LK Series Programmable Logic Controller

Industry Solutions
 Introduction to Products

LK series programmable logic controller, shortly for PLC, is a new

product launched by Hollysys Company on the basis of fifteen years’
experience on control system design and thousands of projects
implementation, which is applicable to controlling field of medium and
high performance. Compared to traditional PLC, the LK series PLC
fully integrated the advantages of DCS and PLC, and by adopting high
performance analog processing technique, small-sized structure in
design, open industrial standard and universal system platform, the product possesses not only powerful
functions and brilliant performance, but also acquires a much higher reliability, better openness and
accessibility.

Supported by advanced computer technique, control technique, communication technique and signal
processing technique, the product is capable of providing customized solutions for users from different
industries, and it is applicable to such fields as logic control, sequence control, process control,
transmission control and motion control, etc.

 Performance Characteristics

 Configured with industrial grade100MHz /266MHz /533MHz processor with nanosecond (13ns)
speed and high-capacity memory, maximumly 16MB if used for programs; and 64MB+1MB
power-down remaining area if used for data.

 The system has high capacity I/O, i.e. max. 57344 points of digital I/O, 3584 points of analog
I/O, which can be configured freely, to satisfy different requirements of the users.

 Solutions for Redundancy system are provided, which support power redundancy, CPU
redundancy, Ethernet redundancy and bus redundancy.

 The modules are hot-pluggable and can

be replaced without interruption of
system operation. The new module will
conduct data initialize settings
automatically and establish
communication with CPU quickly.

 High integration and with various

communication interfaces set inside,
including redundancy PROFIBUS-DP
bus interface, Ethernet interface, RS232
interface and RS232/RS485 interface (configuration optional)

 According to different applications, high-speed backplane bus or PROFIBUS-DP bus can be

used for communication between I/O module and CPU, so as to provide the users with
high-performance, practical and economic solutions.

 Unique design in terminal blocks, i.e. the terminal blocks are fixed on the backplane
independent of I/O module, which can be replaced directly without repeated wiring, thus saves
 LK Series PLC Industry Solutions
time.

 The programming software shall conform to IEC61131-3 international standard and be

available with six languages, namely, LD, IL, FBD, ST, SFC and CFC.

 Open type design is adopted to provide standard interfaces for HMI software.

通讯接口模块 Communication interface module

I/O 模块 I/O module
特殊功能模块 Special function module
24V DC 输入 24V DC Input
本地背板 Local backplane
冗余 PROFIBUS-DP Redundancy PROFIBUS-DP
扩展背板 Extended backplane

 Fields of Application

Power Metallurgy Chemical Industry Water Resource

Transportations Municipal Engineering Energy Resource Environmental Protection
Building Materials Autombile Machinery Foodstuff
Pharmacy Papermaking Textiles ……
Textiles Printing Mines ……

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 LK Series PLC Industry Solutions
Contents

Power .............................................................................................................................................. 4

COAL HANDLING PROGRAMMED CONTROL SYSTEM ......................................................................... 8

CHEMICAL WATER TREATMENT SYSTEM ...................................................................................... 14
ETS SYSTEM ........................................................................................................................... 22
ASH HANDLING SYSTEM ............................................................................................................. 28
Metallurgy ....................................................................................................................................... 34

IRON-MAKING BLAST FURNACE ................................................................................................... 35

ALUMINUM OXIDE ...................................................................................................................... 48
CRUDE COPPER SMELTING ........................................................................................................ 52
Chemical Industry............................................................................................................................. 54

SALINIZATION PLANT ................................................................................................................. 55

COAL WATER SLURRY ............................................................................................................... 61
OILFIELD AUTOMATION MEASUREMENT SYSTEM ........................................................................... 66
Water Resource ............................................................................................................................... 70

GATE MONITORING SYSTEM ....................................................................................................... 72

CONTROL SYSTEM OF PUMP STATION ......................................................................................... 80
MONITORING SYSTEM OF HYDRAULIC POWER PLANT .................................................................... 88
Transportations ................................................................................................................................ 94

EMCS SYSTEM OF SUBWAY....................................................................................................... 95

AUTOMATION OF SUBWAY SUBSTATION ..................................................................................... 102
DEPOT MANAGEMENT SYSTEM (DMS)....................................................................................... 105
Gas.............................................................................................................................................. 109

SCADA SYSTEM OF LONG DISTANCE GAS TRANSMISSION PIPELINE ............................................. 111

URBAN NATURAL GAS SCADA SYSTEM .................................................................................... 114
DISPATCHING CONTROL CENTER .............................................................................................. 117
STATION CONTROL SYSTEM ..................................................................................................... 120
Municipal Engineering ..................................................................................................................... 123

WATER PLANT ........................................................................................................................ 129

SEWAGE TREATMENT PLANT .................................................................................................... 134
RECYCLING OF RECYCLED WATER ............................................................................................ 138
URBAN PUMP STATION ............................................................................................................ 145
HEAT SOURCE PLANT .............................................................................................................. 152
MONITORING OF HEAT-SUPPLY NETWORK .................................................................................. 156
Building Materials ........................................................................................................................... 164

CEMENT CLINKER PRODUCTION LINE......................................................................................... 165

LIME ROTARY KILN .................................................................................................................. 170
TANK FURNACE WIRE-DRAWING FOR GLASS FIBER ..................................................................... 174

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Energy Resource ........................................................................................................................... 179

STRAW POWER GENERATION ................................................................................................... 181

BIOGAS POWER GENERATION ................................................................................................... 184
WIND POWER GENERATION ...................................................................................................... 187
SOLAR ENERGY ...................................................................................................................... 192
Environmental Protection ................................................................................................................. 197

WASTE INCINERATION POWER GENERATION ............................................................................... 198

DESULPHURIZATION SYSTEM .................................................................................................... 201
User List ....................................................................................................................................... 207

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Power
Power is the necessity of human modern civilized society, while fossil-fired power generation forms the
main constituting part of electric power production. The fossil-fired power generation refers to the
process in which fossil fuels (i.e. coal, oil and natural gas) are combusted to release heat energy, the
heat energy is then used to heat working medium, and finally generators are driven by thermal prime
motor to generate electric power. Here, the prime mover mainly refers to boilers and steam turbines, gas
turbines or internal-combustion engines. At present, the fossil-fired power still holds the primary
component of electric power industry.

The programmed control systems of auxiliary equipments in power plants are usually equipped with the
control system of PLC mainly, including plant coal handling programmed control system, chemical water
treatment system, ETS system, ash handling system and plant desulphurization control system, etc.

Plant Coal Handling Programmed Control System

The plant coal handling programmed control system is composed by coal storage system, coal feeding
system and standby feeding system.

 Coal storage system: the coal storage system from the jetty to coal yard is arranged in one way
form, coal delivered from the jetty will be conveyed to the coal yard or directly to main
workshop.

 Coal feeding system: main equipments include belt conveyors. The belt conveyor from coal
yard to main workshop is arranged in double ways, with one of which running and another for
standby, or both running. The coal stored in coal yard is conveyed from bucket-wheel
stacker-reclaimer to main workshop through belt conveyor, and then unloaded to raw coal
bunker by coal bunker layer conveyor and plough unloader.

 Standby coal feeding system: when the conveyor in coal yard fails, the coal will be loaded into
conveyor tail hopper via coal bulldozer loader, and then to main workshop via belt conveyor.

Figure 1 Flow Diagram of Plant Coal Handling System

储煤罐 Coal storage tank

皮带机 Belt conveyor

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锅炉房 Boiler house

碎煤机室 Coal crusher room

转运站 Transfer station

卸煤站 Coal unloading station

煤场 Coal yard

斗轮推取料机 Bucket-wheel stacker-reclaimer

Plant Chemical Water Treatment System

The plant chemical water treatment system mainly includes condensate fine treatment system, make-up
water system and waste water system.

 Condensate Water System

The process flow of condensate water system mainly includes the condensate fine treatment & resin
regeneration system, water& steam sampling analysis system and chemical dosing system, etc.

 The condensate fine treatment & resin regeneration system consists of mixed bed, resin trap,
recirculating pump, bypass and all pipelines, pipe fittings, valves as well as local instruments, etc.
within the unit.

 The water& steam sampling analysis system consists of the water& steam sampling analysis
system of thermodynamic system and the
sampling analysis system of condenser leak
detection. The former is composed by high
temperature and high pressure rack and
instrument panel, while the latter is composed by
leak detection sampling rack and analyzer panel.

 The chemical dosing system consists of ammonia

dosing system for feedwater and condensate
water, hydrazine dosing system for feedwater and Figure 2 Process Flow Diagram of Condensate Fine
Treatment
phosphate dosing system for boiler water.

阳床 Cation exchanger
阴床 Anion exchanger
混床 Mixed bed
阳酸箱 Acid tank for cation exchanger
阴酸箱 Acid tank for Anion exchanger
酸罐 Acid tank
碱罐 Alkali tank
混酸箱 Acid tank for mixed bed
混碱箱 Alkali tank for mixed bed
再生水泵 Regeneration water pump

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 Make-up Water System

The make-up water system includes pretreatment system, RO (reverse osmosis) pre-desalination
system, chemical demineralization system and acid& alkaline system, and its control area covers
hydraulic water purification station.

Figure 3 Flow Diagram of Boiler Make-up Water Treatment System (Chemical Demineralization)
清水 Clean water

阳床 Cation exchanger

除碳器 Decarbonator

中间水箱 Intermediate water tank

中间水泵 Intermediate water pump

风机 Blower

阴床 Anion exchanger

一级钠离子交换器 Primary sodium ion exchanger

一级除盐水泵 Primary demineralized water pump

混床 Mixed bed

二级钠离子交换器 Secondary sodium ion exchanger

二级除盐水泵 Secondary s demineralized water pump

至除氧器 To deaerator

 Waste Water System

The waste water system functions mainly to treat all waste water in the power plant, including ash waste
water, chemical waste water, domestic waste water and desulphurization waste water, etc.

Plant Ash Handling System

The ash handling system of large-sized

units generally includes pyrite coal handling
discharged by coal mill, bottom ash
handling of the boiler, fly ash handling of
economizer, air preheater and electrostatic
precipitator.

图 4 除渣系统流程图
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沉淀池 Sedimentation basin

工业补水 Industrial makeup water
贮水池 Water reservoir
高压泵 High pressure pump
低压泵 Low pressure pump
石子煤斗 Pyrite coal hopper
渣斗 Bottom ash hopper
中转仓 Transfer bin
渣浆泵 Slurry pump
脱水仓 Dewatering bin
溢流池 Overflow basin
溢流泵 Overflow pump
装车外运 Delivery by trucks
装船外运 Delivery by ships
图 4 除渣系统流程图 Figure 4 Flow Diagram of Bottom Ash Handling System

 Bottom Ash Handling System

Bottom ash and pyrite coal are transferred to the transfer bin between boiler electrostatic precipitators
via a hydraulic ejector, and then to dewatering bin via centrifugal slurry pump. The slurry entered into the
dewatering bin will sediment stage by stage through the dewatering bin, sedimentation basin and water
reservoir, and then return to main workshop via water pump for recycle of bottom ash handling system,
and finally the closed type cycle system is formed. One path of industrial makeup water is set in the
water reservoir, and controlled via liquid level meter of the reservoir.

Each boiler is equipped with two sets of high pressure water pumps, with one for continuous operation
and the other for standby, and three sets of low pressure water pumps, normally with only one set is
operating. When the bottom ash hopper is tapping, two LP water pumps will operate and the last one for
standby. Specifically, the two LP water pumps will be started up at the beginning of conveying bottom
ash and pyrite coal, and be stopped when the conveying is finished, so as to ensure the making-up
water for transfer bin and bottom ash hopper in the process. Pressure transmitters are installed on the
header of HP& LP water pump outlets, to avoid excessive pressure at the outlets. Opening/closing of the
makeup water valve for water reservoir is controlled by the water level, so that the HP/LP water pumps
can run in a safe and reliable manner. The high pressure water is mainly used for hydraulic jet pump of
the bottom ash hopper in the ash handling system, nozzle flushing of bottom ash hopper, hydraulic jet
pump of pyrite coal, sedimentation basin and agitating water for nozzle of the water reservoir. The LP
water is mainly used for make up water to the hopper water sealed tank, flushing of the water sealed
tank, make up water to the ash hopper and
transfer bin as well as mixing water of the wet
agitator.

