Platform for testing performance of electrical instrument of integrated device

Abstract

The invention discloses an integrated device electrical instrument performance test platform which is composed of four layers of frames including an operation layer, a control layer, a driving layer and an equipment layer, the operation layer is composed of a performance detection platform and a simulation system platform, and an industrial personal computer and a display which are shared are arranged in the operation layer. The performance detection platform further comprises a data acquisition and monitoring system and a relational database management system which are installed in the industrial personal computer, the simulation system platform further comprises a configuration software system installed in the industrial personal computer and a touch screen electrically connected with the industrial personal computer, and a controller electrically connected with the industrial personal computer is arranged in the control layer. An isolator and a relay which are electrically connected with the controller are arranged in the driving layer, and a transmitter electrically connected with the isolator, an electromagnetic valve, a pneumatic ball valve and an electric actuating mechanism which are electrically connected with the relay, and a pneumatic control valve electrically connected with the controller are arranged in the equipment layer. According to the invention, the problem that the electrical instrument on the integrated device cannot be tested in a manufacturing plant and thus the smooth production of an oil and gas production station is affected is solved.

Description

Technical Field

[0001] The invention belongs to the technical field of oil and gas field processing stations, and in particular relates to an integrated device electrical instrument performance testing platform. Background Art

[0002] Generally speaking, from R&D design to factory processing and manufacturing, the integrated device (hereinafter referred to as the device) does not have the conditions for debugging electrical instruments and equipment due to the lack of professional testing equipment and testing methods. When the device is put into operation at the oil and gas field station, the device cannot be put into operation normally due to the failure to debug the electrical instrument equipment in the device, which affects the production and operation of the oil field. At present, there is no application of the electrical instrument performance test platform of the relevant device in the existing technology. Summary of the invention

[0003] The purpose of the present invention is to provide an integrated device electrical instrument performance test platform, which solves the problem that the electrical instruments on the existing integrated device cannot be tested in the manufacturer, thus affecting the smooth commissioning of the oil and gas production station.

[0004] The technical solution adopted by the present invention is: an integrated device electrical instrument performance test platform, which is composed of a four-layer framework of an operation layer, a control layer, a drive layer and an equipment layer. The operation layer is composed of a performance detection platform and a simulation system platform. The operation layer is provided with an industrial computer shared by the performance detection platform and the simulation system platform and a display module electrically connected thereto. The performance detection platform also includes a data acquisition and monitoring system and a relational database management system installed in the industrial computer. The simulation system platform also includes a configuration software system installed in the industrial computer and a touch screen module electrically connected to the industrial computer. A PLC controller electrically connected to the industrial computer is provided in the control layer. An isolator and a relay electrically connected to the PLC controller are provided in the drive layer. A transmitter electrically connected to the isolator, an electromagnetic valve electrically connected to the relay, a pneumatic ball valve and an electric actuator, and a pneumatic regulating valve electrically connected to the PLC controller are placed in the equipment layer.

[0005] The present invention is also characterized in that:

[0006] The performance testing platform is composed of an industrial computer and an industrial display. SIMATIC Wincc7.4 and MySQL database software for local communication with the industrial computer are installed. The operation interface of the performance testing platform is edited in SIMATIC Wincc7.4. The operation interface consists of a detection operation interface, a parameter setting interface, and a result generation table interface. SIMATIC Wincc7.4 communicates with the PLC controller through Ethernet to display data acquisition, set parameters, and analyze test results. MySQL database software is used for data storage.

[0007] The detection operation interface is used to operate the opening and closing of pneumatic control valves, solenoid valves, pneumatic ball valves and electric actuators, to display the actual detection value of the transmitter, to display the feedback opening of the pneumatic control valve, and to display the switch limit of the solenoid valve, pneumatic ball valve and electric actuator; the parameter setting interface is used to set the detection range of the transmitter and the RS485 communication parameters of the third-party intelligent instrument; the result generation table interface is used to generate a result table after the detection is completed, which is displayed on this interface and can be saved as an electronic version.

[0008] The simulation system platform consists of an industrial computer, an industrial display and an HMI touch screen module. The McgsPro development software is installed in the industrial computer. The simulation system interface is edited in McgsPro and downloaded to the HMI touch screen module. The HMI touch screen module is used to display and view the simulation system interface. The edited interface project is simulated and run on the industrial computer and operated and viewed on the industrial display.

