Online additional arrangement method for DO output power supply redundancy module of DCS (Distributed Control System)

Abstract

The invention discloses a DCS system DO output power supply redundancy module on-line adding method, through on-line adding of a redundancy module of a controlled device solenoid valve working power supply in a DCS control system, it is guaranteed that one power supply is used and the other power supply is standby for a solenoid valve to use, when one power supply fails, loses power and is overhauled, the solenoid valve can still work normally, and the reliability of the system is improved. Off-net faults of oxygen, nitrogen and argon of products caused by tripping of the oxygen generator are prevented. And meanwhile, the problem of energy consumption caused by stopping and starting of the oxygen generator due to a conventional replacement method is solved, so that the continuous and uninterrupted safe operation of public equipment such as a cooling water system, a liquid storage tank and an evaporator and a gas pipe network supply backup system is ensured.

Description

Technical Field

[0001] The invention relates to a DCS control technology, in particular to an online adding method for a power supply redundancy module of a DCS system DO output. Background Art

[0002] Power redundancy is an important redundancy method, including DCS system redundancy (including controllers, I / O cards, communication equipment, operation stations, etc.), relay power redundancy, field load equipment power supply redundancy, etc., which is used to ensure that the DCS system and the load equipment it controls can still work normally when one power supply fails or loses power or is under maintenance.

[0003] At present, the power supply configuration of the DO (digital output) control cabinet of the DCS system of the No. 1 oxygen generator of the gas branch of the Ministry of Energy and Environmental Protection of a large steel enterprise is as follows: Figure 1 As shown in the figure, the DC 24V relay panel in the DO (digital output) control cabinet of the DCS system of the 1# oxygen generator adopts a redundant structure for power supply, while the solenoid valves of many pneumatic control valves only adopt a single UPS power supply mode. These solenoid valves include 33 solenoid valves supporting the pneumatic control valves of the 1# oxygen generator, and 8 solenoid valves of public equipment or gas pipeline network supply backup system equipment such as cooling water system, liquid storage tank, evaporator, etc. built synchronously with the 1# oxygen generator. Even when the 1# oxygen generator is shut down, these equipment still needs to operate normally. This results in the possibility of the solenoid valve losing power and the valve losing control after the pneumatic control valve gas line is cut off when the UPS that provides power to the above solenoid valve coil fails or is repaired, and during the switching test, it will not only cause the 1# oxygen generator to trip and the air separation product to be disconnected from the network, but also cause the cooling water system, liquid storage tank, evaporator, etc. Public equipment and gas pipeline network supply backup equipment to lose control and other safety hazards.

[0004] Generally, dual-circuit power supply is used in the control of important continuous production equipment, but two AC power supplies cannot be simply connected in parallel for redundant power supply, because there is a phase difference due to different AC sources, and direct parallel connection will cause a short circuit accident. Therefore, it is necessary to add a power redundancy switching module, which is used to select one input power supply to output to the lower load when two AC power supplies are input, and the other input power supply is always in standby state. When one input power supply in use loses power, the other input power supply can be quickly switched online to ensure that the output will not be interrupted.

[0005] The solenoid valve of the 1# oxygen generator is powered by AC 220V. Under current technical conditions, a power redundancy module must be added. During the operation, the solenoid valve coil as a load must be powered off first, and then restored after the operation is completed. This process needs to be carried out when the 1# oxygen generator is shut down, and public equipment such as the cooling water system, liquid storage tank, evaporator, or gas pipeline network supply backup system need to be shut down. Not only does it generate additional power consumption when the 1# oxygen generator is shut down and started, but it is also difficult to create conditions for shutting down public equipment and backup systems, because this will affect the output of other units and thus affect the safe operation of the entire gas supply network. Summary of the invention

[0006] In order to solve the above problems in the prior art, the present invention provides a method for online adding a power redundancy module of the DO output of a DCS system, which can add a power redundancy module while ensuring that the power supply of the solenoid valve coil is not lost, so that the solenoid valve power supply realizes a redundant structure and ensures stable power supply.