 Fly Ash Handling System

The fly ash collected in ash bunker is in fluidized

state on the effect of gasified air. When cycle
ash conveying order arrives, E-type material
图 5 除灰系统流程图

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conveying valve will be powered to open, and coal ash is conveyed to bag filter on the top of ash silo by
“attraction force” of negative pressure fan. Inside the bag filter, material separation can be realized, i.e.
coal ash is filtered and falls down, while the air is induced away by the fan. The coal ash is fluidized in
precipitator and pressure balance between the precipitator and air lock valve and air lock valves can be
achieved by opening and closing balance valve after ash unloading order comes. And meanwhile, the
flap valve shall be open, and then the coal ash will fall down into ash silo stage by stage. PLC will
conduct inspection upon negative pressure of pipeline, dust density and ultra material level, etc., and
guarantee process system via program selection and failure alarms.

Figure 5 Flow Diagram of Fly Ash Handling System

气化风 Gasified air

灰斗 Ash bunker

除尘器 Precipitator

锁气阀 Air lock valve

灰库 Ash silo

过滤器 Filter

1# 真空风机 1# Vacuum fan

2# 真空风机 2# Vacuum fan

Coal Handling Programmed Control System

The plant coal handling programmed control system fulfills the task of
conveying coal in coal yard to coal bunker or coal silo, generally
including coal unloading system, coal stacking system, coal feed
system and coal blending system. It is an important system to
guarantee stable and full-load power generation, and the supporting
system for safe and reliable operation of the units.

The plant coal handling programmed control system is characterized

in plenty of equipments located separately, strong interlock relation among the equipments, poor running
environment of the equipments and high requirements for safety& reliability, etc. Hollysys LK series PLC
is adopted as the main monitoring system, to realize the control upon the whole process flow. The PLC
system has such advantages as high cost performance, easy maintenance, simple for use and stable
performance, in addition, it reduces work load of operating and maintenance personnel and decreases
accident occurrence to a great extent, hence contributes a lot to safe and efficient operation of the power
plant.

Design of Coal Handling Programmed Control System

The coal handling programmed control uses LK series PLC equipped with dual CPU (hot standby) to
achieve coal feeding and blending control functions, which is installed in coal handling programmed
control room. Six groups of remote I/O stations are set in coarse crusher room, 1# transfer station, 2#

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transfer station, fine crusher room, coal bunker layer and coal handling complex building, and all signals
shall be connected to the nearby I/O stations. Redundancy PROFIBUS-DP field bus is applied to
communication between each I/O station and PLC. This network is able to satisfy real-time requirements
of coal handling programmed control. Coal handling programmed control room is set with master
monitoring system, and centralized monitoring and controlling of coal handling system can be realized
via two sets of upper level computers (LCD), therefore, conventional simulation screen and instrument
are unnecessary.

Figure 1 Structural Diagram of Coal Handling Programmed Control System

煤水处理间 PLC 系统 Coal water treatment room PLC system

厂级 SIS 监控系统 Plant SIS monitoring system

彩色喷墨打印机 Color ink jet printer

1# 操作员站 1# Operator station

2# 操作员站 2# Operator station

黑白激光打印机 Black and white laser printer

系统预留以太网络通讯接口 System reserved Ethernet communication

interface

100Mbps 环形工业以太网 100Mbps Ring industrial Ethernet

UPS 电源 UPS power supply

PLC 控制主站冗余配置 Redundancy configuration of PLC master station

冗余 PROFIBUS-DP 现场总线 Redundancy PROFIBUS-DP fieldbus

输煤综合楼站 coal handling complex building station

粗碎机室远程站 Remote station of coarse crusher room

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1#转运站 1# transfer station

2#转运站 2# transfer station

细碎机室远程站 Remote station of fine crusher room

煤仓层远程站 Remote station of coal bunker layer

 System Structure

The whole system can be divided into three levels, i.e. production management level (coal handling
programmed control room), field control level (PLC control station) and local control level. Various field
data can be collected via PLC system and transmitted to monitoring computers in central control room
for centralized monitoring and management via the backbone communication network——the ring
industrial Ethernet, with communication rate of 100Mbps and communication medium could be fiber
optic or shielded twisted pair as per the communication distance. In the same way, control commands
from the monitoring computers in central control room can be transmitted to PLC controlling terminal via
the above said channel, to implement distributed control upon each unit.

On account of the equipments of coal handling system located dispersedly and in strong interlock
relation, the system is set with a master station and several remote I/O substations. Field equipment
signals shall be connected to the nearby remote I/O substations directly, and realize communication with
the system master station via redundancy PROFIBUS-DP bus network, so that the master station can
complete monitoring and management upon all equipments of the system.

In view of the requirements of coal handling programmed control system in safety and reliability aspects,
system master station adopts CPU module LK210 with redundancy function of LK PLC, which supports
power supply redundancy, CPU redundancy, Ethernet redundancy and bus redundancy, to guarantee
continuous operation of the whole system.

 Control Mode

Control mode of the coal handling programmed control system is designed as local manual control,
remote manual control and program auto control modes for the field equipments. These three modes
rank from local manual control, remote manual control and program auto control from high to low.

Coal Handling Process Control Scheme

There is big difference in process forms of coal handling system according to specific capacity of units,
coal intake mode, distance from coal yard to raw coal bunker and coal handling equipment, etc.
However, based on different process sections and functions, the general coal handling process can be
divided into coal unloading process, coal stacking process, coal feeding process and coal blending
process.

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Figure 2 Schematic Diagram of Coal Handling System Process Flow

厂外来煤 Plant coal intake from outside

储煤站 Coal storage station

煤场 Coal yard

转运站 Transfer station

煤仓间 Coal bunker bay

燃煤锅炉 Coal-fired boiler

堆取料机 Stacker-reclaimer

输煤皮带 Belt conveyor

取料机 Reclaimer

碎煤机 Coal crusher

犁煤器 Coal plough

煤流 Coal flow

构筑物 Structures

主要设备 Main equipments

 Control Strategy

Control of coal handling system is realized via monitoring upon coal handling equipments to achieve the
task of conveying the coal in coal yard to coal
bunker or coal silo. System control shall abide
by the following principles:

 Coal feeding principle

1） Process pre-start: conduct process selection,

and start up the pre-start equipments on
corresponding processes, to make good
preparation for startup;

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2） Process start: when received permissive signal of process start, main equipments in the system shall
be started up in reverse direction of coal flow and in delayed sequence;

输煤程控系统工艺流程图 Process flow diagram of coal handling

programmed control system

卸煤中 Unloading coal

2# A 上层 2# A upper layer

2# A 下层 2# A lower layer

一级碎煤室 Primary coal crusher room

二级碎煤室 Secondary coal crusher room

转运站 Transfer station

堆取料机 Stacker-reclaimer

圆形煤场 Round coal yard

图例 Legend

圆振筛 Circular vibrating screen

碎煤机 Coal crusher

电动三通 Electric three-way valve

除铁器 Magnetic separator

犁煤器 Coal plough

采样装置 Sampling device

除尘器 Precipitator

煤仓间 Coal bunker bay

紧急停车 Emergency shutdown

连锁 Interlock

解锁 Unlock

程控启动 Program controlled startup

程控停止 Program controlled stop

程控配煤 Program controlled coal blending

手动配煤 Manual coal blending

流程选择 Process selection

流程预起 Process pre-start

方式一运行 Operate in mode 1

3） Process stop: after the stop instruction is given out, main equipments in the system shall be stopped
in coal flow direction and in delayed sequence;

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4） Failure interlock shutdown: when main equipments in the system on the selected process fail,
interlock trip the upstream main equipments of the failure point (in reverse direction of coal flow);

5） Serious failure signal: instructions or signals such as emergency stop, pulling rope, serious
off-tracking, serious blocking and slipping will directly cause system trip by interlock.

 Coal blending principle

1） Sequential blending: firstly set a tail bunker, then start coal blending from the first raw coal bunker,
and meanwhile in coal hoppers in sequence (or according to coal bunker material level), until tail bunker
and all hoppers in front of it transmit a signal of high coal level. During sequential blending, if low level
signal occurs in any bunker, stop the coal blending and start blending to the low level bunker in priority;

2） Preferential blending: when low level signal occurs in any bunker, stop the normal blending of coal
hopper and take memory. Firstly, make up the low level bunker until the low level signal disappears, and
then supply the bunkers to high level as per the normal sequence of memory coal hopper. And when low
level occurs to multiple bunkers at the same time, alternative blending for these bunkers from front to
rear, until low level signal disappears;

3） Residual coal blending: when shutdown signal is transmitted, residual coal on belts shall be
distributed to each bunker evenly, until the belt conveyor of raw coal stops running.

 Process Control

 Process selection, process pre-start

 Coal feeding sequence start-stop control

 Coal blending process control

 Accident disposal

System Characteristics
The programmed control system solution of plant coal handling adopts LK PLC of Hollysys Company as
the core controller and connects computers in central control room with PLC system master station and
PLC system master station with remote I/O substations via redundancy Ethernet network and
PROFIBUS-DP bus network, to form a distributed control system. The system has the following major
characteristics:

 Solution to redundancy

The coal handling programmed control system is designed as redundancy configuration, including
power supply redundancy, CPU redundancy, Ethernet redundancy and PROFIBUS-DP bus network
redundancy, and when any of which fails, the system will never be stopped, thus system reliability and
safety are guaranteed maximumly.

 Centralized management, distributed control

The coal handling programmed control system is designed as network structure of one master station
and several slave stations, with the equipments in the system controlled integrally by the master station,
while data acquisition and equipment driving controlled by remote I/O substations only. The system

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structure not only satisfies the requirements of strong interlock relation among system equipments, but
also dispersed allocation of system equipments.

 Friendly and powerful software interface

PowerPro programming software conforms to IEC61131-3 standard, which is easy to study, understand
and use. FacView configuration software has abundant gallery, powerful network, perfect and
easy-to-use alarm, report forms, historical data and secondary development function.

 Openness

The coal handling programmed control system is designed as an open system. Industrial Ethernet and
PROFIBUS-DP bus network are the industrial communication networks most widely used and with good
openness currently, and the system software supports DDE, OPC, ODBC and SQL, and provides
various API programming interfaces. In addition, the system supports many interface types such as
Modbus/TCP protocol, Modbus RTU protocol and free port protocol, etc., thus can be expanded or
connected seamlessly with the plant auxiliary control networks, MIS and other subsystems conveniently.

Chemical Water Treatment System

As an important constituent part of plant auxiliary equipment

programmed control system, the operation of chemical water treatment
system concerns safety and economy of the whole boiler, and influence
operating safety of the whole power plant and service life of the units.

With continuous updating& changing in chemical water treatment

process, it becomes more complex and exerts more strict requirement
for system automatic control. Based on LK series programmable logic
controller (PLC) of Hollysys Company, the automatic control system of chemical water treatment is
realized combining the control system of field bus network, and its functions include automation control,
state monitoring, data acquisition, real time alarm and statistics printing, etc. for chemical water
treatment system process. The system gives full play to the technical advantages such as reliability,
accessibility and feasibility of LK PLC. Compared with conventional control schemes, the PLC is
characterized by more powerful control function, higher control level and more excellent openness.

System Design

The automation control system of chemical water treatment consists of two operator stations, one
engineer station and three redundancy PLC control stations. Upper level computer system adopts
industrial-grade computer to form a powerful monitoring ad controlling system, with FacView industrial
monitoring and controlling system software of Hollysys Company installed on the computer, to realize
dynamic monitoring and controlling upon the whole chemical water treatment process flow via proper
system design and system configuration. Therefore, automation management and control upon the
whole production process engineering can be achieved via upper level computer system and formidable
industrial control transmission network.

