CN103256828A - Safe cooling tower system based on programmable logic controller (PLC) intelligent control - Google Patents
Safe cooling tower system based on programmable logic controller (PLC) intelligent control Download PDFInfo
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Abstract
本发明涉及一种基于PLC智能控制的安全冷却塔系统,它包括冷却塔主体、风机、水轮机、变频调速水泵、回水水温传感器、变频调速水泵转速传感器、布水系统管道压力传感器、水轮机进水压力传感器、风机转速传感器、集水箱液位传感器、出水水温传感器、采集传输信息数据电缆、PLC控制柜和光纤,其特征在于还包括由上位机组成的中央控制室、工业触摸屏和电磁离合器。本发明可使操作人员直观、轻松和真实地了解整个系统运行的状况,对各个运行环节中出现的故障或不正常情况能够及时做出预警和报警监测,并对异常信号实施人机实时控制,保障冷却塔系统的安全运行。本发明广泛适合于在电力、石油、化工、钢铁、轻纺和服务业等领域中推广应用。
The invention relates to a safety cooling tower system based on PLC intelligent control, which includes a cooling tower main body, a fan, a water turbine, a frequency conversion speed regulation water pump, a return water temperature sensor, a frequency conversion speed regulation water pump speed sensor, a water distribution system pipeline pressure sensor, and a water turbine Water inlet pressure sensor, fan speed sensor, water collection tank liquid level sensor, outlet water temperature sensor, data cable for collecting and transmitting information, PLC control cabinet and optical fiber, and is characterized in that it also includes a central control room composed of an upper computer, an industrial touch screen and an electromagnetic clutch . The present invention enables the operator to intuitively, easily and truly understand the operation status of the whole system, timely make early warning and alarm monitoring for faults or abnormal conditions in each operation link, and implement man-machine real-time control on abnormal signals, Ensure the safe operation of the cooling tower system. The invention is widely suitable for popularization and application in fields such as electric power, petroleum, chemical industry, iron and steel, light textile and service industries.
Description
技术领域 technical field
本发明属于冷却塔技术领域,特别是涉及一种基于PLC智能控制的安全冷却塔系统。 The invention belongs to the technical field of cooling towers, in particular to a safety cooling tower system based on PLC intelligent control.
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背景技术 Background technique
冷却塔系统在电力、石油、化工、钢铁、轻纺和服务业等领域的应用中发挥着重要作用,特别是冷却塔系统的安全可靠运行越来越重要。目前,工业生产中许多循环水冷却塔系统仍采用常规仪表控制,岗位操作人员根据检测仪表显示的工艺参数变化情况,凭经验对生产过程进行人工控制,不但工作强度大、工作效率低,而且安全可靠性差、造成安全事故多发。近10多年来,随着冷却塔系统智能控制技术的不断发展,较好的解决了冷却塔系统运行中工作强度大和工作效率高的难题,但冷却塔系统运行中安全可靠性差的难题尚未得到满意的解决。 Cooling tower systems play an important role in applications in the fields of electric power, petroleum, chemical industry, steel, textile and service industries, especially the safe and reliable operation of cooling tower systems is becoming more and more important. At present, many circulating water cooling tower systems in industrial production are still controlled by conventional instruments. Operators on the posts can manually control the production process based on experience according to the changes in process parameters displayed by the instrumentation. Poor reliability, resulting in frequent safety accidents. In the past 10 years, with the continuous development of cooling tower system intelligent control technology, the problem of high work intensity and high work efficiency in the operation of the cooling tower system has been better solved, but the problem of poor safety and reliability in the operation of the cooling tower system has not yet been satisfied solution.
中国专利申请97246148.5提出的一种“智能型冷却塔” ,该方案虽然能够较好的解决冷却塔的通风量随负荷大小而自动变化的难题,以实现节能和降噪的目的;但这仅是对冷却塔系统的局部控制,冷却塔系统运行中的整体安全可靠性尚未得到应有的监控,安全隐患仍然没有解决。 A kind of "intelligent cooling tower" proposed by Chinese patent application 97246148.5, although this solution can better solve the problem that the ventilation volume of the cooling tower changes automatically with the load, in order to achieve the purpose of energy saving and noise reduction; but it is only The local control of the cooling tower system, the overall safety and reliability of the cooling tower system in operation have not been properly monitored, and the safety hazards have not yet been resolved.
