Design And Implementation Of High-Speed PUMP Monitoring System

High-speed pumps have been widely used in dehydroacetic acid industry with their advantages of low flow, high head. High-speed pumps serving different functions are the key operating equipment in dehydroacetic acid production system. The system may face a crisis of long time reject if the high-speed pump status errors and equipment failure occur, which may cause significant financial losses for production enterprise. The design of an automatic monitoring and control system for high-speed pump is one of the important contents for improving economic effectiveness, because of its special working conditions. With the rapid development of 4C technologies in automatic control system, PLC control technology, HMI technology and remote monitoring technology have become more and more mature, it is imperative to implement automatic control and condition monitoring for high-speed pump system.In this dissertation, we mainly focus on the research of Sundyne high-speed pump, and reform the original high-speed pump control system after analyzing its structure and working principle. We combine sensor technology, PLC control technology, touch screen technology and remote monitoring and control technology, and develop an interactive monitoring and control system for Sundyne vertical high-speed pumps LMV-311.This System realizes the functions of real-time condition supervise and control, data acquisition and recording, abnormal running status warning, emergency fault state alarm, standby device automatic switching, etc.According to the real-time monitoring metrics of high-speed pump in real production process, software and hardware design of high-speed pump monitoring system is described in this thesis. The primary contents and contributions of this thesis are as follows:1. A novel real-time state monitoring and automatic control system of high-speed pump is developed to replace the original manual control system, and the whole design schema of project is also presented. We choose the proper sensor to collect parameter of high-speed pump running state, draw the main electrical circuit and control circuit diagram of the system.2. The designs of PLC hardware system and software program.we confirm the number of system digital and analog Input/Output points according to the control requirements. SIMATIC S7-1200 series CPU 1214 AC/DC/RELAY is selected as the main controller, and the analog input module SM 1234 is selected to collect and process the output signal of transmitters detecting device running state variables. We use analog output module SM 1232 to control the position of valve regulators. We use the latest version PLC programming software STEP7 V12 in SIMATIC Totally Integrated Automation Portal software platform to write the PLC Ladder diagram,which achieving the system control requirements.3. The designs of interactive human machine interface hardware and software. SIMATIC basic HMI device KTP600 Basic PN is used to monitor and control the high-speed pump in the industrial site.We use TIA Portal V12 to design humanized HMI monitoring screens, which is convenient for operators to control high-speed pump device and alarming fault handling.4. The design of configuration monitoring system in the remote PC station.There is an IPC equipped configuration monitoring software SIMATIC WinCC Advanced V12 in central control room. We develop the high-speed pump configuration monitoring system by using SIMATIC WinCC Advanced V12 to achieve the goal of real-time condition supervise and control, data acquisition and recording, abnormal running status warning, emergency fault state alarming, standby device automatic switching, etc. These functions can not only help cental control room timely acquire the accurate information of high-speed pump running state, but also provide reliable historical operation data for later device maintence.