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Figure 1 Schematic Diagram of Automation Control System of Chemical Water Treatment

打印机 Printer

操作员站 Operator station

工程师站 Engineer station

UPS 电源 UPS power supply

LK 冗余系统 LK redundancy system

冗余 PROFIBUS-DP 总线 Redundancy PROFIBUS-DP bus

凝结水精处理 PLC 控制站 Condensate fine treatment PLC control station

补水精处理 PLC 控制站 Makeup water fine treatment PLC control station

综合水处理 PLC 控制站 Comprehensive water treatment PLC control

station

LK series PLC redundancy controller of Hollysys Company is selected for the PLC, dual CPU (hot
standby) redundancy mode is adopted for the control system and field monitoring and controlling points
are connected via remote I/O mode. Master control station of redundancy can guarantee the time for
system outage maintenance to be zero, thus maximumly reduces human intervention to the system. The
redundancy PROFIBUS-DP industrial bus transmission network of high performance is used between
hot standby system of the master control system and remote I/O stations to realize reliable, safe and
stable information transmission. PROFIBUS-DP is a kind of high speed and high cost performance field
bus, which is specially designed for communication between automation control system and equipment
dispersed I/O.

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Industrial Ethernet transmission network is applied between upper level computer system and PLC
control unit. The Ethernet is in line with the international standard, and the industrial Ethernet has met
the requirements of high transmission safety and reliability and has now been widely used in program
maintenance, transmitting factory data to MIS and MES systems, monitoring, connecting man-machine
interface, recording events and warning& alarming. The industrial Ethernet has such advantages as high
transmission rate (currently up to 100Mbps), certainty of exchange technology, no need to consider
network topological structure, various physical media for transmission (twist pair, fiber optic and coaxial
cable), and no need to consider network expanding in application of the hub, etc.

The upper level computer can be closely connected with field monitoring& controlling points via Ethernet
network, to form an integral system. On such a high-speed transmission network, on-line remote
diagnosis function upon computers of the whole control system can be realized by using the unique
functions of PLC conveniently.

System Functions

The system is capable of achieving automation control, state

monitoring, data acquisition, real time alarm, statistics
printing and other functions upon chemical water treatment
process. The software system is designed with adequate
monitoring pictures as per process flow, by which each
process treatment flow can be monitored and operated. The
monitoring interfaces can be used to monitor flow state and
also operate the processes, thus the whole process flow is
reflected on the monitoring pictures, and meanwhile the
pictures display field information in virtual instrument
method, achieving audio-visual, dynamic and real time effect.

茂名热电厂化学水处理 DCS 系统 Chemical water treatment DCS system of

Maoming Cogeneration Power Plant

工程师级别 Engineer level

除盐水系统流程图 Flow diagram of demineralized water system

至#1-4 主厂房 To #1-4 main workshop

至#5 主厂房 To #5 main workshop

自用水至酸碱喷射器 Domestic water to acid/alkaline ejector

至加氨系统 To ammonia dosing system

自混床出口来 From mixed bed outlet

#1、#2、#3、#4 除盐水箱 #1, #2, #3, #4 Demineralized water tanks

#1、#2、#3 除盐水泵 #1, #2, #3 Demineralized water pumps

自用水泵 Domestic water pump

去#5 机内冷水箱 To #5 generator inner cooling water tank

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 LK Series PLC Industry Solutions

内冷水泵 Inner cooling water pump

主菜单 Main menu

P1 储水系统 P1 water storage system

P2 高效纤维 P2 high efficiency fiber

P3 除盐系统 P3 demineralization system

P15 阳床阴床 P15 cation/anion exchanger

P4 阳床阴床 P4 cation/anion exchanger

P5 混床系统 P5 mixed bed system

P6 压缩空气 P6 compressed air

P7 酸碱系统 P7 acid/alkaline system

P8 程序运行 P8 program running

P9 数据一览 P9 data list

P10 流量累计 P10 flow accumulated

P12 制氢系统 P12 hydrogen production system

P13 化学加氨 P13 chemical ammonia dosing

P14 阀门储水 P14 valve storage water?

The operators can conduct state monitoring of production

process, data acquisition, real time graphic monitoring, real time
alarm and statistics printing, etc. upon the whole chemical water
treatment system via computers. Specifically, the operators can
make real time query of report forms and graphs in the control
room, so as to comprehend the production conditions and give
out guidance, to finally realize production management
automation, network& communicate with upper level computer
and improve the automation level of the whole plant.

茂名热电厂化学水处理 DCS 系统 Chemical water treatment DCS system of

Maoming Cogeneration Power Plant

工程师级别 Engineer level

#1、#2 阳床阴床系统流程图 #1, #2 Cation/anion exchanger system flow

diagram

压缩空气母管来气 Air from main pipe of compressed air

1#、#2 阳床 #1, #2 Cation exchanger

#1、#2 除碳器 #1, #2 decarbonator

#1、#2 中间水箱 #1, #2 Intermediate water tank

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 LK Series PLC Industry Solutions

1#、#2 阴床 #1, #2 Anion exchanger

去阴床出水母管 To outlet water main pipe of anion exchanger

阳床再生喷射器来酸 Acid from regeneration ejector of cation exchanger

高效过滤器出水母管来 From outlet water main pipe of high efficiency filter

去#3 中间水箱出口 To outlet of #3 intermediate water tank

去#3 中间水泵出口母管 To outlet main pipe of #3 intermediate water pump

阴床再生液来 From regeneration liquid of anion exchanger

废碱液排至废碱池 Waste alkaline discharged into waste alkaline

basin

废酸液排至废酸池 Waste acid discharged into waste acid basin

主菜单 Main menu

P1 储水系统 P1 water storage system

P2 高效纤维 P2 high efficiency fiber

P3 除盐系统 P3 demineralization system

P15 阳床阴床 P15 cation/anion exchanger

P4 阳床阴床 P4 cation/anion exchanger

P5 混床系统 P5 mixed bed system

P6 压缩空气 P6 compressed air

P7 酸碱系统 P7 acid/alkaline system

P8 程序运行 P8 program running

P9 数据一览 P9 data list

P10 流量累计 P10 flow accumulated

P12 制氢系统 P12 hydrogen production system

P13 化学加氨 P13 chemical ammonia dosing?

P14 阀门储水 P14 valve storage water?

The specific control programs are designed including:

 Normal water production program control

 Water tank level control

 Auto switching& operating control of water

production equipment

 Cleaning and auto switching control of mechanical

filter

 Full-automatic cycle operating control of

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 LK Series PLC Industry Solutions
desalination, backwash and regeneration

 Regeneration program control of anion exchanger and cation exchanger

 Automatic cycle operating control of mixed bed regeneration

 Control of acid and alkaline dosing systems

 Control of waste acid and alkaline neutralization system

 Control of compressed air system

 Other control functions

茂名热电厂化学水处理 DCS 系统 Chemical water treatment DCS system of

Maoming Cogeneration Power Plant

工程师级别 Engineer level

混床系统测点图 Measuring point diagram of mixed bed system

由混床碱液喷射器来 From alkaline liquid ejector of mixed bed

由阴床出口来 From outlet of anion exchanger

由盐酸喷射器来 From hydraulic acid ejector

由储气罐出口来 From outlet of air storage tank

至除盐水箱 To demineralized water tank

#1、#2、#3 混床 #1, #2, #3 Mixed bed

至废酸碱沟 To waste acid/alkaline ditch

主菜单 Main menu

P1 储水系统 P1 water storage system

P2 高效纤维 P2 high efficiency fiber

P3 除盐系统 P3 demineralization system

P15 阳床阴床 P15 cation/anion exchanger

P4 阳床阴床 P4 cation/anion exchanger

P5 混床系统 P5 mixed bed system

P6 压缩空气 P6 compressed air

P7 酸碱系统 P7 acid/alkaline system

P8 程序运行 P8 program running

P9 数据一览 P9 data list

P10 流量累计 P10 flow accumulated

P12 制氢系统 P12 hydrogen production system

P13 化学加氨 P13 chemical ammonia dosing?

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 LK Series PLC Industry Solutions

P14 阀门储水 P14 valve storage water?

The automatic control upon operation and regeneration of primary demineralization equipment can be
realized by PLC, or by remote operations on operator stations in control room via keyboard and mouse.
When outlet water conductivity of the primary demineralization equipment exceeds the specified value or
cycle water production quantity reaches the specified value, the equipment will be disconnected
automatically and alarm, and then put regeneration program into operation automatically. The automatic
control upon operation and regeneration of mixed bed exchanger can be realized by PLC, or by remote
operations via keyboard and mouse. When outlet water conductivity and SiO2 of the mixed bed
exchanger exceeds the specified value, or cycle water production quantity reaches the specified value,
the exchanger will be disconnected automatically and alarm, and then put regeneration program into
operation automatically. The automatic control upon high efficiency filter and activated carbon filter
can be realized by PLC, or by remote operations on operator stations in control room via keyboard and
mouse. When their outlet/inlet pressure difference exceeds the specified value, or cycle water
production quantity reaches the specified value, they will be disconnected automatically and alarm, and
then put backwashing program into operation automatically. All the above stated operations are finished
by operators before, while in this system, all those can be
achieved without any human intervention.

Intermediate water tank level is controlled automatically by

PLC (via adjusting the control valve at inlet of cation
exchanger), so as to maintain the tank level in normal position
when operating primary demineralization system. Startup and
shutdown of intermediate water pump are interlocked with
intermediate water level, i.e. the pump will be started in low
level and stopped in high level, to ensure safe service of the
intermediate water pump.

茂名热电厂化学水处理 DCS 系统 Chemical water treatment DCS system of

Maoming Cogeneration Power Plant

工程师级别 Engineer level

#1 制氢系统流程图 Flow diagram of #1 hydrogen production system

氢侧压力调节阀 Pressure control valve at hydrogen side
氢液位 Hydrogen level
氢综合塔 Hydrogen complex tower
氢槽温 Hydrogen bath temperature
槽压 Bath pressure
碱液温度 Alkaline liquid temperature
碱液流量 Alkaline liquid flow
冷却水调节阀 Cooling water control valve
电解塔 Electrolysis tower
循环泵 Circulating pump
制氢装置电解允许 Permissive electrolysis of hydrogen production
device

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 LK Series PLC Industry Solutions

制氢装置电解禁允 Prohibited electrolysis of hydrogen production

device
硅整流故障 Failure of silicon rectifier
去#2 制氢系统流程图 To flow diagram of #2 hydrogen production system
干燥压力 Drying pressure
干燥压力调节阀 Control valve of drying pressure
氢站测爆仪报警 Alarm of explosimeter in hydrogen station
储氢罐 Hydrogen storage tank
干一塔 Drying tower 1
干二塔 Drying tower 2
干 1、2 塔温 Drying tower 1/2 temperature
分离器 Separator
主菜单 Main menu

P1 储水系统 P1 water storage system

P2 高效纤维 P2 high efficiency fiber

P3 除盐系统 P3 demineralization system

P15 阳床阴床 P15 cation/anion exchanger

P4 阳床阴床 P4 cation/anion exchanger

P5 混床系统 P5 mixed bed system

P6 压缩空气 P6 compressed air

P7 酸碱系统 P7 acid/alkaline system

P8 程序运行 P8 program running

P9 数据一览 P9 data list

P10 流量累计 P10 flow accumulated

P12 制氢系统 P12 hydrogen production system

P13 化学加氨 P13 chemical ammonia dosing?

P14 阀门储水 P14 valve storage water?

Control state display of valves and pumps, etc. is interlocked with auto/manual/local operation and
selection. The flow and pressure of the system can be monitored on operating interface, and raw water
flow, outlet flow of anion exchanger and outlet flow of mixed bed can be displayed& integrated and kept
for historical record. Therefore, water production quantity by primary demineralization and mixed bed
regeneration can be viewed separately.

The system controls operation, stop and regeneration program of each line of demineralization device,
auto acid/alkaline dosing program and auto/semi-auto startup of another demineralization device
program, etc. Necessary step by step operation, group operation or independent operation, etc. are set
for sequence control, and also the skipping, interrupting or bypass functions. System operation, cleaning
of activated carbon, regeneration of primary demineralization and regeneration of mixed bed can be
fulfilled automatically by the system itself, or with operators’ step delay and stepping intervention, in

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 LK Series PLC Industry Solutions

addition, set time and remaining time of each step, stepping and delaying indication will be displayed on
the operator station interface.

4 System Characteristics
 The system is advanced, reliable and high in cost performance.

 The system has high level of automation, which is favorable for ensuring continuous and stable
production as well as stable product water quality.

 The system has various control modes, with perfect interlock, protection functions and strong
self-adaptability.

 The system has various operating modes, set with program control, stepping, single operating
and local manual and other functions.

 Master monitoring software is of abundant and complete functions, flexible operation and
convenient maintenance.

 The system is excellent in its openness and expandability, with reserved communication
interfaces with other systems.