中国专利申请200910242250.5提出的一种冷却塔风机智能驱动装置,该方案是一种基于混合动力和智能控制的冷却塔风机智能驱动装置,由智能控制器控制风机电机投入运行或退出运行,解决节能和可靠性问题,但是该智能驱动装置中的棘轮机构是通过多齿轮相互啮合工作的,在其运行过程中必然会发生机械磨损,若其中某一齿轮无法正常工作,可能导致整个棘轮机构出现故障,因此存在很大的安全隐患,且无安全控制手段。 Chinese patent application 200910242250.5 proposes an intelligent driving device for cooling tower fans. This solution is an intelligent driving device for cooling tower fans based on hybrid power and intelligent control. Reliability issues, but the ratchet mechanism in the intelligent drive device works through multiple gears meshing with each other, and mechanical wear will inevitably occur during its operation. If one of the gears fails to work normally, it may cause the entire ratchet mechanism to fail. Therefore, there is a great potential safety hazard, and there is no safety control means.
张弘昱的学位论文报告发表的“基于PLC的循环水冷却塔控制系统的研究”一文,提出了采用西门子工控机作为上位机、PLC作为下位机,对循环水冷却塔整个工艺过程进行监控和管理,以数据采集、PID控制实现对主要生产指标和质量指标的控制,但不是对循环水冷却塔系统运行的安全监控,冷却塔系统运行中的整体安全可靠性问题仍然未能得到解决。 Zhang Hongyu's dissertation report "Research on the Control System of Circulating Water Cooling Tower Based on PLC" proposed to use Siemens industrial computer as the upper computer and PLC as the lower computer to monitor and manage the entire process of the circulating water cooling tower. Data acquisition and PID control are used to control the main production indicators and quality indicators, but it is not the safety monitoring of the operation of the circulating water cooling tower system, and the overall safety and reliability issues in the operation of the cooling tower system have not yet been resolved.
如何克服现有技术的不足已成为当今冷却塔技术领域中亟待解决的重点难题之一。 How to overcome the deficiencies in the prior art has become one of the key problems to be solved urgently in the technical field of cooling towers today.
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发明内容 Contents of the invention
本发明的目的是为克服现有技术的不足而提供一种基于PLC智能控制的安全冷却塔系统,本发明具有对冷却塔系统运行的预警、报警和实时监控的效能,保障冷却塔系统的安全运行。 The purpose of the present invention is to provide a safety cooling tower system based on PLC intelligent control in order to overcome the deficiencies of the prior art. The present invention has the effectiveness of early warning, alarm and real-time monitoring of the operation of the cooling tower system to ensure the safety of the cooling tower system run.
根据本发明提出的一种基于PLC智能控制的安全冷却塔系统,它包括冷却塔主体、风机、水轮机、变频调速水泵、回水水温传感器、变频调速水泵转速传感器、布水系统管道压力传感器、水轮机进水压力传感器、风机转速传感器、集水箱液位传感器、出水水温传感器、采集传输信息数据电缆、PLC控制柜和光纤,其特征在于还包括由上位机组成的中央控制室、工业触摸屏、电磁离合器,PLC控制柜通过采集传输信息数据电缆与设置在回水管道上的回水水温传感器、设置在变频调速水泵上的转速传感器、设置在水轮机出口的布水系统管道压力传感器、设置在水轮机进口的进水压力传感器、设置在水轮机与风机连接轴上的风机转速传感器、设置在集水箱上的集水箱液位传感器和设置在出水管道上的出水水温传感器连接;PLC控制柜采集的冷却塔系统运行的信息通过光纤传输到中央控制室,再通过中央控制室实施远程监控或通过现场的工业触摸屏实施现场手动控制;水轮机的输出轴通过电磁离合器与风机连接,电磁离合器根据中央控制室或现场的工业触摸屏发出的信号,对水轮机与风机实施连接或断开。 A safety cooling tower system based on PLC intelligent control proposed according to the present invention, which includes a cooling tower main body, a fan, a water turbine, a frequency conversion speed regulation water pump, a return water temperature sensor, a frequency conversion speed regulation water pump speed sensor, and a water distribution system pipeline pressure sensor , water turbine inlet pressure sensor, fan speed sensor, water collection tank liquid level sensor, water outlet water temperature sensor, data acquisition and transmission information cable, PLC control cabinet and optical fiber. The electromagnetic clutch, the PLC control cabinet collects and transmits information through the data cable and the return water temperature sensor set on the return water pipe, the speed sensor set on the frequency conversion speed regulating water pump, the water distribution system pipeline pressure sensor set at the outlet of the turbine, and set in the The water inlet pressure sensor at the inlet of the turbine, the fan speed sensor installed on the connecting shaft between the turbine and the fan, the liquid level sensor of the water collection tank installed on the water collection tank, and the outlet water temperature sensor installed on the outlet pipe are connected; the cooling collected by the PLC control cabinet The operation information of the tower system is transmitted to the central control room through optical fiber, and then remote monitoring is implemented through the central control room or on-site manual control is implemented through the on-site industrial touch screen; The signal sent by the industrial touch screen on site connects or disconnects the turbine and the fan.
