[Summary]
The metallurgical industry, especially the steel industry, is an important basic industry of the national economy. It is a pillar industry that realizes industrialization and is a technology, capital, resource, and energy-intensive industry. Not only does it require advanced equipment and process flow, efficient, safe and reliable automation and interface technology are essential.
In engineering design, the choice of electrical control and interface components is critical, which directly affects whether the project can be successfully put into production and operation and maintenance in the future, affecting the construction investment and operating costs. This paper introduces the selection of electrical control and interface components in Maanshan Iron and Steel New District, and highlights the application and results of the PHOENIX CONTACT product in this project.
As a world-renowned supplier in the field of automation, PHOENIXCONTACT provides customers with tens of thousands of products that are space-saving, easy to install and highly reliable. Whether it is in the system devices, or in the system solutions, Phoenix Contact's products have outstanding performance.
[Key words]
Ma Gang New District, PHOENIX CONTACT, Material Plant, Pellet, Sintering, Blast Furnace, Hot Rolling, etc., Basic Automation System
[use background]
In 2002, a 2500 cubic meter blast furnace was built at the second ironmaking plant of the old plant of Masteel, which was designed by MCC Huatian Engineering Technology Co., Ltd. In this project, Masteel firstly used PHOENIXCONTACT's terminal blocks, PLC series relays, 24VDC DC switching power supplies, analog signal transmitters, and safety barriers for the first time. After several years of use, customers were very satisfied with the product performance. The quality is stable, which greatly reduces the loss caused by the device downtime on the spot, thus improving the production efficiency and saving the maintenance cost for the customer. Therefore, in the Maanshan New District project, customers are very confident about PHOENIX CONTACT.
1. Project Overview]
Magang New Area is one of the key projects in national planning and construction. The construction scale is 5 million tons, and the total investment is over 23 billion yuan. It has opened the prelude to the construction of super-large projects in the steel industry. The project was formally approved by the State Council at the end of November 2004. It was designed the same year and completed and put into production in 2007. It took four years before and after.
In the project of Maanshan Iron and Steel, apart from the basic automation control system of the blast furnace adopting the latest generation distributed control computer system (DCS) of the Westinghouse Company, the other process sections and the auxiliary control systems are respectively controlled by PLCs of AB and SIEMENS. The auxiliary control systems are networked via Ethernet, and the master-auxiliary control system is networked through the upper computer to realize the data sharing of the whole plant.
In Maanshan New District Project, AC, DC input/output relays, control relays, time relays, DC power supplies, analog signal transmitters, and safety on the material processing plants, pellets, coking, sintering, blast furnaces, and rolling mills. PHOENIX CONTACT products are used for gates, terminals, and terminal fuses. During the construction, commissioning, commissioning and operation of the project, the above-mentioned electrical control components never had any problems that affected the progress of the project or production, and its quality and reliability were well received in all aspects. (Figure 1, a corner of Maanshan New District)
figure 1
2. PHOENIXCONTACT Series Selection
2.1 Selection of main control and auxiliary system input/output relays and control relays
The reliability of the input/output signal is the basic condition for the normal operation of the control system. There is no reliable system input/output signal, and even the best control system cannot work normally. Due to the large number of subsystems in each process segment, and the decentralized and poor field conditions, in which the on-site signal is disturbed, the relay cannot work properly. This is one of the most difficult problems. Therefore, in order to ensure the normal operation of the device, the input/output signal relays are selected. It is the key. In order to solve the above problems, after comparison, Masteel chose PHOENIX CONTACT PLC-RSC-230UC/21/SO46, PLC-RSC-230UC/21-21/SO46 anti-jamming relay and PLC-RSC-24DC/21, PLC- RSC-24DC/21 DC relay. There are two main reasons to choose PLC-RSC-230UC/21/SO46, PLC-RSC-230UC/21-21/SO46 anti-jamming relay: First, the relay drive current is large (usually about 8mA) and has a signal Filtering function, RC circuit and elevation relay action level are used to suppress the interference signal, which is especially suitable for detecting the components farther in the field, and the normal relay is difficult to work due to the leakage current of the field proximity switch or PLC module. The various complex industrial control sites; the second is that the relay is a terminal type relay, small size, can effectively save installation space and easy to install and wiring. In the project of Masteel New Area, a total of more than 30,000 PLC relays from PHOENIX CONTACT are used, providing an effective guarantee for reliable on-site input/output switching. (Figure 2-1, PLC Series Relays)
Figure 2-1
Figure 2-2
2.2 Selection of Analog Signal Transmitter and Safety Barrier
In the past, the customer deeply felt that the interface device's protective effect on the control system is very important. It can greatly reduce the failure rate of the system, improve the operating efficiency of the equipment and save the maintenance cost of the system. Therefore, in the project of Maanshan New District, The customer requires that all analog signals be isolated or converted before entering the control system. In the Maanshan New District project, customers have adopted PHOENIXCONTACT's MCR series of analog signal transmitters, including distributors, isolators, temperature measurement transmitters, and frequency transmitters, totaling more than 5,000.