ETS System

Steam turbine, as a key power equipment of fossil-fired power plant, is

driven by high temperature and high pressure steam generated by the
boiler to conduct high speed rotation. The emergency trip system (ETS) of
steam turbine is one of the subsystems in the power plant which requires
the highest reliability, as it servers as the outlet of electric trip of steam
turbine and its operation safety directly influences the safe operation of the
steam turbine.

The steam turbine ETS system, based on LK plc, supports CPU redundancy, power supply redundancy
and network redundancy, and is capable of realizing seamless connection with DEH and DCS integrally
but independent of DEH and DCS. And meanwhile, it can conduct data exchange with DEH and DCS via
PROFIBUS-DP bus, with rapid dynamic response. The system is widely used for its characteristics such
as high reliability, rapid processing and convenient logic modifying, etc.

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System Configuration

ETS of steam turbine, with PLC as the core, is

composed by control cabinet, actuator,
acoustic-optical alarm, and primary and secondary
peripheral elements. Inside ETS control cabinet, there
are mainly dual PLC, alarm relay, trip relay and
protection activate/deactivate panel, etc. Each input
and output channel has its own corresponding
indicator lamp, by which action of any channel can be
checked and the system can conduct on-line test.

Via programming logic, PLC can realize state

inspection, alarm and control upon ETS shutdown
protection device. Ann meanwhile, manual simulation 图1 ETS 系统示意图
trip test and panel indicator lamp test can be
conducted via button switches. Vibration protection of steam turbine realizes reliable trip of vibration
system to improve the reliability of the system, prevent units trip caused by failure happened in vibration
single circuit measurement and finally enhance safe operation of steam turbine.

Figure 1Schematic Diagram of ETS System

操作员站 Operator station

工业以太网 Industrial Ethernet

电厂 DCS 系统 Power plant DCS system

LK 系列 PLC LK series PLC

润滑油压力 Lubricating oil pressure

凝汽器真空 Condenser vacuum

汽机转速 Rotating speed of steam turbine

转子振动 Rotor vibration

轴向位移 Axial displacement

跳闸电磁阀 Trip solenoid valve

汽轮机主汽阀 Main steam valve of steam turbine

汽轮机调节阀 Governing valve of steam turbine

LK series PLC of Hollysys Company, power supply module, CPU module, DI module and DO module
are selected for ETS system. CPU of PLC can fulfill logic processing of all input signals and logic control
of all output signals. As the system has very high requirement for reliability of the equipment, that is,
under any possible emergency condition, the equipment shall be able to ensure shutdown steam turbine
correctly, therefore, it is designed as dual PLC operating mode. As the dual PLC operate in parallel,
without interference but with “Or” relation, it is unnecessary to conduct on-line hot switching, so problems
such as switching disturbance will never happen. If any set fails, another PLC can still operate normally,

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 LK Series PLC Industry Solutions

and at this time, protection functions of turbine operation are still complete. The dual PLC control
scheme has higher reliability than dual redundancy control scheme.

Control Functions
ETS system of steam turbine can fulfill opening/closing functions of all electric valves in the process of
turbine emergency trip control, including completing data acquisition, processing, calculation and real
time output of switching value, and transmitting relevant data to operation station of central control room.
Cooperated with turbine supervisory instruments system, the ETS system can monitor some important
signals of steam turbine, and guarantee safety of the turbine. When parameters entering into ETS, such
as lub.oil pressure, condenser vacuum, turbine rotating speed, rotor vibration and axial displacement,
etc. exceed the limit values, a trip signal will be output to trip solenoid valve, which will unload the
security oil of security system to make main steam valves and governing valves of the turbine closed
quickly, and finally turbine trip function is completed. At last, the turbine is shut down emergently and
stands in safe state, avoiding serious results incurred.

Input signals can be set and combine, for example, two out of
three(ensuring misoperations eliminated) and two out of
four(applciable to on-line test situation), by which the
characteristics of PLC are played to its utmost. Via writing
programs of “fucntion”, “sub-program” and “interrupt", etc., the
purposes of complete control function and rapid operation can
be achieved. As contact reliability of a certain function of the
traditional cotnrol mode is limited by device, while after PLC is
adopted, the contact of this function turns into an internal
virtual address of the controller, whose service can be decided according to specific need completely.

新源热电公司自控系统 Automatic Control System of Xinyuan

Cogeneration Power Plant

北京和利时系统工程股份有限公司 Beijing Hollysys Co., Ltd

工程师级别 Engineer level

全厂区 Entire plant area

前进 Forward

历史 History

后退 Back

流程列表 Flow list

登陆 Log in

系统状态 System state

报警 Alarm

趋势 Trend

日志 Log

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 LK Series PLC Industry Solutions

报表 Report

打印图形 Printing graphs

主汽门关闭 Main steam valve closed

超速保护 Overspeed protection

#2 机超速 3420 转 #2 turbine overspeed 3420rpm

超速信号记忆状态 Memory status of overspeed signal

轴向位移大保护 Axial displacement protection

轴向位移大.-0.6mm Excess axial displacement.-0.6mm

轴向位移记忆状态 axial displacement

润滑油压低保护 Lubricating oil pressure low protection

润滑油压低- Lubricating oil pressure low

润滑油压记忆状态 Memory status of lubricating oil pressure

发电机故障保护 Generator failure protection

发电机故障 Generator failure

发电机故障状态记忆 Memory status of generator failure

主汽门关闭控制信号 Control signal of main steam valve closed

主汽门已经关闭 Main steam valve closed

背压高保护 High backpressure protection

背压高记忆状态 Memory status of high backpressure

保护复位 Protection reset

Output signal applies DO output card with isolated and independent circuit, and the load capacity of
output contact can fully satisfy the requirement of actuator element in the system.

Basic functions of ETS inlcude relevant switching value

monitoring and trip protection.

Under various working conditions, ETS can output alarms and

trip signals when normal operation of thermodynamic system
and equipments can not be guaranteed or equipment safety is
endangered. The ETS system composed by LK seris PLC is
an independent system, whose operaiton is independent of
DCS system, and it exchanges data with DCS system via DP
bus. The communication between ETS and DCS is only used
for monitoring, and communication itnerrupted or DCS failure
will not influence normal operaiton of ETS system.

新源热电公司自控系统 Automatic Control System of Xinyuan

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 LK Series PLC Industry Solutions

Cogeneration Power Plant

北京和利时系统工程股份有限公司 Beijing Hollysys Co., Ltd

工程师级别 Engineer level

全厂区 Entire plant area

前进 Forward

历史 History

后退 Back

流程列表 Flow list

登陆 Log in

系统状态 System state

报警 Alarm

趋势 Trend

日志 Log

报表 Report

打印图形 Printing graphs

高加电磁阀动作保护 Solenoid valve action protection of HP heater

高加加热器水位保护 Water level protection of HP heater

1#高加高三值保护 HHH protection of 1# HP heater

#2 高加高三值保护 HHH protection of 2# HP heater

保护复位 Protection reset

高加加热器保护记忆 Protection memory of HP heater

控制高压旁路电磁阀 Control solenoid valve of HP heater Bypass

高加保护动作联系 Protection action relation of HP heater

抽汽逆止门保护 Extraction check valve protection

发电机油开关跳闸 Outlet circuit breaker trip of generator

#2 机抽汽逆止门关闭 Extraction check valve closed of #2 turbine

2 机主汽门关闭 Main steam valve closed of #2 turbine

至电气主控室 To electric main control room

#2 机功率限制信号 Power limit signal of of #2 turbine

润滑油压低 Lubricating oil pressure low to 0.55kg

启动交流润滑油泵 Start AC lubricating oil pump

主汽门关闭保护 Protection of Main steam valve closed

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 LK Series PLC Industry Solutions

启动直流润滑油泵 Start DC lubricating oil pump

抽汽逆止门大连锁 Big interlock of extraction check valves

停止盘车 Stop turning gear

#1、#2 高加水位高一值 H of #1, #2HP heaters

关#1、#2 高加紧急放水电动门 Close emergency drain electric valves of #1,

#2HP heaters

#1、#2 高加水位高二值 HH of #1, #2HP heater

开#1、#2 高加紧急放水电动门 Open emergency drain electric valves of #1,

#2HP heaters

ETS device is arranged soly in a small cabinet, and each protective item of the system is equipped with
independent protection activate/deactivate switch and a general protective switch. 24V power supply
used by ETS device needs to be monitored. The system is set with manual shutdown function, i.e.
buttons on operator table are directly connected with DEH trip relay by hard wire. On-line test of ETS
system will not influence normal action of unit protection, which means, in testing, if there is a protective
signal acted by logic judgement, ETS system can send out shutdown signal normally. Field input signal
is isolated with PLC by relay, to prevent inteference on the one hand and to guarantee the isolation
between redundancy PLC. And meanwhile, extension of field input signal is ensured (this signal shall
enter into SOE, etc.).

Application Features

The ETS system based on LK series PLC has the following performance features:

 High Correctness and High Reliability

Correctness and reliability are the key points of turbine ETS system. The system uses dual PLC
operating mode, which guarantees that the whole set of device is capable of realizing turbine trip
function under any condition. The problems of turbine “trip failure” or “unexpected trip happened in the
equipments previously are solved properly and thoroughly in designing process, hence high reliability of
the system is ensured in technology aspect. As to type selection of PLC, LK series PLC of Hollysys
Company has super quality and high cost performance, which ensures high reliability of the system in
hardware aspect.

 Strong System Function

As the programmable logic controller is characterized by small volume, high integration, fast operation
and large logic control capacity, beside state alarm, trip shutdown and other conventional functions,
on-line testing function is added to the whole program. The function aims to inspect the state of
peripheral elements such as pressure switch and solenoid valve during normal operation of the unit, so
as to improve safety coefficient of the whole device.

In addition, memory function of turbine trip first-out causes is added to help the operators understand the
first cause of shutdown at the first time, thus avoiding the previous situations that, several alarm
indications are displayed on the display panel, but the operators can not distinguish the first cause, or

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 LK Series PLC Industry Solutions

cannot find out the first cause as field situation keeps changing and indicator lamps going out. And
meanwhile, the existence of this function provides verification means for sequence of event (SOE). The
function can be written completely via program by using programming skills, without any need to add any
hardware equipment. When shutdown conditions are not met, it is unnecessary to execute this function
and take up the time for system inspection, therefore, monitoring and shutdown function of the system
can be realized to the largest extent.

 High Automation Level

As for signal processing, for example, the function of “delay”, formerly it requires the operator to keep
“pressing” the button, while now the operator only needs to “press once” the soft button, then the buzzer
will generate a sound. The requirement of maintaining several seconds before can be achieved by
“pulse per second” logic in the program. The function can be applied in a wide scope without “resource
shortage” problem during programming. Meanwhile, the system has the functions of some separating
devices, such as “timer”, “RS trigger” and “PID regulator”, etc. All these devices are virtual ones in PLC,
and the requirement of their functions can be fully satisfied. For the system, the applying quantity of
these devices is negligible and can be used as much as you like. Various states are clearly indicated on
state indicator lamps on DI and DO module panels of PLC, which is helpful for easy and convenient
troubleshooting.

Hardwire of the whole device involves only the signals determined to be input in and output from the
programmable logic controller, while control logic is completely programmed into EPROM. As to
requirement of function increasing and decreasing, you may download the program after modifying
program, to finish the content modification in EPROM. The working condition of the whole device shall
be monitored, including state simulation of signals, “off-line” or on-line debugging of control logic function,
etc. which can all be finished on a PC.

Ash Handling System

The task of plant ash handling system is to centralize, store and transport ash and slag produced after
boiler coal combustion to the designated places (i.e. ash yard, ash silo). The whole ash handling system
is a very important support system in fossil-fired power plants and also the important system which
guarantees normal continuous power generation of the units. Bottom ash handling system includes
bottom ash discharge system, bottom ash/water separation system and fly ash/bottom ash conveying
system generally; while fly ash handling system includes fly ash system, vessel pump, fly ash discharge
pipeline, ash-removing air compressor system and ash silo system, etc.