本发明的安全运行原理:随着循环水冷却塔系统个体运行向群体协同运行的提升,对运行安全的要求越来越高,使得常规的工艺质量控制方式无法满足系统的安全控制要求。本发明基于PLC智能控制的安全冷却塔系统,通过预先设置其中不同参数之间的约束关系及各个参数安全运行的范围,实时监测出冷却塔系统中的各个设备是否处于安全运行状态,以及各个设备之间的协同配合是否异常。当冷却塔系统某处出现异常情况时,该安全冷却塔系统会自动对其进行故障分析,并对故障点进行排除,保证了冷却塔系统的安全运行的可靠性。同时本发明在保证单个冷却塔系统安全可靠运行的前提下,还可对冷却塔系统群实施安全最优控制,使得整个冷却塔系统群中单个系统所带负荷均匀化,以预防单个冷却塔系统因负荷过重而发生故障,由此提高冷却塔系统群安全运行年限,实现对冷却塔系统群的安全最优控制。 The principle of safe operation of the present invention: With the promotion of individual operation to group cooperative operation of the circulating water cooling tower system, the requirements for operation safety are getting higher and higher, so that the conventional process quality control method cannot meet the safety control requirements of the system. The safety cooling tower system based on PLC intelligent control in the present invention monitors in real time whether each equipment in the cooling tower system is in a safe operating state, and whether each equipment Whether the synergy among them is abnormal. When an abnormal situation occurs somewhere in the cooling tower system, the safety cooling tower system will automatically analyze the fault and eliminate the fault point to ensure the reliability of the safe operation of the cooling tower system. At the same time, under the premise of ensuring the safe and reliable operation of a single cooling tower system, the present invention can also implement safe and optimal control on the cooling tower system group, so that the load of a single system in the entire cooling tower system group can be uniformed to prevent the single cooling tower system from Faults occur due to overload, thereby increasing the safe operating life of the cooling tower system group, and realizing the optimal control of the cooling tower system group.
本发明与现有技术相比其显著优点在于:一是本发明的安全冷却塔系统受PLC智能控制,可以使工作人员直观、轻松和真实地了解整个系统的运行状况,对冷却塔系统各个运行环节中出现的故障或不正常运行情况能够及时做出预警和报警监测,并对异常信号实施人机实时控制;二是本发明不仅具有安全监控的显著效能,而且对提高冷却塔系统的工作效率、节约能耗也发挥了重要的作用;三是本发明的安全运行原理还可实现对冷却塔系统群的安全最优控制,以便解决单个安全冷却塔系统与整个冷却塔系统群的同步协同运行监控的难题。本发明广泛适合于在电力、石油、化工、钢铁、轻纺和服务业等领域中推广应用。 Compared with the prior art, the present invention has significant advantages as follows: First, the safety cooling tower system of the present invention is intelligently controlled by PLC, which can make the staff intuitively, easily and truly understand the operating conditions of the entire system, and control the operation of each cooling tower system. Faults or abnormal operating conditions in the link can be timely given early warning and alarm monitoring, and the abnormal signal can be controlled in real time by man-machine; secondly, the present invention not only has the remarkable effectiveness of safety monitoring, but also can improve the working efficiency of the cooling tower system. , saving energy consumption has also played an important role; the third is that the safe operation principle of the present invention can also realize the optimal control of the safety of the cooling tower system group, so as to solve the synchronous cooperative operation of the single safe cooling tower system and the entire cooling tower system group The monitoring problem. The invention is widely suitable for popularization and application in fields such as electric power, petroleum, chemical industry, iron and steel, light textile and service industries.
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附图说明 Description of drawings
图1是本发明提出的一种基于PLC智能控制的安全冷却塔系统的结构示意图。 Fig. 1 is a schematic structural view of a safety cooling tower system based on PLC intelligent control proposed by the present invention.
图2是本发明提出的一种基于PLC智能控制的安全冷却塔系统的控制原理示意图。 Fig. 2 is a schematic diagram of the control principle of a safety cooling tower system based on PLC intelligent control proposed by the present invention.
图3是本发明提出的一种基于PLC智能控制的安全冷却塔系统的控制流程示意图。 Fig. 3 is a control flow diagram of a safety cooling tower system based on PLC intelligent control proposed by the present invention.