[0009] The simulation system platform is used to simulate the process flow of crude oil transfer integration and triethylene glycol dehydration skid.

[0010] The control layer is also provided with an I / O expansion module and an RS485 communication module electrically connected to the PLC controller. The DI digital module in the I / O expansion module is used to collect high-level signals of the switch limit of the solenoid valve, pneumatic ball valve, and electric actuator; the output signal of the DO digital module in the I / O expansion module controls the contacts through the relay coil to control the opening and closing of the solenoid valve, pneumatic ball valve, and electric actuator; the AI ​​analog module in the I / O expansion module is connected to the transmitter through the isolator, collects the detection value of the transmitter, and judges the quality of the transmitter by comparing the detection value with the reference value; the AO analog module in the I / O expansion module is connected to the pneumatic control valve to control its opening, and judges the quality of the pneumatic control valve by comparing the output opening with the feedback opening; the RS485 communication module is connected to the pneumatic control valve for RS 485 data communication test.

[0011] The transmitter includes a flow sensor, a temperature sensor, a pressure sensor, a differential pressure sensor and a tuning fork liquid level switch.

[0012] The beneficial effects of the present invention are as follows: the integrated integrated device electrical instrument performance test platform of the present invention can perform performance tests on transmitter instruments (flow, temperature, pressure, differential pressure, tuning fork liquid level switch), solenoid valves, pneumatic ball valves, electric actuators, pneumatic control valves and other components in the factory. After the test is completed, a judgment is made on whether the components are qualified. If they are unqualified, they are replaced or calibrated. At the same time, simulation tests are performed to simulate the on-site process flow, thereby ensuring the smooth commissioning of the device at the oil and gas production station. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1It is a framework logic diagram of the integrated device electrical instrument performance test platform of the present invention;

[0014] Figure 2 It is a schematic diagram of the structure of a piano-type control cabinet of the integrated device electrical instrument performance test platform of the present invention;

[0015] Figure 3 It is a schematic diagram of the installation layout structure of the integrated device electrical instrument performance test platform of the present invention;

[0016] Figure 4 It is a schematic diagram of the panel layout structure in the integrated device electrical instrument performance test platform of the present invention. DETAILED DESCRIPTION

[0017] The present invention is described in detail below with reference to the accompanying drawings and specific embodiments.

[0018] Example 1

[0019] The present invention provides an integrated device electrical instrument performance test platform, which classifies and counts the electrical instrument equipment required for the research and development and manufacturing of the integrated device, mainly divided into several categories such as transmitters, flow meters, control valves, actuators, etc. According to the working principles and working performances of various types of instruments, relevant signal types, power supply modes, analog input (AI), analog output (AO), digital input (DI), digital output (DO) and RS485 signals are counted, and then summarized into the following Table 1.

[0020] Table 1 Points statistics

[0021]

[0022] like Figure 1 As shown, according to the electrical and instrumentation components of the equipment to be tested, the electrical and instrumentation components of the equipment to be tested (pneumatic control valves, flow sensors, temperature sensors, pressure sensors, differential pressure sensors, tuning fork level switches, solenoid valves, pneumatic ball valves, electric actuators, and pneumatic control valves) are first placed on the equipment layer; isolators and intermediate relays are set on the drive layer; RS485 communication modules and I / O modules (DI, DO, AI, AO) are set on the control layer; the operation layer is set up with two modules, the performance detection platform and the simulation system platform. The performance detection platform is mainly used for performance detection of electrical instrumentation equipment, and the simulation system platform is mainly used for process simulation of crude oil transfer integrated device and triethylene glycol dehydration integrated device. The obtained test platform consists of four layers of frameworks: operation layer, control layer, drive layer, and equipment layer, as follows:

[0023] Operation layer: The operation layer consists of a performance test platform and a simulation system platform. The performance test platform is mainly composed of an ARK3500 industrial computer and a 19-inch industrial capacitive touch display. SIMATIC Wincc7.4 and MySQL database software are installed in the industrial computer. The interface development of the performance test platform is completed in Wincc7.4. Wincc7.4 communicates with PLC 1200 via Ethernet to display data acquisition, set parameters, and analyze test results. MySQL is used for data storage.