LK series PLC of Hollysys Company of high cost performance is adopted for the whole system to
conduct centralized control upon the equipments, while upper level computer system of dual CPU hot
standby provides security guarantee for the software. The upper level computer system possesses
perfect configuration function, by which automation level of the plant ash handling and production can be
improved, normal operation of the units is ensured and cost for maintenance is greatly reduced as there
is little maintenance& repairing work. Staffs of monitoring system are able to comprehend material level
and operating state of vessel pumps accurately, hence they can acquire effective signal basis for
operations of vessel pumps, by which operating efficiency of vessel pumps and other equipments will be

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 LK Series PLC Industry Solutions

boosted and equipment depreciation and energy waste will be reduced. At last, the whole system is
capable of operating normally as per its process requirements, providing powerful guarantee for normal
running of the power plant.

Design of Centralized Control System

As process equipments of plant ash handling

system are dispersed with long distance and
wide range, relevant conditions, interlock
relation and pressure parameters shall be
strictly abided by during operation control. In
view of these features, we apply a
full-automation program control with PLC as
the core. PLC control cabinets and upper level
computers are set in the ash handling control
room, and PLC control station communicates
data with monitoring computers via Ethernet.

Figure 1 Diagram of Ash Handling Automation

Control System

图1 除灰除渣自动化控制系统图

打印机 Printer

操作员站 Operator station

电厂 SIS 系统 Power plant SIS system

100Mbps 环形工业以太网 100Mbps ring industrial Ethernet

LK 大型 PLC LK large-sized PLC

冗余 PROFIBUS-DP 总线 Redundancy PROFIBUS-DP bus

除灰系统 PLC 控制站 PLC control station of ash handling system

The field PLC control system is an intelligent control system subordinate to but relatively independent of
central control system, which receives parameter setting and operating instructions transmitted by
central control monitor and controls the ash handling system in reserving mode. In this way, the
centralized monitoring management of the whole system is guaranteed on the one hand, and real-time
of various protections is ensured on the other hand, therefore, distributed control and centralized
management can be achieved materially.

The field system is composed by LK series PLC and is equipped with central processing module,
network module, communication module, input module & output module of switching value, and input
module & output module of analog quantity, etc.

The monitoring computer applies dual CPU redundancy configuration and is installed with monitoring
configuration software of FacView. Two upper level computers are connected via Ethernet. In normal
condition, host computer can communicate with PLC control system, and when any abnormal happens

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 LK Series PLC Industry Solutions

to the main computer, the subordinate computer can communicate with PLC control system, with
synchronous data backup. Thus, data consistency and completeness can be ensured and safe& stable
production be realized.

The operators can conduct centralized monitoring upon ash handling control system according to
monitoring pictures of process flow design via upper level computers (LCD operator station); LCD
picture displays process flow, measuring parameters and equipment running conditions; the system has
such functions as displaying of data acquisition, management of data storage, alarm output, storage of
historical data and generation of report forms, etc. and is connected with network printer, for convenient
generating various necessary report forms& files in production process. The system is capable of
displaying parameter off-limit alarm and failure of control objects (signal alarming function) in different
colors; and be capable of printing the measured parameters and alarm signals, etc. (function of
recorder).

The system applies dual circuit power supply, which can be served as standby for each other and
automatically switched in power supply cabinet. When the working power supply fails, it will switch to
standby power supply automatically, but not influence normal operation of the control system, therefore,
any part of the system will not lose power if any channel of power supply fails. In order to ensure the
power supply uninterrupted, the system is connected with UPS device, which further ensures the
stability of system power.

Local operating box is installed near the process system equipments, on which auto/manual changing
switch and manual operated switch are set for the convenience of debugging before equipment auto
operation and maintenance after failures happened during the operation.

System Functions

According to demand of system process, the system is designed with abundant picture displays, which
vividly and dynamically display the layout of ash handling vessel pump and ash conveying pipeline&
valve, and meanwhile the system uses different colors to reflect operating states of the equipments. The
system is set with simulation, remote operation, automatic and manual control functions, which can
realize multiple types of control upon the equipments. Upper level computer monitoring system can
display time, current and pressure, etc in the way of bar graphs and trend graphs to form effective data
analytical graph. With perfect alarm processing, alarm pictures will prop up automatically to display the
alarm detail and the alarm will be recorded when there is any alarm appeared to the system, for
convenience of query and printing. In order to enhance system security, corresponding protective
measures shall be taken automatically according to fault type when any fault occurs to the system, and
shall have protective functions against overcurrent,
overload and abnormal medium, etc. Hardware and
software configurations of the system possess
expandability and can be expand to auxiliary control
system of the whole power plant conveniently, so as to
realize centralized control of the whole plant.

 Display of Process Flow Diagram

The process flow diagram includes operating&

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monitoring diagram of #1 boiler negative pressure system, which is used to conduct real time monitoring
and operations upon #1 boiler; operating& monitoring diagram of #2 boiler negative pressure system,
which is used to conduct real time monitoring and operations upon #2 boiler; monitoring diagram of
negative pressure system, used to conduct real time monitoring upon the negative pressure system;
monitoring diagram of vessel pump system, used to conduct real time monitoring upon positive pressure
vessel pump system.

仓 A1、A2、A3（B1、B2、B3）泵 Vessel pumps A1, A2, A3 (B1, B2, B3)

压力设置 Pressure setting

下限 Lower limit

上限 Upper limit

上上限 Ultimate upper limit

工作参数 Working parameters

料位监控计数 A1、A2、A3（B1、B2、B3） Material level monitoring counting A1, A2, A3 (B1,

B2, B3)

输送总数值 Total conveyed value

输送时间 Convey time

输送次数 Convey times

仓泵手动 Vessel pump manual

仓泵自动 Vessel pump auto

时间设置 Time setting

料位监控 Material level monitoring

进料时间 Feeding time

加压监控 Pressuring monitoring

输送监控 Convey monitoring

投入 On

退出 quit

报警复位 Alarm reset

 Data Management

The system is to conduct data acquisition and reflects on simulated pictures, generate real-time report
forms via report form tool and conduct storage via historical record function, so as to generate historical
trend and historical report and provide reliable basis for process data analysis. The system is capable of
generating files upon these analyzed data result conveniently, for outputting or storing purpose.

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 System Alarm Function

With perfect alarming function, the system adopts

different colors on equipment monitoring pictures to
represent states. Analog quantity is set with limit alarm,
while switching value is set with state transition alarm,
and general alarm list picture is set specially to display
all of the alarm states and relevant information. The
system is equipped with voice alarm, to generate
voice prompt for the convenience of providing alarm
information for staff and conduct corresponding
disposal to accidents. The alarms can be stored as
basis of post disturbance review (PDR).

1#、2#、3#、4# 输灰管 1#, 2#, 3#, 4# Ash conveying pipes

1#、2# 灰库 1#, 2# Ash silo

加热器 Heater

1#、2# 搅拌机 1#, 2# agitator

1#、2# 散装机 1#, 2# Bulk loader

1#、2# 气化风机 1#, 2# Gasification fans

 System Network Function

By using dual CPU hot standby function of monitoring configuration software, the system configures
these two upper level computers of monitoring center in redundancy mode, so as to ensure system
security, realize uniform processing of historical data and guarantee completeness& reliability of the data.
Network expandability provides communication interface for plant auxiliary control system, for
convenient communication.

 Failure Query and Disposal

During system running, industrial personal computer honks to indicate an alarm when there is any failure
occurred, then the operator can switch the pictures to home screen and click the button of “alarm list” to
open alarm list picture for query.

The operators can conduct troubleshooting at corresponding locations on site according to prompt in
description item of failure “alarm list”.

 Event Recording& Query

The system provides event recording and query function (mainly for vessel pump system), i.e. available
to inquire action of each valve so as to aid the fault query.

Application Features

Ash handling control system adopts the control mode of LK series PLC for control and LCD for
monitoring, which is of advance technology, perfected functions and powerful logic, thus ensures safe

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and reliable operation of plant ash handling control system. The system has the following features as:

 The automation control device adopts full-automatic program control, with high automation
level. The system operates in timing cycle, with little manual intervention.

 The monitoring methods are complete and reliable. You may observe and control the running
conditions of ash handling control system on LCD. With LK series PLC of dual CPU hot
standby function, switching can be conducted when failures happen to LCD, so as to ensure
normal operation of the system.

 LCD control mode improves the cost performance and meanwhile avoids misoperation and
failure operations caused by poor contact or bad quality of the traditional control switch under
severe environment of power plants.

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Metallurgy

Metallurgy is an important industry related to national economy and people's livelihood, also an industry
with intensive information and higher level of automation. With the development of computer technology,
digital control technology and network communication technology, the metallurgy industry has entered a
brand-new age.

Blast Furnace System for Iron Making

Blast furnace iron making is the main method for iron making, also
an important part of iron & steel production in modern times. This
method is developed and improved from ancient shaft furnace iron
making. Though many new iron making methods have been
researched and developed in countries throughout the world, iron
produced by this method still accounts for over 95% of total world
iron output due to good technological and economic index, simple
process, large production capacity, high labor productivity and low energy consumption of blast furnace
iron making technology.

During production by blast furnace, iron ores, cokes and fusing agent (limestone) for slag-forming are
loaded from furnace top, and the preheated air is blown in from tuyeres circumferentially arranged on
lower part of the furnace. Carbon in coke (some blast furnaces blow in auxiliary fuels such as coal
powder, heavy oil and natural gas) combusts with oxygen in the air blown in under high temperature,
which generates CO and H2, during this ascending process, oxygen in iron ores is removed and iron is
obtained from this reduction process. The molten iron is released from iron tapping hole. Irreducible
impurities in iron ores bond with fusing agents like limestone to form slag discharged out from slag notch.
The gas generated is led out of furnace top and used as fuel for hot air oven, heating furnace, coke oven
and boiler after dust removal.

Aluminum Oxide

Aluminum oxide production technology is to treat aluminum ores by alkali

to change aluminum oxide in ores into sodium aluminate solution.
Impurities such as iron and titanium in ores and the vast majority of silicon
become insoluble compounds. Insoluble residue is separated from the
solution, washed, discarded or comprehensively utilized for reclaiming
useful components. Pure sodium aluminate solution is decomposed and
the precipitated into aluminum hydroxide which is separated from mother liquid, washed and roasted,
accordingly aluminum oxide product is obtained. Mother liquid for decomposition can be recycled for
treating another batch of ores.

Copper Smelting

Copper is a nonferrous metal closely related to mankind, and it is widely

used in fields such as electrical, light industry, mechanism manufacture,
construction industry and machinery, and its consumption is only second to
aluminum among nonferrous metals.

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Copper smelting methods can be classified into two categories, one is pyrometallurgy and the other is
hydrometallurgy. For the time being, over 85% of refined copper output is reclamation by pyrometallurgy
from copper sulphide concentrate and secondary copper, only 15% or so is produced by
hydrometallurgy.

Iron-making Blast Furnace

Blast furnace control system mainly covers furnace body control,

feeding and batching control, hot-air oven control, dedusting system
control, etc.. Automatic control system for blast furnace iron making is
to guarantee that the iron making process is continuous and under real
time monitoring, thus to ensure four main issues on blast furnace
operation: correct batching and timely feeding into furnace in a certain
sequence; controlling furnace charge material’s uniform falling;
regulating furnace charge material’s distribution and keeping it well contact with hot gas flow; and
maintaining the whole blast furnace under proper hot state.

Automatic control system for blast furnace has characteristics such as composition by many devices at
dispersed locations, strong interlocking among equipment, bad equipment operating environment and
high requirements on safety and reliability. Blast furnace control system based on LK series PLC of
Hollysys Company not only considers characteristics and requirements on blast furnace iron making
system, but fully utilizes LK PLC’s advantages such as high reliability, outstanding performance, rich
functions, good expandability and convenient use, consequently puts forward highly pertinent and
special solutions.

System Design

Blast furnace control technology is a collection of machinery and electricity control and computer
application and a the centralized and distributed automatic control system with core as LK series PLC of
Hollysys Company and this system consists of one central control room and four control stations for
charging system, furnace body, hot-air oven and dedusting and the system uses 100Mbps optical
industrial Ethernet for data communication. Layout and network configuration of automatic process
monitoring system is shown as figure 1.Importance shall be attached on charge material batches control
program, bunker and batching control, charge material flow governing valve opening control, chute tilting
and rotating control; charging skip’s winding, trial rod’s winding, charge distributor’s tilting charging
system, hot air and bag-type dust remover shall meet not only fundamental technological requirements
but also those specified by the design.