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具体实施方式 Detailed ways
下面结合附图和具体实施方式对本发明作进一步的详细说明。 The present invention will be further described in detail below in conjunction with the accompanying drawings and specific embodiments.
结合图1,本发明提出的一种基于PLC智能控制的安全冷却塔系统,它包括冷却塔主体(1)、风机(2)、水轮机(3)、变频调速水泵(4)、回水水温传感器(5)、变频调速水泵(4)转速传感器(6)、布水系统管道压力传感器(7)、水轮机(3)进水压力传感器(8)、风机转速传感器(9)、集水箱液位传感器(10)、出水水温传感器(11)、采集传输信息数据电缆(12)、PLC控制柜(13)、光纤(14)、上位机组成的中央控制室(15)、工业触摸屏(16)和电磁离合器(17),其中:回水水温传感器(5)设置在回水管道上,转速传感器(6)设置在变频调速水泵(4)上,布水系统管道压力传感器(7)设置在冷却塔主体(1)的水轮机(3)出口,进水压力传感器(8)设置在冷却塔主体(1)的水轮机(3)进口,风机转速传感器(9)设置在水轮机(3)与风机(2)的连接轴上,集水箱液位传感器(10)设置在集水箱上,出水水温传感器(11)设置在出水管道上,PLC控制柜(13)通过采集传输信息的数据电缆(12)对风机(2)的转速、布水系统的压力、水轮机(3)进水压力、变频调速水泵(4)的转速、回水管道上的回水温度、集水箱液位和出水管道上的出水温度实施实时信息采集与监控,水轮机(3)的输出轴通过电磁离合器(17)与风机(2)连接,电磁离合器(17)根据中央控制室(15)发出的信号,对水轮机(3)与风机(2)实施连接或断开。 Combined with Fig. 1, the present invention proposes a safety cooling tower system based on PLC intelligent control, which includes a cooling tower main body (1), a fan (2), a water turbine (3), a variable frequency speed regulating water pump (4), return water temperature Sensor (5), variable frequency speed regulating water pump (4) speed sensor (6), water distribution system pipeline pressure sensor (7), water turbine (3) water inlet pressure sensor (8), fan speed sensor (9), water collection tank Position sensor (10), outlet water temperature sensor (11), data cable for collecting and transmitting information (12), PLC control cabinet (13), optical fiber (14), central control room composed of upper computer (15), industrial touch screen (16) and electromagnetic clutch (17), wherein: the return water temperature sensor (5) is set on the return water pipe, the speed sensor (6) is set on the frequency conversion speed regulation water pump (4), and the water distribution system pipeline pressure sensor (7) is set on The water turbine (3) outlet of the cooling tower main body (1), the water inlet pressure sensor (8) is set at the water turbine (3) inlet of the cooling tower main body (1), and the fan speed sensor (9) is set at the water turbine (3) and the fan ( 2) On the connecting shaft, the water collecting tank liquid level sensor (10) is set on the water collecting tank, the water outlet water temperature sensor (11) is set on the water outlet pipe, and the PLC control cabinet (13) is connected to the data cable (12) for collecting and transmitting information The speed of the fan (2), the pressure of the water distribution system, the water inlet pressure of the water turbine (3), the speed of the variable frequency speed control pump (4), the return water temperature on the return water pipe, the liquid level of the water collection tank and the outlet water on the outlet pipe The temperature is collected and monitored in real time. The output shaft of the water turbine (3) is connected to the fan (2) through an electromagnetic clutch (17). The electromagnetic clutch (17) controls the water turbine (3) and The fan (2) is connected or disconnected.
结合图2,本发明的各传感器通过采集传输信息数据电缆(12),将采集到的冷却塔系统运行中现场风机(2)的实时转速、布水系统的压力、水轮机(3)进水压力、变频调速水泵(4)转速、回水管道上的回水温度、集水箱液位和出水管道上的出水温度信号输入到PLC控制柜(13)中,由光纤(14)传输到中央控制室(15)并经对应的程序运算后输出信号,对风机(2)、水轮机(3)、变频调速水泵(4)和电磁离合器(17)进行自动控制,或者通过现场的工业触摸屏(16)对风机(2)、水轮机(3)、变频调速水泵(4)和电磁离合器(17)进行现场手动控制,以此实现对冷却塔系统的安全可靠控制。 In conjunction with Fig. 2, each sensor of the present invention collects and transmits the information data cable (12), and collects the real-time rotational speed of the on-site fan (2), the pressure of the water distribution system, and the water inlet pressure of the water turbine (3) during the operation of the cooling tower system. , The speed of the frequency conversion speed regulating water pump (4), the return water temperature on the return water pipe, the liquid level of the water collection tank and the outlet water temperature signal on the outlet pipe are input into the PLC control cabinet (13), and are transmitted to the central control by the optical fiber (14). room (15) and output signals after corresponding program calculations, to automatically control the fan (2), water turbine (3), frequency conversion speed regulation water pump (4) and electromagnetic clutch (17), or through the on-site industrial touch screen (16 ) On-site manual control of the fan (2), water turbine (3), variable frequency speed regulating water pump (4) and electromagnetic clutch (17), so as to realize safe and reliable control of the cooling tower system.