[0024] In addition to the ARK 3500 industrial computer and 19-inch industrial capacitive touch display, the simulation system platform also includes an HMI 15-inch ultra-large screen. The industrial computer has built-in embedded MCGSPro development software, which can simulate the on-site process flow of two skid-mounted equipment: the crude oil transfer integrated device and the triethylene glycol dehydration skid.

[0025] Control layer: Siemens 1200 is used as the controller (strong versatility). The controller integrates PROFINET interface, powerful integrated process functions and flexible scalability. CPU1214 can expand 8 SM signal modules and 3 CM communication modules. Solenoid valves, pneumatic ball valves, and electric actuators are isolated and controlled by relays. Flow meters, thermometers, pressure gauges, differential pressure gauges (4-20ma), and tuning fork level switches are connected through input isolation safety barriers to separate dangerous areas from safe areas to prevent wrong wiring during testing.

[0026] Dangerous isolation layer: The analog (4-20ma) input isolation safety barrier is connected to the on-site pressure, differential pressure, flow, temperature and other transmitters, and the intermediate relay indirectly controls the on-site solenoid valve, pneumatic ball valve, and electric actuator.

[0027] Equipment layer: The equipment layer is mainly composed of solenoid valves, pneumatic ball valves, electric actuators, thermometers, flow meters, pressure gauges, differential pressure gauges, tuning fork liquid level switches, and pneumatic control valves.

[0028] The component list is shown in Table 2 below:

[0029] Table 2 Components List

[0030]

[0031] Example 2 - Test platform construction

[0032] The test platform is a piano-type control cabinet, such as Figure 2 As shown, universal wheels are installed at the bottom of the cabinet to facilitate the movement of the test bench; keyboard and mouse drawers are configured.

[0033] The test platform installation layout is as follows Figure 3As shown, electrical components (including PLC+IO, DC power supply, circuit breaker, isolator, intermediate relay, and wiring terminals) are installed on the left side of the front inner lining plate, and an ARK 3500 industrial computer is installed on the right side (the upper development software Wincc7.4 and MySQL database are installed in the industrial computer).

[0034] The test platform panel layout is as follows Figure 4 As shown, the simulation system platform is on the left side of the panel. The simulation system platform consists of a 15-inch MCGS touch screen, which is mainly used to simulate the process flow of two types of skid-mounted equipment on site: the crude oil transfer integrated device and the triethylene glycol dehydration skid. The intelligent integrated ground skid-mounted equipment performance testing platform is on the right side of the panel. The testing platform consists of a 19-inch industrial capacitive touch display and a control system PLC. Between the panels are the network port, power indicator light, and power switch.

[0035] Example 3 - Performance Testing Platform

[0036] The performance testing platform is mainly composed of Advantech ARK 3500 industrial computer, 19-inch industrial capacitive touch screen, SIMATIC S7-1200 series CPU 1214 controller + I / O module, analog input and output isolator, and intermediate relay. According to the needs of instrument points, AI 9 points, AO 2 points, DI 9 points, DO 8 points, RS485 2 points are tested. In the case of actual statistical point requirements, 20% is reserved to facilitate the expansion of the test bench function in the later stage. The performance testing platform includes the following hardware modules:

[0037] -Advantech industrial computer ARK3500 module;

[0038] -19-inch industrial display module;

[0039] -CPU 1214 controller module;

[0040] -DI digital quantity SM 1221 1 module;

[0041] -DO digital quantity SM 1222 1 module;

[0042] -AI analog SM 1231 1 module;

[0043] -AO analog SM 1232 1 module;

[0044] -CM 1241RS485 / 422 communication 1 module;

[0045] -AI analog isolator CZ3047 8 modules;

[0046] -RS485 / 422 communication isolator CZ3093 1 module;

[0047] -10 modules of intermediate relays;

[0048] The performance testing platform requires the operator to complete the component testing through the upper interface operation and the lower PLC control, so the combination of upper computer interface operation + lower computer logic control is adopted. Here, both the upper and lower are German Siemens brands, and Siemens upper Wincc7.4 and lower CPU 1214+I / O expansion modules are widely used in various industrial environments to ensure the stability and practicality of the testing platform.

