly, how to generate benefits through optimization, combine specific processes and equipment, tap potentials of equipment and technology, promote production increase, reduce consumption, and make production process more secure. In short: "To control and optimize for efficiency."
In addition, how to transform an “automated island†in a company into a unified platform and realize “process visualization†while expanding information sharing, improving information utilization rate, and improving enterprise’s decision-making level and effectiveness, and achieve management and control integration. "Management and information systems need to be effective" is also a major issue.
In general, industrial "IT" has the following characteristics: digital intelligence of field instruments, digitization of production process, design digitization, management digitization and informationization. Specifically:
(1) A new type of industrial automation network system technology based on modern computers, networks, communications and modern control technologies, serving the process industries and manufacturing industries, has strengthened the information on the basis of further improving the information collection function. The network transmission technology of processing and processing, especially measurement and control information of industrial production processes, is more open and has been rapidly developed.
(2) The traditional automation instrument goes digital and intelligent, has an open network communication interface, and becomes a node of the networked control system. Distributed industrial control networks will become the dominant technology for future control systems.
(3) Using field bus, industrial Ethernet and other industrial control networks as platforms to utilize the software and hardware resources (such as functional modules) of field devices to achieve full decentralized control, while also enabling remote access, monitoring and calibration of field instruments. , diagnosis, maintenance and other management functions.
(4) The control system and information system achieve smooth connection and multi-network integration. Industrial Ethernet technology will be more widely promoted in the field of control. Real-time control information can be shared, detected, controlled and managed via Intranet/Internet.
(5) The industrial control system software and various application software development and system integration technologies have become core technologies and have become high value-added carriers instead of system hardware. Through advanced control and optimization software, advanced intelligent control such as predictive control, fuzzy control, neural network control, and expert system control can be realized, as well as data correction, process simulation, quality monitoring, scheduling and scheduling, fault diagnosis, and safety management. The optimal management of the production process.
(6) The company's business management uses ERP-Enterprise Resource Planning (ERP) software and Supply Chain Management (Supply Chain Management) software as its platform to implement bill of material, routing, inventory management, production planning, material requirements planning, and capabilities. Requirements planning, cost management, financial management, sales management, product data management, quality management, equipment maintenance management, laboratory management, transportation management, formula management, human resources management, strategic management, customer service management, development and research management, etc. Integrated management.
(7) Dedicated IC chips, communication modules of various industrial control networks, bridges, repeaters, gateways, remote I/O nodes, and functional modules have become the key products in the new generation of distributed network control systems, and have been associated with network information. The technology is developing at the same time.
IV. Comprehensive enterprise automation will become an effective means for enterprises to improve their core competitiveness. After 50 years of development in China's petroleum and chemical automation industries, the level of automation has achieved significant progress through technology introduction, digestion and absorption, and continuous innovation. With the rapid development of China's economic construction, China's petrochemical industry has encountered unprecedented opportunities for development, but it is also facing more and more severe challenges. Compared with advanced countries, China's petrochemical industry still has problems such as large energy consumption, poor product quality, backward production process, low automation level, low management level, low information integration, and weak comprehensive competitiveness. The integrated enterprise automation system integrates advanced process equipment technology, modern management technology, and information technology represented by advanced control and optimization technologies, and controls the production process control, optimization, operation, planning, and management as a whole. With management, providing a total solution to achieve the company's optimal operation, optimization control and optimization management, thus becoming the core high technology to improve the competitiveness of enterprises.
Foreign large-scale process companies, especially petrochemical companies, attach great importance to the application of information integration technology and have organized plant-level, company-level, or even super-corporate information integration systems with great enthusiasm and energy. In 1995, more than 100 refining and chemical companies in the United States, Japan, Western Europe and other countries have implemented the CIMS program, which has promoted the application of integrated process automation technology in actual production, such as Japan Mitsui Petrochemical Industry Co., Ltd. Chemical companies such as GOL have successively established integrated automation systems.
In general, the requirements of the process automation industry for integrated automation technology mainly focus on four issues. (1) Security: The need to use high-reliability control systems, inspection and enforcement agencies to provide guarantees for the operation of equipment and devices, and then the fault diagnosis and health maintenance of key devices. (2) Low cost: Through advanced technology and process parameters to reduce energy consumption and raw material consumption, and through advanced modeling technology, control technology and real-time optimization technology to improve product qualification rate and conversion rate. (3) High efficiency: Improve equipment utilization and labor productivity through advanced planning, scheduling and scheduling technologies and process simulation technologies. (4) Improve competitiveness: Through the integrated integration of data and information, such as advanced management technologies (including ERP, CRM, SCM, etc.), e-commerce, and value chain analysis technologies, etc. Comprehensive Competitiveness.
According to the development trend of integrated automation technology at home and abroad and the development status of network technology, the overall structure of the process industry integrated automation technology can be divided into three layers, as shown in Figure 1.
Fig. 1 The overall structure of the process industry integrated automation technology (1) The basic automation layer represented by the PCS (Process Control System). The main contents include advanced control software, soft measurement technology, real-time database technology, reliability technology, data fusion and data processing technology, distributed control system (DCS), field control system (FCS), multi-bus networked control system, based on high-speed Ethernet On-site control equipment, sensor technology, special actuators, etc.