[0007] A method for online adding a power redundancy module for DO output of a DCS system comprises the following steps:

[0008] S1. Using the UPS power distribution terminal of the control cabinet power supply output by the DCS system DO, the main power supply is provided for the online additional AC power redundancy module, which is used to temporarily provide the same-phase backup power supply for the DC power module and the solenoid valve load;

[0009] S2. Use the mains power of the control cabinet power supply output by the DCS system DO as the auxiliary power supply for the AC power redundancy module, and complete the online work of switching the main power supply to the auxiliary power supply to ensure that there is no interference with the original power load;

[0010] S3. Under the premise of ensuring that the load does not lose power, remove the temporary main power supply circuit of the AC power redundancy module;

[0011] S4. Transform the UPS power distribution circuit of the control cabinet power supply of the DCS system DO output to provide the formal main power supply for the AC power redundancy module to achieve dual-channel redundant power supply.

[0012] The control cabinet power supply output by the DCS system DO includes a UPS power supply circuit breaker K1, a terminal block XT1, a mains power supply circuit breaker K2, and a terminal block XT2. Terminals 1-5 of the terminal block XT1 are short-circuited to serve as the live wire row L of the UPS power supply, and terminals 6-10 are short-circuited to serve as the neutral wire row N of the UPS power supply; terminals 1-5 of the terminal block XT2 are short-circuited to serve as the live wire row L of the mains power supply, and terminals 6-10 are short-circuited to serve as the neutral wire row N of the mains power supply;

[0013] The step S1 specifically includes the following steps:

[0014] S11. Connect the L1 and N1 terminals of the input port of the A channel of the AC power redundancy module to be added to the No. 4 and No. 9 terminals of the terminal block XT1, respectively, to provide a temporary power supply for the A channel of the AC power redundancy module, and then connect the output terminals L and N of the AC power redundancy module to the No. 5 and No. 10 terminals of the terminal block XT1, respectively;

[0015] S12. Close the incoming line switch A on the AC power redundancy module.

[0016] The step S2 specifically includes the following steps:

[0017] S21. Disconnect the mains power supply circuit breaker K2, so that the AC 220V power supply of the solenoid valve and the DC 24V power supply of the relay panel are both provided by the UPS power supply. Connect the No. 2 and No. 7 terminals of the terminal block XT2 to the L2 and N2 terminals of the B input port of the AC power redundancy module respectively;

[0018] S22. Close the incoming switch B on the AC power redundancy module;

[0019] S23. Disconnect the UPS power supply circuit breaker K1 to switch the output of the AC power redundancy module to the B input.

[0020] The step S3 specifically comprises the following steps:

[0021] S31. Disconnect the wiring switch A on the AC power redundancy module, and remove the line between the L1 and N1 terminals of the AC power redundancy module and the No. 4 and No. 9 terminals of the terminal block XT1.

[0022] The step S4 specifically comprises the following steps:

[0023] S41. Add a new terminal block XT0, terminals 1-5 of terminal block XT0 are short-circuited to serve as the live wire row L of the UPS power supply, and terminals 6-10 of terminal block XT0 are short-circuited to serve as the neutral wire row N of the UPS power supply;

[0024] S42. Remove the wiring between circuit breaker K1 and terminals 1 and 6 of terminal block XT1, and connect them to terminals 1 and 6 of terminal block XT0, making terminal block XT0 the distribution bar of the UPS power supply;

[0025] S43. Connect the L1 and N1 terminals of the A input port of the AC power redundancy module to the No. 1 and No. 6 terminals of the terminal block XT0 respectively, to provide a formal power supply line for the A input port of the AC power redundancy module;

[0026] S44. Remove the wiring on terminals 2 and 7 of terminal block XT1, and connect them to terminals 2 and 7 of terminal block XT0;

[0027] S45. Close the UPS power supply circuit breaker K1, and then close the incoming line switch A on the AC power redundancy module.

