| Emergency Shutdown Device (ESD) is the key equipment in ensuring the safe operation of large-scale plant in petroleum chemical enterprises. According to the importance of reaction process of regeneration in FCCU safety process, a set of dual-redundancy emergency shutdown device based on S7-400 fault-tolerant controller was studied and designed in this paper, on the basis of understanding the characteristics of its technology and device. Three level control system including field level, control level and supervisory level was adopted in this system. The primary responsibilities are as follows:(1) Five system self-preservation projects including feeding self-preservation, two devices self-preservation, main air low flow self-preservation, main air unit self-preservation and booster self-preservation were designed according to the characteristics of technology and device in reaction regeneration process.(2) The hardware design, hardware configuration selection of PLC and hardware configuration was completed and the control point scale in the system was confirmed by technology and interlock logic. Dual-redundancy configuration was adopted in CPU, ET200M station and communication media in order to improve reliability of the system.(3) Redundancy of the central controller was realized by event-driven synchronous technology of Siemens. The I/O redundancy function was implemented by STEP7.(4) The communication network between control level and supervisory level was designed by Ethernet loop network to improve reliability of the system. The communication between host monitor software and lower PLC was realized by OPC technology. SIMATIC NET was adopted as the OPC server and the OPC link based on SIMATIC NET between S7-400H and WinCC was implemented by CP1613.(5) Monitoring interface of the ESD was designed by WinCC. Online monitoring of the system operation state, process data tendency and history data inquire and alarm record were realized in this paper. |
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