Design of Automation Instrument for Metallurgical Plant
Abstract
This paper elaborates the design of automation instrument for metallurgical plant. First, the overall project analysis is carried out from the perspective of safety, reliability and cost optimization. Secondly, the on-site measurement and control system composed of embedded PLC and HMI operation system, as well as other process automation instruments, are reasonably allocated according to the specific operational process of the metallurgical plant to meet the actual needs. At the same time, in order to ensure the safe and reliable operation of the metallurgical plant, various fault alarm and tripping protection functions are designed and configured. Finally, based on the complete test requirements of the metallurgical plant and the process parameters, the parameter and calibration methods of the instrument are summarized and discussed.
Keywords: Automation Instrument; Metallurgical Plant; Process Analysis; Fault alarm
Introduction
Metallurgical process is an important material process engineering project. During the whole process, the environmental protection problems need to be fully taken into account. The realization of automation instrument for metallurgical plant is to build an online measurement and control system for the metallurgical process, so as to realize the automation, reduction of manual labor cost, and improve the production quality, technical level, process control accuracy and production efficiency. Automation instrument, as an indispensable part in the modern control system, is essential for the control automation of the whole metallurgical process. The design of the instrument includes process system analysis, selection of instruments and components, as well as installation, commissioning, parameter setting and maintenance.
Overall Project Analysis
Generally, the automation instrument design of the metallurgical plant is divided into two major parts: system analysis and component selection. System analysis includes material selection, equipment selection, overall budget analysis, safety and reliability evaluation, etc. In addition, it is also necessary to investigate the space area and layout of relevant instruments, so as to achieve the goal of reasonable layout and convenient maintenance. The instrument selection part mainly includes comprehensive consideration of various performance indicators such as accuracy, repeatability, sensitivity, range and cost, so as to make correct selection according to the actual process demand.
Based on the actual situation of the metallurgical plant, this project is designed to achieve safety, reliability and cost optimization through overall project analysis. The material selection and equipment selection of the metallurgical plant are determined according to its actual situation. Its overall budget analysis is managed and analyzed through the unified control of total investment scale and cost structure. In order to ensure the safety and reliability of the system operation, pre-trip fault alarm functions and tripping protection measures are designed and configured in the system. The overall design is optimized through a variety of factors such as repeatability, accuracy, sensitivity and cost.
On-site Measurement and Control System
On-site measurement and control system is the core part of the whole system and the foundation of the automation instrument. It consists of embedded PLC and HMI (human-machine interface) operation system. The task of the PLC is mainly to complete the acquisition and collection of signal parameters and transmit the data to the PLC; while the HMI is mainly responsible for real-time system monitoring, process adjustment and trouble-shooting. Moreover, this system can also be integrated with other process automation instruments to further realize the accurate and stable operation of the whole production process.
Besides, according to the actual operation process of the metallurgical plant, the instrument selection and allocation should be reasonable. The instruments applicable to the on-site measurement and control system including pressure measurement, temperature measurement, flow measurement, level measurement, position measurement and analysis. In addition, the sensors installed in each equipment should be appropriately selected according to the specified range and accuracy.
Fault Alarm and Tripping Protection
In order to ensure the safe and reliable operation of the metallurgical plant, various fault alarm and tripping protection functions are designed in the process of the automation instrument design. The fault alarm should adopt the flexible combination of sensors and controllers, so as to achieve the automatic, real-time and accurate control of the metallurgical plant. In addition, reasonable tripping protection measures should be taken to reduce the frequency and risk of the tripping.
Other process automation instruments
In addition to the core part of the embedded PLC, HMI and on-site measurement and control system, other process automation instruments should also be equipped according to the specific operation requirements of the metallurgical plant. For example, process transmitters should be reasonably installed and configured in the process to realize the accurate sensing and control of material flow, liquid level and pressure parameters, so as to optimize the use of resources and materials in the production process. In the process, the transparency and reliability of data exchange should be taken into consideration in order to ensure the overall system control.
Parameter and Calibration of Instruments
On the basis of the complete test requirements of the metallurgical plant, the various parameters and calibration methods of the instruments need to be discussed and summarized. Firstly, according to the materials and production requirements of the metallurgical plant, reasonable selection should be made for each type of instrument to meet the requirements of accuracy and sensitivity. Secondly, strict inspection and testing should be carried out on site before installation, so as to ensure the normal operation of the instruments. Finally, after the completion of the installation, the measurement and calibration of parameters should be implemented, so as to ensure the accuracy of the instruments in the subsequent production process.
Conclusion
The design of automation instrument for metallurgical plant is an important means to realize the process optimization and resource utilization of the material process. This paper elaborates the design and implementation of the automation instrument from the perspective of safety, reliability, cost optimization and process analysis by introducing the overall project analysis, on-site measurement and control system, fault alarm and tripping protection, as well as parameter and calibration of instruments. The operation and maintenance of automation instrument can effectively improve the production efficiency and quality of the process.