[0028] In step S1, an offline power failure simulation test is first performed on the AC power redundancy module to be added to ensure that the power output will not be interrupted when one input power fails and the other input power is normally supplied.

[0029] The offline power failure simulation test is specifically as follows: connect an AC 220V power supply to the A and B input terminals of the AC power redundancy module respectively; use the AC voltage range of the multimeter to measure the output voltage of the power redundancy module; then disconnect any one of the input power supplies and observe whether the output AC voltage of the power redundancy module is always maintained at 220V to confirm that the AC power redundancy module is working properly.

[0030] The method for online adding power redundancy modules of the DCS system DO output of the present invention is adopted. By online adding a redundant module of the working power supply of the electromagnetic valve of the controlled equipment in the DCS control system, two power supplies are guaranteed to be used for the electromagnetic valve, one for use and one for backup. When one power supply fails, loses power or is under maintenance, the electromagnetic valve can still work normally, preventing the oxygen generator from tripping and causing the product oxygen, nitrogen and argon to be disconnected from the network. At the same time, it also solves the energy consumption caused by the shutdown and startup of the oxygen generator caused by the conventional replacement method, thereby ensuring the continuous and uninterrupted safe operation of the cooling water system, liquid storage tank, evaporator and other public equipment and the gas pipeline network supply backup system. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 It is the single-line diagram of the power supply of the existing DCS system DO output control cabinet;

[0032] Figure 2 This is the power wiring diagram of the existing DCS system DO output control cabinet;

[0033] Figure 3 It is a wiring diagram for temporarily supplying power to the A-way of the AC power redundancy module of the present invention;

[0034] Figure 4 This is a diagram of connecting the mains to the AC power supply redundant module B circuit of the present invention;

[0035] Figure 5 It is a formal power supply diagram for the A circuit of the AC power redundancy module of the present invention;

[0036] Figure 6 This is a wiring diagram after the online addition of a power redundancy module of the present invention. DETAILED DESCRIPTION

[0037] The following further describes a method for online adding power supply redundancy modules of a DCS system DO output of the present invention, which method comprises the following steps:

[0038] As Figure 2 Take the original DCS system DO output control cabinet power wiring diagram as an example. Figure 2 In the figure, K1 is the UPS power supply circuit breaker, terminals 1-5 of terminal block XT1 are short-circuited to serve as the live wire row L of the UPS power supply, terminals 6-10 of terminal block XT1 are short-circuited to serve as the neutral wire row N of the UPS power supply; K2 is the AC power supply circuit breaker, terminals 1-5 of terminal block XT2 are short-circuited to serve as the live wire row L of the AC power supply, terminals 6-10 of terminal block XT2 are short-circuited to serve as the neutral wire row N of the AC power supply.

[0039] First, conduct an offline power failure simulation test on the AC 220V power redundancy module to be added to ensure that the power output will not be interrupted if one input power fails and the other input power is normally supplied. Specifically: connect one AC 220V power supply to the A and B input terminals of the AC power redundancy module respectively, use the AC voltage range of the multimeter to measure the voltage at the output terminal of the power redundancy module, and then disconnect any input power supply to observe whether the output AC voltage of the power redundancy module is always maintained at 220V, so as to confirm that the AC power redundancy module is working normally and ensure that the power load will not lose power during the subsequent operation of adding power redundancy modules.

[0040] like Figure 3 As shown, the L1 and N1 terminals of the input port of the A route of the AC power redundancy module are connected to the No. 4 terminal and the No. 9 terminal of the terminal block XT1 respectively, so as to provide a temporary power supply for the A route of the AC power redundancy module, and then the output terminals L and N of the AC power redundancy module are connected to the No. 5 terminal and the No. 10 terminal of the terminal block XT1 respectively.

[0041] Close the incoming switch A on the AC power redundancy module. At this time, because the input of the AC power redundancy module is the UPS power supply, its output AC power is in the same phase as the UPS power supply, and will not cause faults such as short circuits.