To guarantee safe running of various technological processes, all control stations use LK redundancy
system and support power redundancy, CPU redundancy and bus redundancy, and all modules support
hot plugging, which highly improves safety and reliability of the system.

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Figure 1 Schematic Diagram for Blast Furnace’s Automatic Control System

打印机 Printer
操作员站 Operator station
工程师站 Engineer station
UPS 电源 UPS power
100Mbps 环形工业以太网 100Mbps ring industrial Ethernet
LK 冗余系统 LK Redundancy system
上料操作站 Charging operation station
本体操作站 Furnace body operation station
热风炉操作站 Hot-air oven operation station
卸灰操作站 Ash discharge station
冗余 PROFIBUS-DP 总线 Redundancy PROFIBUS-DP bus
槽下、上料系统 PLC 控制站 Under-chute, charging system’s PLC control station
高炉本体 PLC 控制站 Blast furnace body’s PLC control station
热风炉 PLC 控制站 Hot-air oven’s PLC control station
卸灰系统 PLC 控制站 Ash discharge system’s PLC control station

There are 2 operator stations and 1 engineer station in central control room. One is chief operator station
for displaying blast furnace material monitoring and operating screen and charging monitoring and
operating screen; the other is mainly used for displaying technical parameters on production operation
and images such as zone map and curve diagram, and both can serve as standby for each other.
Operators observe displaying and working state on computer monitor screen and control various
equipment. Engineer station is with functions such as having right to configuring and operating various
systems, setting charging sequence, displaying current charging skip’s number, periodic time, program
information, displaying production technology process and printing programs.

In addition, various stations are provided with under-chute operation station, charging operation station,
furnace body operation station, hot-air oven operation station and bag-type dust remover operation
station to adapt to process operation. All digital output points are electric isolated by relays with external
equipment, and modules with optoelectronic isolators are used for all analogy input and output signals.

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 Communication Network

The whole automatic system consists of a secondary-stage control system and a two-layer
communication network. System integrity and reasonability are guaranteed to ensure system’s
automatic running.

 Industrial Ethernet: blast furnace’s four control stations are able to independently complete
their individual tasks. High-speed industrial Ethernet is used to link independent control
stations and operation stations with central control room’s operation stations and engineer
station according to demand of production process to realize resource sharing, mutual use of
data and images, which forms an integral process monitoring system. Ethernet’s
communication speed is 100Mbps and the transmission medium is optical fiber.

 PROFIBUS-DP field bus: PLC main stations of all control stations have data communication
via PROFIBUS-DP field bus with their individual I/O stations. The communication speed is
1.5Mbps and transmission medium is shielded twisted pair (STP).

 Operation Mode

The entire operation system consists of operation stations and operation platforms. Operation stations
realize centralized manual and automatic control, mainly used for setting technological and electrical
parameters, selecting operation mode, controlling general operations before and after furnace running,
including automatic control and soft manual control of various electric-control equipment on site.
Operation consoles are mainly used for manual operation and implementation of manual intervention
under automatic mode.

System Functions

This system is a computer-aided control and management

system integrating sequence control, process control, data
acquisition, conditions monitor and data management. The
system’s functions are controlling of switching value of motors,
valves and complete electromechanical equipment, including
group interlocked starting, group interlocked closing,
inter-group automatic interlocked control, inter-group
single-step interlocked control, system single-step debugging;
acquiring and processing process control data (including
switching value and analogy) and perfect alarming; displaying,
verifying, recording and printing of switching value and
analogy alarm; dynamic displaying of process flow diagram
images which are of free switchover; displaying and printing of
history curve, real-time curve, electrical instrument diagram
and bar chart.

矿槽控制 Ore chute control

焦自动 Coke automatic
焦手动 Coke manual
矿自动 Ore automatic
矿手动 Ore manual
非常手动 Emergency manual

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矿槽上料控制 Ore chute charging control

1#焦筛 1# coke screen
2#焦筛 2# coke screen
入 In
切 Changeover
西侧 West side
焦1 Coke 1
焦2 Coke 2
焦3 Coke 3
焦4 Coke 4
东侧 East side
3#焦筛 3# coke screen
4#焦筛 4# coke screen
周期车号 Periodic are number
西侧焦称量 West-side coke weighing
西侧矿称量 West-side ore weighing
东侧焦称量 East-side coke weighing
东侧矿称量 East-side ore weighing
1#碎焦皮带 1# crushed coke belt
烧5 Sintered 5
杂2 Impurity 2
烧2 Sintered 2
杂1 Impurity 1
烧1 Sintered 1
球2 Ball 2
球1 Ball 1
到顶 To top
空 Empty
满 full
焦 Coke
球3 Ball 3
球4 Ball 4
烧3 Sintered 3
杂3 Impurity 3
烧4 Sintered 4
杂4 Impurity 4
碎焦皮带解锁 Crushed coke belt unlocking
碎矿皮带解锁 Crushed ore belt unlocking
1#碎矿皮带 1# crushed ore belt
1#矿石皮带 1# ore belt
2#矿石皮带 2# ore belt
开 On
关 Off
1焦 1 coke
1矿 1 ore

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2矿 2 ore
2焦 2 coke
闸门禁开 Gate control open
称斗模拟 Weighing hopper simulation
皮带操作 Belt operation
1#焦斗 1# coke hopper
1#矿斗 1# core hopper
开 On
关 Off
手动 Manual
控制 Control
停 Stop
模满 Simulating full
模空 Simulating empty
西车号 West car number
西空车 West empty car
装焦 Loading coke
装矿 Loading ore
东车号 East car number
东空车 East empty car
#2 矿斗 #2 ore hopper
#2 焦斗 #2 coke hopper
故障复位 Fault resetting
矿槽监控 Ore chute monitoring
高炉炉顶 Blast furnace top
液压站 Hydraulic station
参数设定 Parameter setting
周期及配料设定 Period and batching setting
自动 Auto
西车上 West car up
东车上 East car up
急停 Emergency stop
手动布料方式 Manual distributing mode
环布 Circular distribution
扇布 Sector distribution
点布 Point distribution
西料车到底 West charging car to bottom
主卷扬就绪 Main hoist in place
主卷扬运行 Main hoist running
料流阀 Charge flow valve
下密 Lower seal
开度 Opening degree
西尺清零 West scale clearing
东尺清零 East scale clearing
西尺 West scale

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东尺 East scale
倾动 Tilting
旋转 Rotating
反转 Reversing
上次料线 Last-time charge line
圈数 Number of turns
圈 Turns
度 Degree
顶压 Top pressure
布料代号 Distributing code
下料批数 Number of charging batches
东车上行 East car ascending
东料车到底 East distributing car to bottom

重叠的两个图中处于下方的图：

受料斗满空模拟 Receiver hopper full and empty simulation

满 Full
空 Empty
料空延时 Charge empty delay
下罐满空模拟 Lower bucket full and empty simulation
料位选择 Charge level selection
时间 Time
秒 Second
时间 Time
布料器控制 Distributing device control
旋转方向 Rotation direction
逆时针 Counter clockwise
α 上升 αrising
β 正转 βforward rotating
α停 αstopping
β停 βstopping
α 下降 αfalling
β 反转 βcounter rotating
α 调角 αangle modulation
度 Degree
α 不动 αimmobility
禁止下料 Forbidding blanking
强制布料 Forced blanking
手动布料方式 Manual blanking mode
环布 Circular blanking
扇布 Sector blanking
点布 Point blanking
空 Empty
西料车到底 West charging car to bottom
主卷扬就绪 Main hoist in place

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主卷扬运行 Main hoist running

西放散阀 West discharging valve
高炉炉顶控制 Blast furnace top control
东放散阀 East discharging valve
炉顶阀门 Valve on blast top
到顶 To top
车数 Car number
矿 Ore
柱塞阀 Plunger valve
上密 Upper seal
一次均压阀 Primary equalizing valve
二次均压阀 Secondary equalizing valve
均压 Pressure equalizing
罐压 Tank pressure
满焦 Full coke
料流阀 Charge flow valve
下密 Lower seal
度 Degree
开度 Opening degree
西尺清零 West scale clearing
东尺清零 East scale clearing
西尺 West scale
东尺 East scale
倾动 Tilting
旋转 Rotating
反转 Reversing
上次料线 Last-time charge line
圈数 Number of turns
圈 Turn
度 Degree
顶压 Top pressure
矿槽监控 Ore chute monitoring
高炉炉顶 Blast furnace top
布料代号 Distributing code
东车上行 East car ascending
下料批数 Number of charging batches
东料车到底 East distributing car to bottom
满 full
故障复位 Fault resetting
液压站 Hydraulic station
参数设定 Parameter setting
周期及配料设定 Period and batching setting
炉顶控制 Blast furnace top control
全自动 Fully-automatic
手动 Manual

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非常手动 Emergency manual

柱塞阀 Plunger valve
开 On
停 Stop
关 Off
上密阀 Upper seal valve
下密阀 Lower seal valve
料流阀 Charge flow valve
放散阀 Discharging valve
均压选择 Pressure equalizing option
一均 Primary equalizing
二均 Secondary equalizing
一均制 Primary equalizing system
料尺控制 Charge scale control
西尺为准 West scale is prevail
提西尺 Raise west scale
西尺切入 West scale cut-in
放西尺 Put down west scale
停 stop
东尺为准 East scale is prevail
提东尺 Raise east scale
东尺切入 East scale cut-in
放东尺 Put down east scale
料线设定 Charge line setting
米 m
卷扬控制 Hoist control
自动 Automatic
手动 Manual
西车上 West car up
东车上 East car up
急停 Emergency stop

Blast furnace system is divided into four subsystems according to its functions and structures:
under-chute and charging control system, furnace body system, hot-air oven system and dedusting
control system. Control functions of each subsystem are
introduced in details as follows:

 Under-chute and Charging Control System

Material preparing system mainly controls bunker systems’

equipment such as feeder, vibrating screen and belt conveyer;
charging system mainly controls main hoist’s electrical
equipment and 2 sets of trial rods; distributor system on furnace
top mainly controls tilting and rotating of rotary distributor,
plunger valve, top-sealed valve and bottom-sealed valve; these

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systems are all equipped with control boxes beside.

氮气罐压力 Nitrogen tank pressure

上密阀温度 Upper seal valve’s temperature
下密阀温度 Lower seal valve’s temperature
料罐压力 Charge tank pressure
上阀箱温度 Upper valve box’s temperature
气密箱温度 Air-tight box’s temperature
炉顶温度 Furnace top temperature
炉顶压力 Furnace top pressure
东南 Southeast
西南 Southwest
西北 Northwest
东北 Northeast
炉衬温度 Furnace lining’s temperature
炉衬 Furnace lining
十八段冷却壁 18-stage cooling wall
十五段冷却壁 15-stage cooling wall
十四段冷却壁 14-stage cooling wall
十一段冷却壁 11-stage cooling wall
九段冷却壁 9-stage cooling wall
八段冷却壁 8-stage cooling wall
六段冷却壁 6-stage cooling wall
冷却壁温度 Cooling wall’s temperature
透气性 Air permeability
压差 Differential pressure
调压阀 Pressure regulating valve
混风阀位 Mixed air valve position
冷风压力 Cold air pressure
冷风流量 Cold air flow rate
料尺 Charge scale
东 East
西 West
炉底温度 Furnace bottom temperature
热风围管 Hot air enclosure pipe
炉底板 Furnace baseboard
炉基 Furnace foundation
一段冷却壁 One-stage cooling wall
热风温度 Hot air temperature
热风压力 Hot air voltage
混前温度 Temperature before mixing
冷风 Cold air
热风 Hot air
操炉监控 Furnace operation monitoring
炉体监视 Furnace body monitoring

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冷却水监视 Cooling water monitoring

顶压调节 Top pressure regulation
风温调节 Air temperature regulation
开始 Start
WinCC-运行系统 WinCC-operation system
操作监控 2-画图 Operation monitoring 2- drawing picture

 Blast Furnace Body System

Main items of blast furnace’s process detection and

control are divided into categories such as monitoring of
reaction in furnace, stabilizing operation of blast furnace,
protecting furnace body and personal safety etc., therefore,
the selection of blast furnace detecting instrument and control
system is very important. It directly influences blast furnace’s
normal production, furnace body’s maintenance and
equipment protection