[0049] The host needs to run in the industrial computer, and the operating table needs to be moved frequently. The Advantech ARK 3500 fanless embedded industrial computer is used. The industrial computer is installed in the operating table. It is small, powerful, stable, efficient, and suitable for working conditions that move back and forth. The Siemens SIMATIC Wincc7.4 SCADA (data acquisition and monitoring) system and MySQL relational database management system are installed in the industrial computer.

[0050] The operation interface is edited in SIMATIC Wincc7.4. The operation interface consists of the detection operation interface, parameter setting interface, and result generation table interface. The detection operation interface has two functions: operation and detection data display. It mainly operates the opening and closing of components such as pneumatic control valves, solenoid valves, pneumatic ball valves, and electric actuators. Display the actual detection values ​​of flow sensors, pressure sensors, differential pressure sensors, temperature sensors, and tuning fork liquid level switches, display the feedback opening of pneumatic control valves, and display the switch limits of solenoid valves, pneumatic ball valves, and electric actuators. The parameter setting interface mainly sets the detection range of flow sensors, pressure sensors, differential pressure sensors, temperature sensors, and tuning fork liquid level switches, and the RS485 communication parameters of third-party intelligent instruments. The result generation table interface is mainly used after the detection is completed. The system will automatically generate a result table on this interface and it can be saved as an electronic version.

[0051] The lower controller uses Siemens SIMATIC S7-1200 controller CPU 1214 + I / O expansion module. The CPU is responsible for logic processing, and the extended I / O module is responsible for collecting field sensors and controlling field valves. The CPU and the expansion module are hard-connected through the connectors on both sides of the hardware module. The CPU and I / O modules are connected together to form the lower system of the performance testing platform. Program programming is completed in Botu TIA Portal V15. After the program is edited and compiled without error, it is downloaded to CPU 1214. The software supports five types of IEC61131-3 programming. The programming statements of this system use ladder diagrams. The ladder diagram has clear logical levels and is easy to read and understand.

[0052] DI digital quantity SM 1221 1 module collects 24V high-level signals of solenoid valves, pneumatic ball valves, and electric actuator switch limits.

[0053] DO digital quantity SM 1222 1 module outputs 24V signal to control the intermediate relay coil to control the contacts to control the opening and closing of the solenoid valve, pneumatic ball valve, and electric actuator.

[0054] AI analog SM 1231 1 module connects the + and - ends of the detection sensor (flow sensor, pressure sensor, differential pressure sensor, temperature sensor, tuning fork level switch) through AI analog isolator CZ3047, collects the detection value of flow sensor, pressure sensor, differential pressure sensor, temperature sensor, tuning fork level switch through 4-20mA signal, and judges the quality of the sensor by comparing the detection value with the reference value. The sensor channel adopts dual channels, which can detect 2 sensors of the same type at the same time.

[0055] AO analog SM 1232 1 module connects to the AI+ and - terminals of the pneumatic control valve and outputs a 4-20mA current signal to control the opening of the pneumatic control valve. The quality of the pneumatic control valve can be judged by comparing the output opening with the feedback opening.

[0056] CM 1241RS485 / 422 communication 1 module connects the A+ and B- terminals of a third-party device (independent control system) to perform RS 485 data communication tests.

[0057] The data exchange between the upper Wincc7.4 and the lower controller CPU 1214 is completed through Ethernet communication. The upper Wincc7.4 communicates locally with the MySQL database, and the data communication between Wincc7.4 and the MySQL database is established, so that the data generated in the detection can be stored in the data table of the MySQL database, and the data in the data table can be read from the database at any time in the generated result table for data processing and analysis.

[0058] Example 4 - Simulation System Platform

[0059] The simulation system platform includes the following hardware modules:

[0060] -HMI 15-inch touch screen TPC1570Gi module;

[0061] -Advantech industrial computer ARK3500 module;

[0062] -19-inch industrial display module;

[0063] The HMI 15-inch touch screen group can be operated by finger touch. Install McgsPro 3.3.6.6205SP1.1 in Advantech industrial computer ARK3500, edit the simulation system interface in McgsPro, download the edited simulation system interface to the HMI 15-inch touch screen, and the HMI touch screen can display and view the simulation system interface; the edited interface project can also be simulated and run on the Advantech industrial computer and operated and viewed on the 19-inch display.

[0064] The simulation system is mainly composed of the crude oil transfer integrated simulation system and the triethylene glycol dehydration skid simulation system. The system is selected and entered in the startup interface.