[0042] Disconnect the mains power supply circuit breaker K2. At this time, the AC 220V power supply of the solenoid valve and the DC 24V power supply of the relay panel are both provided by the UPS power supply. Then connect the No. 2 and No. 7 terminals of the terminal block XT2 to the L2 and N2 terminals of the B input port of the AC power redundancy module respectively. Figure 4 shown.

[0043] Close the incoming switch B on the AC power redundancy module. At this time, because the power supply of channel A has been input in advance, the output of the AC power redundancy module is still provided by the input of channel A, and channel B is in standby state.

[0044] Disconnect UPS power supply circuit breaker K1. At this time, the output of the AC power redundancy module is immediately switched to the B input, completing the B power supply online work.

[0045] Turn off the wiring switch A on the AC power redundancy module and remove the temporary power supply line of AC power redundancy module A, that is, the line between the L1 and N1 terminals of the AC power redundancy module and the No. 4 and No. 9 terminals of the terminal block XT1.

[0046] Add a new terminal block XT0. Terminals 1-5 of terminal block XT0 are short-circuited to serve as the live wire row L of the UPS power supply. Terminals 6-10 of terminal block XT0 are short-circuited to serve as the neutral wire row N of the UPS power supply.

[0047] Remove the wiring between circuit breaker K1 and terminals 1 and 6 of terminal block XT1, and connect them to terminals 1 and 6 of the newly added terminal block XT0, making terminal block XT0 the distribution bar of the UPS power supply.

[0048] Connect the L1 and N1 terminals of the A input port of the AC power redundancy module to the No. 1 and No. 6 terminals of the terminal block XT0 respectively to provide a formal power supply line for the A input port of the AC power redundancy module.

[0049] Remove the AC 220V power supply line of power module A, that is, the wiring on terminals 2 and 7 of terminal block XT1, and connect them to terminals 2 and 7 of terminal block XT0. Figure 5 shown.

[0050] Close the UPS power supply circuit breaker K1, and then close the incoming switch A on the AC power redundancy module. At this time, the AC 220V input of the AC power redundancy module A and the DC 24V output of the power module A are both in standby mode. Figure 6 As shown, the entire work of adding an AC power redundancy module online is completed.

[0051] In summary, the online addition of the DCS power redundancy module of the present invention enhances the stability of the DCS control system and the controlled equipment, and realizes the normal operation of the DCS system during the separate maintenance or testing of the UPS power supply system and the mains system, which makes it possible to shut down the UPS system for periodic maintenance and switching tests. At the same time, it also avoids the systemic risks caused by the shutdown of production equipment and the need to shut down public equipment such as the cooling water system of the oxygen generator, liquid storage tanks, evaporators, and gas pipeline network backup equipment due to conventional methods. This method has a wide range of applications and is suitable for automated detection and control industries such as metallurgy, petrochemicals, gas production, and industrial manufacturing, and has broad promotion value.

[0052] However, those skilled in the art should recognize that the above embodiments are only used to illustrate the present invention, and are not intended to limit the present invention. As long as they are within the spirit of the present invention, any changes or modifications to the above embodiments will fall within the scope of the claims of the present invention.

Claims

1. A method for online adding power redundancy modules for DO output of a DCS system, characterized in that: The following steps are involved: S1. Using the UPS power distribution terminal of the control cabinet power supply output by the DCS system DO, the main power supply is provided for the online additional AC power redundancy module, which is used to temporarily provide the same-phase backup power supply for the DC power module and the solenoid valve load; S2. Use the mains power of the control cabinet power supply output by the DCS system DO as the auxiliary power supply for the AC power redundancy module, and complete the online work of switching the main power supply to the auxiliary power supply to ensure that there is no interference with the original power load; S3. Under the premise of ensuring that the load does not lose power, remove the temporary main power supply circuit of the AC power redundancy module; S4. Transform the UPS power distribution circuit of the control cabinet power supply of the DCS system DO output to provide the formal main power supply for the AC power redundancy module to achieve dual-channel redundant power supply.