结合图1和图3,以PLC控制柜(13)控制的出水温度设定值为T-SP,出水温度的实际温度为T-PV,出水温度上限值为T-SP上限,出水温度下限值为T-SP下限。当T-PV<T-SP下限时,关闭风机(2);当T-PV>T-SP上限时,则需要停止冷却塔系统的运行,并对其进行停机检查;当T-SP下限<T-PV<T-SP上限时,若T-PV<T-SP,则需要提高变频调速水泵(4)转速或增加变频调速水泵(4)运行的数量,即增大了水轮机(3)进水压力;若T-PV>T-SP时,则需要降低变频调速水泵(4)的转速或减少变频调速水泵(4)运行的数量,即降低了水轮机(3)进水压力。同理,对该冷却塔系统中布水系统的压力、水轮机(3)进水水压、回水管道上的回水温度、集水箱液位、出水管道上的出水温度进行监测,分别设定上、下限值,当数据出现异常时系统会及时发生报警,警铃同时响起。本发明的PLC控制柜(13)通过采集传输信息的数据电缆(12)将风机(2)的转速、布水系统的压力、水轮机(3)进水压力、变频调速水泵(4)的转速、回水管道上的回水温度、集水箱液位和出水管道上的出水温度实施实时采集,采集后的信号经过数据处理后运用STEP7-Micro/WIN进行程序编写,应用组态王设置相应的人机界面,中央控制室(15)通过光纤(14)对PLC控制柜(13)内的信息进行采集并通过上位机的工业触摸屏(16)显示,PLC控制柜(13)的输出端又与现场设备相连,从而实现对该冷却塔系统的智能控制。 Combining Figure 1 and Figure 3, the set value of the outlet water temperature controlled by the PLC control cabinet (13) is T-SP, the actual temperature of the outlet water temperature is T-PV, the upper limit of the outlet water temperature is the upper limit of T-SP, and the outlet water temperature The limit is the T-SP lower limit . When T-PV<T-SP lower limit , turn off the fan (2); when T-PV>T-SP upper limit , you need to stop the operation of the cooling tower system, and stop it for inspection; when T-SP lower limit < When T-PV<T-SP upper limit , if T-PV<T-SP, it is necessary to increase the speed of the variable frequency speed regulation water pump (4) or increase the number of frequency conversion speed regulation water pumps (4), that is, increase the water turbine (3 ) water inlet pressure; if T-PV>T-SP, it is necessary to reduce the speed of the variable frequency speed regulation water pump (4) or reduce the number of operation of the frequency conversion speed regulation water pump (4), that is, reduce the water inlet pressure of the water turbine (3) . In the same way, the pressure of the water distribution system in the cooling tower system, the water inlet pressure of the water turbine (3), the return water temperature on the return water pipe, the liquid level of the water collection tank, and the outlet water temperature on the outlet pipe are monitored, and respectively set When the data is abnormal, the system will generate an alarm in time, and the alarm bell will sound at the same time. The PLC control cabinet (13) of the present invention controls the rotational speed of the fan (2), the pressure of the water distribution system, the water inlet pressure of the water turbine (3), and the rotational speed of the variable frequency speed regulating water pump (4) through the data cable (12) for collecting and transmitting information. , the return water temperature on the return water pipe, the liquid level of the water collection tank, and the outlet water temperature on the outlet pipe are collected in real time. After the collected signal is processed, the program is written using STEP7-Micro/WIN, and the corresponding settings are set by KingView Man-machine interface, the central control room (15) collects the information in the PLC control cabinet (13) through the optical fiber (14) and displays it through the industrial touch screen (16) of the host computer, and the output terminal of the PLC control cabinet (13) is connected with the Field devices are connected to realize intelligent control of the cooling tower system.
本发明经反复试验验证,取得了满意的应用效果。 The invention has been verified through repeated tests and has achieved satisfactory application effects.
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