热风炉工艺画面 Hot air oven process image

煤气放散阀 Gas discharging valve
煤气总管压力 Gas main pressure
煤气总管流量 Gas main flow rate
煤气 Gas
热风压力 Hot air pressure
热风温度 Hot air temperature
煤气支管流量 Gas branch pipe flow rate
空气支管流量 Air branch pipe flow rate
混风切断阀 Mixed air isolating valve
热风阀 Hot blast valve
调节阀 Control valve
煤气切断阀 Gas isolating valve
炉顶温度 Furnace top temperature
放散阀 Discharging valve
炉阀位调节 Furnace valve position regulating
炉煤气调节阀调节 Furnace gas control valve regulating
空气放散阀 Air discharging valve
煤气燃烧阀 Gas burning valve
空气燃烧阀 Air burning valve
炉膛压力 Hearth pressure
废气温度 Exhaust temperature
烟道阀 Flue valve
烟道阀差压 Flue valve differential pressure
废气阀 Exhaust valve
燃烧 Burning
炉 Furnace

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自动 Automatic
手动 Manual
焖炉 Hearth closed natural temperature decrease
送风 Blowing-in
冷风阀 Cold air valve
冷风阀差压 Cold air valve’s differential pressure
充风阀 Air charging valve
废气 Exhaust
炉顶温度 Furnace top temperature
炉废气温度 Furnace exhaust temperature
废气阀 Exhaust valve
放风阀 Air discharging valve
风机出口阀 Fan outlet valve
助燃风 Combustion air
冷风 Cold air
油压 Oil pressure
冷却水流量 Cooling water flow rate
冷却水压力 Cooling water pressure
冷风总管温度 Cold air main temperature
冷风总管流量 Cold air main flow rate
冷风总管压力 Cold air main pressure
换热器温度压力 Heat exchanger temperature pressure
烟囱 Chimney
工艺参数 Technological parameter
阀位调节画面 Valve position regulating screen
设备操作画面 Equipment operating screen
温度历史趋势 Temperature history trend
流量历史趋势 Flow rate history trend
液压站控制 Hydraulic station control
返回连锁运行 Return interlock running
充风阀设定 Air charging valve setting
除尘工艺画面 De-dusting process screen

 Hot-air Oven System

Generally, blast furnace is equipped with 3 hot-air ovens, and each of them has the working cycle
consisting of burning, blowing-in and oven changing, within each circulation, temperature in hot-air oven
periodically changes. Air temperature gradually lowers as the time of blowing-in goes by. Shortening
blowing-in time can increase air temperature, which consequently shortens combustion time. Therefore,
hot-air oven shall have an appropriate working cycle under a certain condition. Appropriate blowing-in
time is finally subject to combustion time necessary for guaranteeing hot-air oven’s adequate
temperature level (appearing as temperature at arch crown) and heat storage (appearing as exhaust gas
temperature), therefore, reasonable setting of hot-air oven’s combustion system (combustion control
system) and blowing-in system (oven changing control system) is critical for full exertion of hot-air oven
control system’s potential to meet technological requirements (increasing heat storage capacity and air
temperature), guarantee hot-air oven equipment safety, improve thermal efficiency and reduce energy

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consumption.

布袋除尘工艺画面 Screen of bag-type de-dusting process

北京森亦好公司 Beijing Senyihao Company
煤气总管压力 Gas main pressure
煤气总管温度 Gas main temperature
荒煤气压力 Raw coal gas
荒煤气温度 Raw coal gas temperature
氮气罐压力 Nitrogen tank pressure
氮气罐前温度 Temperature before nitrogen tank
大灰仓压差 Large ash bunker’s differential pressure
箱体压差 Box differential pressure
出口蝶阀故障 Outlet butterfly valve fault
反吹选择 Back blowing option
自动 Automatic
手动 Manual
卸灰选择 Ash discharging option
箱体阀控 Box valve control
打开 Opening
关闭 Closing
箱体反吹 Box back blowing
反吹 Back blowing
单体反吹 Single back blowing
自动反吹 Automatic back blowing
定压 Constant pressure
定时 Timed
在线 Online
离线 Offline
反吹初始化 Back blowing initailizing
单体卸灰 Single ash discharge
自动卸灰 Automatic ash discharge
参数设定 Parameter setting
压力上限 Upper pressure limit
反吹间隔 Back blowing interval
反吹时间 Back blowing time

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 LK Series PLC Industry Solutions

循环间隔 Cycle interval

大灰仓反吹间隔 Large ash bunker back blowing interval
卸灰间隔 Ash discharge interval
除尘温度趋势图 De-dusting temperature trend chart
除尘压力趋势图 De-dusting pressure trend chart
热风炉工艺流程 Hot-air oven process flow

 De-dusting System Function

Blast furnace gas dedusting device is ancillary facility of blast furnace and an important part during blast
furnace’s production process, and it aims to purify blast furnace gas and improve gas quality to create
conditions for full utilization of blast furnace gas. After treatment by gravity dust catcher, blast furnace
gas temperature is controlled within 80-300 , and it directly enters main box of bag-type dust remover
for purification, and the purified gas is supplied to users after pressure regulation. If gas temperature is
less than 8 or more than 300 , it is diffused via gravity dust catcher but not sent to main box of
bag-type dust remover.

System Characteristics

Based on Hollysys Company’s LK PLC blast furnace automatic control system, redundancy Ethernet
and PROFIBUS-DP bus network are used for connecting central control room’s computers with PLC
system’s master station, and connecting PLC system’s master station with remote I/O substation, which
forms a distributed control system with characteristics described in details as follows:

 Perfect and Powerful Function

It supports redundancy CPU configuration, with more powerful functions and faster speed. In addition, it
is equipped with various functional modules, able to fully meet users’ various site demands. It is able to
normally work even under bad and unstable industrial environment; non-fan design improves system
reliability; hot plugging is allowed for all modules during running.

 Redundancy Solution

Redundancy configuration is designed for blast furnace remote control system. The redundancies cover
power, CPU, Ethernet and PROFIBUS-DP bus, so failure of whichever will not stop the system, which
guarantees system reliability and safety to the uttermost extent.

 Centralized Management and Distributed control

Blast furnace control system is designed to be a network of master station/ remote I/O substation, and
the master station uniformly manages system equipment, while the remote I/O substation is responsible
for data acquisition and equipment driving. This system structure not only meets requirements for strong
interlocking among system equipments but also meets requirements on dispersed locations of system
equipment.

 Openness

Blast furnace control system is designed to be an open system with industrial Ethernet and
PROFIBUS-DP bus network which are the most widely used and open industrial communication
networks. The system supports softwares DDE, OPC, ODBC and SQL, and provides rich API interfaces,
convenient for system expansion or seamless connection of auxiliary control networks and MIS with
other subsystems.

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Aluminum Oxide

Aluminum is the second general metal in the world, and its output and
consumption are only second to those of iron and steel. It is a metal
material with supporting effect and strategic position in national economy.
Aluminum oxide is the main raw material for aluminum smelting and
production of 1 ton aluminum costs about 2 ton aluminum oxide. With
gradual enhanced emphasis on automatic production by some large-scale
aluminum oxide factories and use of new techniques and processes and improvement of equipment,
more and more importance has been attached on control and management of aluminum oxide
production process, and advanced detection system, analysis devices and control system have been
utilized.

Automatic control system based on LK series PLC of Hollysys Company is used in aluminum oxide
production, basically realizing automatic control of various production links and procedures. Complicated
production processes difficult to be described by mathematical model, such as ore grinding process,
intelligent control technology and soft measurement reasoning technology are used for measuring some
ore pump compositions difficult to be directly measured, which optimizes the control of main
technological parameters and production indexes, improves aluminum oxide production’s automation
level and management level and has significant promoting role for improving system reliability and
production continuity.

Typical Configuration Scheme

System configuration is as shown in figure 1, with the whole system divided into four subsystems
according to main procedures of aluminum oxide production. To guarantee system integrity, the system
is equipped with one monitoring center where all sub-procedures of the whole aluminum oxide
production can be monitored. To facilitate management and improve system’s informatization level, the
system can have web publishing via network server, which enables any authorized client to browse
system’s state via Internet at any place.

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Figure 1 Schematic Diagram of System Network Structure

打印机 Printer
监控计算机 Monitoring computer
网络服务器 Network server
客户端 Client
交换机 Switch
环形光纤以太网络 Ring optical fiber Ethernet
工程师站 Engineer station
操作员站 Operator station
冗余工业以太网络 Redundancy industrial Ethernet
LK 系统主站 LK system master station
冗余 DP 总线网络 Redundancy DP bus network
浆料制备系统 Slurry preparation system
熟料烧成系统 Clinker sintering system
种分、碳分系统 Seed and carbon composition system
熟料溶出系统 Clinker digestion system

 There are monitoring computer, network switch, printer, UPS and other office facilities in the
monitoring center, and they are connected with all subsystems of aluminum oxide
manufacturing plant via ring optical fiber Ethernet.

 Four subsystems are independent as well as integrated. Every subsystem is of Redundancy

network structure, equipped with equipment such as redundancy monitoring computer, LK
large-scale PLC, PLC cabinet and site I/O station. LK large-scale PLC is the core of the system
and completes monitoring of automatic flow control of aluminum oxide production process and
monitoring of equipment.

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Critical Process Control

 Clinker Sintering Process

Clinker sintering is a critical process of aluminum oxide production by sintering method, and its function
is to sinter raw slurry from raw material preparation procedure into
soluble solid sodium aluminate clinker in rotary kiln. Exhaust due
to combustion is discharged into atmosphere after three-level dust
remove respectively by gravity, whirlwind and static electricity, and
the clinker is sent to clinker bunker.

The overall objective of clinker sintering process is to realize that

the whole sintering process is stable in long term, with good
quality, high output and low consumption. In addition, running rate
of electric precipitator is improved and dust content at outlet and
alkali consumption is reduced; accidents due to coal loss are avoided and dust removal efficiency is kept
optimal.

 Process of Crystal Seed Decomposition and Carbonization Decomposition

Sintering decomposition process is divided into two parts: crystal seed decomposition and
carbonization decomposition. Stock solution with seeds and
crystal seeds continuously decompose in seed decomposing tank
and are stirred by compressed air from high pressure station, the
slurry afterward is send to the process of filtering and washing by
aluminum hydroxide. Stock solution with carbonaceous
compositions is placed in carbon decomposing tank, and purified
and compressed carbon dioxide is filled in for continuously
decomposing carbonaceous compositions and the slurry
afterward is send to the process of filtering and washing by
aluminum hydroxide.

 Process of Alkali Liquor Evaporation and Preparation

Evaporation process is equivalent to recycle bin during aluminum oxide production process and its
objective is to maintain water balance, to inspissate seed mother liquor from Bayer method or sintering
method to the density required by production and to remove impurities accumulated during production
process.

Alkali liquor preparation process is one of important aluminum oxide production processes, and its
task is to provide quality circulatory alkali liquor for workshops for high-pressure digestion, grating
grinding and raw material (by sintering method) grinding. Circulatory alkali liquor generated by Bayer
method is prepared out of mother liquor (for evaporation by Bayer
method), stock solution, liquid alkali and mother liquor with seed
(for evaporation by sintering method), and it is used for blending
material of feeding process of grating grinding, adjusting solid
content of feeding for high-pressure digestion and preparing raw
slurry for sintering.

 Processes of Digestion, Separation, Washing and Red

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Mud Discharge

Process of digestion and separation system is to send clinker from cooling machine to crusher via apron
conveyer and plate conveyer for medium crushing before it is transported to clinker bunker. Afterwards,
digestion mill is measured and fed by plate feeder, and red mud wash solution, carbonaceous mother
liquor and clinker is added with digestion mill of a certain proportion for crushing digestion. Digested
slurry is sent to classifier for size grading, and coarse grains is ground further and classifier’s overflow is
sent via digestion pump to settling tank for separating red mud.

Red mud washing and discharging are to back flush separated red mud for reclaiming alkali and
aluminum oxide in red mud, and it is a key link of aluminum oxide production system as far as saving
energy and reducing consumption are concerned.

Main devices of this process are ball grinder, classifier, adjustment notch, settler, wash settler and
discharged oil separating pump. They mainly finish control functions as follows:

 Detecting digestion mill’s charging quantity, adjustment notch’s liquid level, digestion mill tile
temperature, settler rake’s load, flocculating agent notch’s liquid level, oil station’s oil pressure
and temperature, settler’s L/S, settler’s temperature, oil separating pump’s pressure, red mud
chute’s liquid level and motor-current inspection of
all pumps.