2. The method for online adding power supply redundancy modules of DO output of a DCS system as claimed in claim 1, characterized in that: The control cabinet power supply output by the DCS system DO includes a UPS power supply circuit breaker K1, a terminal block XT1, a mains power supply circuit breaker K2, and a terminal block XT2. Terminals 1-5 of the terminal block XT1 are short-circuited to serve as the live wire row L of the UPS power supply, and terminals 6-10 are short-circuited to serve as the neutral wire row N of the UPS power supply; terminals 1-5 of the terminal block XT2 are short-circuited to serve as the live wire row L of the mains power supply, and terminals 6-10 are short-circuited to serve as the neutral wire row N of the mains power supply; The step S1 specifically includes the following steps: S11. Connect the L1 and N1 terminals of the input port of the A channel of the AC power redundancy module to be added to the No. 4 and No. 9 terminals of the terminal block XT1, respectively, to provide a temporary power supply for the A channel of the AC power redundancy module, and then connect the output terminals L and N of the AC power redundancy module to the No. 5 and No. 10 terminals of the terminal block XT1, respectively; S12. Close the incoming line switch A on the AC power redundancy module.

3. The method for online adding power supply redundancy modules of DO output of a DCS system as claimed in claim 2, characterized in that: The step S2 specifically includes the following steps: S21. Disconnect the mains power supply circuit breaker K2, so that the AC 220V power supply of the solenoid valve and the DC 24V power supply of the relay panel are both provided by the UPS power supply. Connect the No. 2 and No. 7 terminals of the terminal block XT2 to the L2 and N2 terminals of the B input port of the AC power redundancy module respectively; S22. Close the incoming switch B on the AC power redundancy module; S23. Disconnect the UPS power supply circuit breaker K1 to switch the output of the AC power redundancy module to the B input.

4. A method for online adding power supply redundancy modules for DO output of a DCS system as claimed in claim 3, characterized in that: The step S3 specifically comprises the following steps: S31. Disconnect the wiring switch A on the AC power redundancy module, and remove the line between the L1 and N1 terminals of the AC power redundancy module and the No. 4 and No. 9 terminals of the terminal block XT1.

5. The method for online adding power supply redundancy modules of DO output of a DCS system as claimed in claim 4, characterized in that: The step S4 specifically comprises the following steps: S41. Add a new terminal block XT0, terminals 1-5 of terminal block XT0 are short-circuited to serve as the live wire row L of the UPS power supply, and terminals 6-10 of terminal block XT0 are short-circuited to serve as the neutral wire row N of the UPS power supply; S42. Remove the wiring between circuit breaker K1 and terminals 1 and 6 of terminal block XT1, and connect them to terminals 1 and 6 of terminal block XT0, making terminal block XT0 the distribution bar of the UPS power supply; S43. Connect the L1 and N1 terminals of the A input port of the AC power redundancy module to the No. 1 and No. 6 terminals of the terminal block XT0 respectively, to provide a formal power supply line for the A input port of the AC power redundancy module; S44. Remove the wiring on terminals 2 and 7 of terminal block XT1, and connect them to terminals 2 and 7 of terminal block XT0; S45. Close the UPS power supply circuit breaker K1, and then close the incoming line switch A on the AC power redundancy module.

6. The method for online adding power supply redundancy modules of DO output of a DCS system as claimed in claim 1, characterized in that: In step S1, an offline power failure simulation test is first performed on the AC power redundancy module to be added to ensure that the power output will not be interrupted when one input power fails and the other input power is normally supplied.

7. A method for online adding power supply redundancy modules for DO output of a DCS system as claimed in claim 6, characterized in that: The offline power failure simulation test is specifically as follows: connect an AC 220V power supply to the A and B input terminals of the AC power redundancy module respectively; use the AC voltage range of the multimeter to measure the output voltage of the power redundancy module; then disconnect any one of the input power supplies and observe whether the output AC voltage of the power redundancy module is always maintained at 220V to confirm that the AC power redundancy module is working properly.

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