In addition, PHOENIX CONTACT PI-Ex series safety barriers are used in explosive areas such as pulverized coal injection and gas cleaning. These series of safety barriers have pluggable structures and switch functions on the base, which brings about installation, commissioning and maintenance. Great convenience. (Figure 2-2, Analog Signal Transmitter)
2.3 Selection of 24VDC DC Switching Power Supply
There are many field devices, on-site detection components, and control system interfaces that require DC power for power supply. Different devices have different requirements on the capacity and reliability of the power supply. Therefore, it is particularly important to choose a DC power supply device with excellent performance and various forms. . PHOENIXCONTACT QUINT POWER series DC power supply has three alarm functions: LED display, dry contact output, and 24V active output, due to its complete range, high reliability, and stable output in the on-site power grid fluctuations. In the design selection, after repeated comparisons of various brands of power sources in terms of performance, volume and price, the PHOENIX CONTACT QUINT POWER series power supply was finally selected.
Because the power supply has complete specifications, many types and small size, it can be arbitrarily selected according to needs and can be assembled and installed with ease. These advantages bring great convenience to the design work of the design institute.
The Maanshan New District project uses more than 500 PHOENIX CONTACT QUINT POWER series switching power supplies (2.5A, 5A, 10A, 20A), which are installed in the control cabinets of various electrical and control rooms, hydraulic stations, and on-site control boxes. (Figure 2-3, QUINT POWER Switching Power Supply)
Figure 2-3
2-4
2.4 Selection of Fuse Terminals
In the design, a circuit breaker or fuse is usually added to the input of the secondary circuit power supply of the equipment control unit. However, whether the circuit breaker or the fuse is added requires a certain amount of installation space. In order to save the installation space for electrical components, the design institute uses PHOENIXCONTACT UK5-HESI fuse terminals instead of the original circuit breakers or fuses. UK5-HESI terminal fuse has high breaking capacity and LED display indicating fuse status. This terminal fuse is small in size and can be installed together with common terminals or PLC series relays. It has the characteristics of convenient use and maintenance. In Maanshan New District project, customers used about 20,000 pieces of UK5-HESI terminal fuses, effectively saving installation space and reducing engineering investment.
2.5 Selection of Terminals
Many customers often encounter such failures during the on-site commissioning process. They may appear as a signal sometimes or without a low input level. Because such failures are sometimes absent, it is often difficult to eliminate them immediately. Under normal circumstances, such Faults are caused by poor terminal connections. In order to avoid similar problems in Magang New District project, special attention was paid to the choice of terminal brands. After several comparisons of electrical characteristics, connection methods, materials selection, volume, and price for domestic and foreign brands of terminals, Masteel finally selected PHOENIX CONTACT UK series terminals. (Figure 2-4, UK Series Terminal Blocks)
2.6 Selection of Lightning Protection Products
With the rapid development of modern science and technology, modern electrical and electronic equipment such as control systems, switches, and on-site smart meters are becoming more and more integrated and their operating speeds are getting faster and faster. Increasingly weak, the iron and steel industry is a large application of these electrical equipment. In the past, some devices were often damaged due to the impact of lightning, electronic pulse switching, etc., resulting in great losses. Therefore, the lightning protection technology has received more and more attention from the steel industry.
In the Maanshan New District project, PHOENIXCONTACT's power supply lightning protection overvoltage protection products make customers' equipment power supply worry-free. (Figure 2-5, secondary lightning protection products; Figure 2-6, primary lightning protection products)
Figure 2-5
Figure 2-6
3. PHOENIXCONTACT Products Used in Maanshan New District Project
At the end of 2006, the sintering process, material mill, first blast furnace and other process sections in Maanshan New District project were put into operation smoothly. The second blast furnace was put into production in March 2007. All other process sections in the new area project were completed and put into production before September 2007. . During the entire project commissioning and commissioning process, PHEONIXCONTACT's products have been fully recognized by customers for its excellent quality, stable and reliable performance, and made important contributions to the smooth operation of the Maanshan New District project.