[0065] The crude oil transfer integrated simulation system edits four process interfaces, namely crude oil production process, associated gas production process, venting and sewage discharge process, and production accident process, based on the crude oil transfer integrated process flow chart. Each interface can simulate an independent process system.

[0066] The TEG dehydration skid simulation system edits a process interface based on the TEG dehydration skid process flow chart. Each interface can simulate an independent process system.

Claims

1. The integrated device electrical instrument performance test platform is characterized by: It consists of four layers of framework, namely, operation layer, control layer, drive layer and equipment layer. The operation layer consists of a performance detection platform and a simulation system platform. The operation layer is provided with an industrial computer shared by the performance detection platform and the simulation system platform and a display module electrically connected thereto. The performance detection platform also includes a data acquisition and monitoring system and a relational database management system installed in the industrial computer. The simulation system platform also includes a configuration software system installed in the industrial computer and a touch screen module electrically connected to the industrial computer. The control layer is provided with a PLC controller electrically connected to the industrial computer. The drive layer is provided with an isolator and a relay electrically connected to the PLC controller. The equipment layer is provided with a transmitter electrically connected to the isolator, a solenoid valve electrically connected to the relay, a pneumatic ball valve and an electric actuator, and a pneumatic regulating valve electrically connected to the PLC controller.

2. The integrated device electrical instrument performance test platform according to claim 1, characterized in that: The performance testing platform is composed of an industrial computer and an industrial display. SIMATIC Wincc7.4 and MySQL database software for local communication with the industrial computer are installed in the industrial computer. The operation interface of the performance testing platform is edited in SIMATIC Wincc7.

4. The operation interface consists of a detection operation interface, a parameter setting interface, and a result generation table interface. SIMATIC Wincc7.4 communicates with the PLC controller through Ethernet to display data acquisition, set parameters, and analyze test results. The MySQL database software is used for data storage.

3. The integrated device electrical instrument performance test platform according to claim 2, characterized in that: The detection operation interface is used to operate the opening and closing of the pneumatic control valve, solenoid valve, pneumatic ball valve and electric actuator, to display the actual detection value of the transmitter, to display the feedback opening of the pneumatic control valve, and to display the switch limit of the solenoid valve, pneumatic ball valve and electric actuator; the parameter setting interface is used to set the detection range of the transmitter and the RS485 communication parameters of the third-party intelligent instrument; the result generation table interface is used to generate a result table after the detection is completed, which is displayed on this interface and can be saved as an electronic version.

4. The integrated device electrical instrument performance test platform according to claim 1, characterized in that: The simulation system platform is composed of an industrial computer, an industrial display and an HMI touch screen module. The McgsPro development software is installed in the industrial computer. The simulation system interface is edited in McgsPro and downloaded to the HMI touch screen module. The HMI touch screen module is used to display and view the simulation system interface. The edited interface project is simulated and run on the industrial computer and operated and viewed on the industrial display.

5. The integrated device electrical instrument performance test platform according to claim 1 or 4, characterized in that: The simulation system platform is used to simulate the process flow of crude oil transfer integration and triethylene glycol dehydration skid.

6. The integrated device electrical instrument performance test platform according to claim 1, characterized in that: The control layer is also provided with an I / O expansion module and an RS485 communication module electrically connected to the PLC controller. The DI digital module in the I / O expansion module is used to collect high-level signals of switch limits of solenoid valves, pneumatic ball valves, and electric actuators; the output signal of the DO digital module in the I / O expansion module controls the opening and closing of the solenoid valves, pneumatic ball valves, and electric actuators through the relay coil control contacts; the AI ​​analog module in the I / O expansion module is connected to the transmitter through the isolator, collects the detection value of the transmitter, and judges the quality of the transmitter by comparing the detection value with the reference value; the AO analog module in the I / O expansion module is connected to the pneumatic control valve to control its opening, and judges the quality of the pneumatic control valve by comparing the output opening with the feedback opening; the RS485 communication module is connected to the pneumatic control valve for RS 485 data communication test.

7. The integrated device electrical instrument performance test platform according to claim 1, characterized in that: The transmitter includes a flow sensor, a temperature sensor, a pressure sensor, a differential pressure sensor and a tuning fork liquid level switch.

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