(2) The optimization layer of the production process represented by MES (Production Process Manufacturing Execution System). The main contents include Advanced Modeling Technologies (AMT), Advanced Planning and Scheduling (APS), Real-time Optimization (RTO), Fault Diagnosis and Health Maintenance Technology, Data Mining and Data Correction. Technology, Dynamic Quality Control and Management Technology, Dynamic Cost Control and Management Technology, and more.
(3) The optimized production and management layer represented by ERP (Enterprise Resource Management). The main contents include enterprise resource management (ERP), supply chain management (SCM), customer relationship management (CRM), product quality data management (PqDM), data warehouse technology, equipment resource management, enterprise e-commerce platform and so on.
By studying the production process manufacturing execution system (MES) and related technologies, online cost prediction, control and feedback correction can be realized to form a production cost control center to ensure the optimal operation of the production process; the entire production process can be optimized and unified Command to form a production command center to ensure the optimal control of the production process; to achieve quality tracking and safety monitoring of the production process to form a quality management system and equipment health protection system to ensure the optimal management of the production process.
The key technologies that enterprises need to solve in integrated automation are:
(1) Information integration, mining, and value-added information integration is the core of integrated automation, and database management systems are the foundation of information integration. Due to the characteristics of the process industry, there are a large number of real-time mass data that reflect the status of the production process needs to be processed, managed, and effectively applied. Therefore, the real-time database management system uses real-time data to supervise and control the production process, and analyzes and evaluates the production status. Foundation. Therefore, the process industry information integration environment needs to set up a relational database and a real-time database system at the same time as the distribution center of the entire system information. These two databases can operate independently and cooperatively, processing all kinds of information from the whole plant in parallel or in a timely manner, and truly integrate and share information.
The purpose of information mining and value-added is to fully and effectively use information.
(2) Scientific decision-making Supporting production and business decision-making is an important part of the company's production and operation activities. However, the traditional production management model is still in the experience of decision-making, with a greater degree of randomness, and scientific decision-making support is the key to business success.
The cost-benefit analysis refers to the process of applying the financial analysis method to the production and business activities of an enterprise for analysis and evaluation to obtain the comprehensive economic indicators of the entire enterprise. In the comprehensive automation of refinery enterprises, cost-benefit analysis is an important part in the production management of refineries, and it is also a necessary step in the production and operation decisions of refiners.
Cost-benefit analysis aims to achieve the maximum profit for the company. A cost-benefit analysis of the company's production and operation, and a profit and loss analysis of the production program on the basis of this, provide business leaders with economic indicators of the actual production and operation process and production plans, in order to improve the level of enterprise decision-making and strengthen the competitiveness of enterprises in the market .
In order to achieve the company's pre-established profit target, it is necessary to coordinate the work of various departments of the company, namely, crude oil procurement, production planning, production scheduling, and product sales. Since crude oil is the main raw material for refinery production, the cost of crude oil accounts for 80-90% of the total cost of the product. Therefore, in order to achieve the profit target, it is necessary to first control the cost of crude oil, that is, to control the purchase price of crude oil.
The break-even analysis refers to the use of financial analysis methods and mathematical tools to analyze the production and management plans or plans, and to obtain the maximum purchase price of crude oil (poly points) and non-destructive operations (profits of 0) that achieve the profit target. Price (maintenance point). The break-even analysis has important reference value for crude oil procurement, control of costs, and improvement of economic efficiency. It is an important link in the development of a reasonable production plan. It controls production costs, expands profits, and thus guarantees the realization of profit targets, and guides the production and operation of the whole company. , has a very important significance.
(3) Perform process simulation, establish process model, realize process optimization, perform process simulation, establish process model, and realize process optimization. This is another key technology of process automation.
The scientificization of production planning/scheduling is the key to achieve a certain degree of production flexibility in the refining production process, and it is a research topic that has been highly valued by the academic community and industry. Because of the highly complex nature of refining production, it is necessary to closely integrate the modeling of the production process mechanism with the system engineering theory to find a solution to this problem. The practical results show that a computer-aided production planning/scheduling system based on full-process simulation combined with the application of linear programming, nonlinear programming or dynamic programming is an effective way to achieve optimal scheduling/optimization scheduling.
The optimization of process operations is another key to the flexibility of production in the refining industry to adapt to changes in the market for raw materials and product requirements. The technical difficulty first is to establish a steady state mathematical model of the process. Due to the complexity of process technology and different device mechanisms, some complex reaction process mechanisms are still unclear. Moreover, modeling involves process mechanisms and information processing technologies and is interdisciplinary. Therefore, it is extremely difficult to establish industrial application models.
In addition, there are soft measurement technology, new process fault diagnosis technology, safety protection technology of the production process, and data adjustment technology for processing data measured in real time, which are urgent problems to be solved in the automation field.
V. Concluding remarks Applying field bus technology and information technology to petrochemical industry, developing comprehensive integrated automation solutions and integrated technologies can improve product quality, increase product output, reduce production costs, achieve significant economic and social benefits, and strengthen enterprises. The competitiveness is the trend of the development and application of automation technology in the petrochemical industry in the future.
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