 Controlling clinker charging and adjustment liquid.

 Automatic control of liquid-to-solid ratio of flow at

bottom of settling tank: is realized by adjusting
separated bottom flow rate by separating bottom
flow’s liquid-to solid ratio and settling bank rake’s
load.

 Automatic control of bottom flow’s liquid-to solid

ratio and discharged oil separating pump.

 Automatic control of liquid level of red mud chute: is realized by adjusting speed of red mud oil separating
pump.

System Characteristics

 The system running is highly stable. Redundancy LK PLC solution avoids the problem of
system stopping due to failure of system’s various links to the uttermost extent, which greatly
improves system stability.

 The system is of a large scale covering many comprehensive disciplines such as computer
technology, industrial control technology and measuring instrument technology.

 The system management is advanced and automatic, with high level of informatization.

 The system is with reasonable control program, scientific control strategy and fully meets
demand of aluminum oxide production line.

 The system is of good accessibility. System software platform provides many data access
modes such as OPC, DDE and ODB, which guarantees accessibility and is compatible with
third-party soft wares, realizing seamless linking.

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Crude Copper Smelting

Copper is a nonferrous metal closely related to mankind, and it is widely

used in fields such as electricity, light industry, mechanism manufacture,
construction industry and machinery, and its consumption is only second to
aluminum among nonferrous metals. Copper smelting methods can be
classified into two categories, one is pyrometallurgy, and the other is
hydrometallurgy. For the time being, over 85% of refined copper output is
reclamation by pyrometallurgy from copper sulphide concentrate and secondary copper, only 15% or so
is produced by hydrometallurgy.

LK series PLC of Hollysys Company is used for copper smelting, and the system is of high integration
level, flexible networking, strong anti-interference capability, applicable to copper smelting workshop
with strong magnetic interference, also it runs safely and reliably. Its product performance, network
structure and software functions reach advanced level of current industry. Moreover, PLC of LK series
supports online modification and program downloading, and all modules support hot plugging, which
makes maintenance more convenient and faster.

Process Flow

 Smelting

Copper ore concentrate is sent to charging bunker, measured by

electronic balance and conveyed by belt conveyer to kneading
machine, after it is kneaded, it is sent by belt conveyer to shuttle belt
charger on furnace top to be charged into closed blast furnace. Fusing
agents and fuel required by closed blast furnace (coke, quartzite,
limestone, blowing slag and blast furnace slag) are sent to respective
intermediate bins, and measured by electronic balance and sent by
belt conveyer to blast furnace. Oxygen-enriched air with 30% oxygen
content is blown into blast furnace and the melt after reaction self flows to fore hearth for clarification and
separation. Since converting furnace requires that copper matte is discontinuously emitted and
continuously blown in converting furnace, 0.12~0.2MPa compressed air shall be blown in. Operation
duration includes slag-forming stage and copper-forming stage. During slag-forming stage, quartzite is
charged in by electric feeder from furnace top discontinuously. Generated slag self-flows to slag casting
machine which automatically releases mould for cast slag to drop onto ground. The generated crude
copper self-flows to copper casting plant for ingot casting.

 Dust Collection

Fume containing dust about 65g/Nm3 and with a temperature

450~550 is discharged from top of blast furnace; dust of larger grain
is captured by internal settling chamber and rotoclone collector; fume
generated by converting furnace is fast cooled by spray cooler to
about 1100 -400 .Two fumes uniformly mix in mixing chamber, then
they are sent by high-temperature blower to electric dust precipitator
for purification, with dust content at outlet of electric dust precipitator
controlled under 0.5g/Nm3, then they enters acid making system.

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 Sulfuric Acid Zone

Mixed fume (300 ) from dust collecting system is sent to purification section. This fume is firstly sent to
one-stage dynamic wave scrubber where it is isolated, cooled and washed, and is separated by
gas-liquid separating tank, and the separated gas enters composite gas cooling tower for further cooling
and dust removing before entering two-stage tube electric demister for
removing acid mist, then the purified fume is sent to dry absorption
workshop section where moisture in fume is removed in drying tower by
spraying 93% sulfuric acid, after drying, fume with moisture ≤0.1 g/Nm3 is
sent by SO2 blower to conversion workshop. Conversion section employs
“3+1” four-segment double-contact technology and “ —— ” heat
exchange process flow. Cool SO2 from SO2 blower is heated by heat exchanger and oxidized to SO3
by catalyst layers of segment 1, 2, and 3 and sent to first absorbing tower for making sulfuric acid, and
cool SO2 from first absorbing tower is heated by heat exchanger and oxidized to SO3 by catalyst
layers of segment 4 and sent to second absorbing tower for making sulfuric acid, and residual off-gas is
discharged by chimney.

System Structure

This crude copper computer control system is divided into three levels namely production management
level, field control level and local control level, and it uses high-speed communication network for
sharing information and resource, with perfect control ability, high reliability, convenient and flexible
expansion ability. The system is designed according to process flow, realizing automatic control of
production process.

Figure 1 Schematic Diagram of System Network Structure

焙炼区域 Smelting zone

硫酸区域 Sulfuric acid zone
打印机 Printer
1#监控计算机 1# monitoring computer
2#监控计算机 2# monitoring computer
工业以太网络 Industrial Ethernet
LK PLC 主站 LK PLC master station

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Profibus-DP 总线网络 Profibus-DP bus network

1#循环水 1# circulating water
2#循环水 2# circulating water
焙炼车间 Smelting workshop
硫酸仪表配电室 Switching room for instruments of sulfuric acid
烟气收尘 Fume dust removal
原料库及配料系统 Raw material storehouse and batching system
3#循环水 3# circulating water

 Production Management Level

Master control room in smelting zone and that in sulfuric acid zone are respectively equipped with two
monitoring computers, one printer, UPS power and Ethernet switch, for data acquisition and display of
main processing equipment’s running state and technological parameters of production process. The
two computers are also used as I/O server on which monitoring software runs. The server is with
Redundancy configuration, fully realizing hot standby for two computers. Master control rooms in both
zones are linked by high-speed optical Ethernet, realizing share of data and resource. Moreover,
computers at other locations can easily link with it by LAN if necessary.

 Field Control Level

It is PLC control. One PLC master station is arranged respectively in smelting zone and sulfuric acid
zone according to functions of process zones. Both PLC stations acquire and control process data and
communicate with master stations via high-speed real-time industrial Ethernet; PLC master stations
communicate with respective remote I/O stations via Profibus field bus. Field control level is subject to
dispatching from production management level, but runs independent of production management level:
all field control stations continues to work normally when monitoring computer fails or is not put into use
or communication network fails, which has no influence on the whole technological process.

 Local Control Level

Generally, local control boxes are provided for installed field equipment for realizing equipment’s local
manual control. Local manual control is of top priority and is mainly used during equipment debugging
and maintenance stages.

Chemical Industry

Petrochemical industry is the pillar industry of national economy, and also one of the industries at the
highest level of automation. DCS and PLC automation control systems
are of special importance in processes of various production units in
the industry. They are like the eyes of production processes serving as
the brain and nerve to command and control chemical production
processes. They are also the keys to long, safe and stable operations
of various chemical units in an energy-efficient manner to optimize
operations and production management practices, and are
indispensable to APC strategies and the integration of management & control as well as large chemical
production processes.

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As one of the leading domestic DCS and PLC manufacturers, HollySys boasts
many senior process experts and excellent system designers in the petrochemical
industry and a capable R&D & construction team. It can provide users with a
complete set of specialized & industrialized solutions, comprehensive and
satisfactory technical advices, conceptual design and project implementation
services. HollySys has rich experiences in the practical applications of more than
1,000 sets of DCS & PLC systems within the petrochemical and chemical industries.
It also owns proprietary hardware and software technologies & patents and a professional base of
production, R&D and integration.

HollySys is an eligible manufacturer recognized by China Huanqiu Contracting & Engineering

Corporation which is the largest chemical design institute in China.

By virtue of excellent DCS systems, HollySys has become one of eligible suppliers for The Chemical
Company of BASF.

Salinization Plant

The salinzation plant uses deep brine as feedstock to conduct a series of

treatments including purification, clarifying filtration, vacuum evaporation,
concentration and crystallization. All these treatments constitute a
production and manufacturing process with closed circulation.. The whole
process contains two systems, namely, brine purification and co-production
of salt and sodium sulfate. Among them, the brine purification system
covers the raw brine pretreatment, bittern pretreatment and filtering
sections; while the co-production of salt and sodium sulfate system covers
tank battery, saltpetre evaporation, saltpetre drying and salt drying systems.

According to process requirements and overall configuration and with a view to the construction of the
information system of "integration of management and control", the sanilization plant designs and adopts
the computer monitoring system based on the HollySys’ LK series PLC. The system consists of a
computer monitoring station, field control station (PLC Station), Ethernet, and detection instruments and
others.

 Brine purification system is made up of a monitoring computer, a UPS, a HUB and a field
control station. The communication between monitoring computer and LK PLC is conducted
though the industrial Ethernet;

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 Co-production of salt and sodium sulfate system is made up of two monitoring computers, a
UPS, a HUB and a field control station. One monitoring computer is used as master server and
the other is slave server. Communication network between Monitoring computers and PLC
adopts the industrial Ethernet.

 The brine purification system and the co-production of salt and sodium sulfate system use the
industrial Ethernet for dada communication between them and their monitoring computers
could serve as the hot standby for each other.

System Structure

The computer control system in salination plant has a three-tier structure including production
management level, field control level and local control level. The system uses a high speed
industrial Ethernet (TCP/IP protocol) for connection in order to achieve information and resource sharing.
It has remarkable control capacity, very high reliability and convenient & flexible expansion capability.
The system design starts from the process flow to achieve the automatic control of production
processes.

 The production management level is

located in the control rooms of both brine
purification and co-production of salt and
sodium sulfate systems. Each system is
equipped with a monitoring computer to
acquire and display the process
parameter data of operating conditions &
processes of main process equipment.
These two monitoring computers are
used as I/O servers on which the
monitoring software runs. The servers
are Redundancy configurations and can 图 1 盐化厂自控系统图
be the hot standbys for each other. If
necessary, computers distributed at other places in the plant can easily connect to these
servers through LAN.

盐化厂局域网 LAN of Salinzation Plant

生产部 Production Department
厂长室 GM’s Office
总工室 Chief Engineer’s Office
打印机 Printer
操作员站 Operator Station
UPS 电源 UPS
打印机 Printer
操作员站 Operator Station
操作员站 Operator Station
UPS 电源 UPS
卤水净化系统 Brine Purification System
盐硝联产系统 Co-production of salt and sodium sulfate system
图 1 盐化厂自控系统图 Figure 1 Diagram of Automatic Control System in

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the Salination Plant

 The field control level is the PLC control level. Two PLC control stations are provided on the
basis of the functional zoning of process control. The PLC1control station is located in the
control room of brine purification whose data acquisition and control area consists of raw brine
pretreatment, bittern pretreatment and filtration sections. The PLC2 control station is located in
the control room of co-production of salt and sodium sulfate system whose data acquisition and
control area consists of a tank battery, saltpetre evaporation, saltpetre drying and salt drying
systems. The field control level is subject to the scheduling of production management level,
but it runs in a mode that is independent from the production management level. In the event
that the monitoring computer has faults or is not put in service, or that the communication
network has faults, field control stations can continue working without any impacts on the entire
process.

 The local control level switches the equipment to field manual mode to achieve the local
manual control of the equipment. The local manual control has a highest priority and is mainly
used in equipment commissioning and maintenance phases.

Communication Network
The automation control system in the salination plant is an open control system. In addition to sound
network communication capabilities, it has a function of communication with other control systems and a
standard external communication interface which can later be used to randomly extend the control
systems. Its MTBF is 1 million hours.

The system adopts the hierarchical network architecture with two levels - Industrial Ethernet and
PROFIBUS-DP to separate the real-time process data and operation monitoring data information from
non-real-time information and sharing resources information. These two levels use different networks, so
that the communication efficiency is effectively improved and the communication load is reduced.

 The Industrial Ethernet is used to exchange the data between control room’s monitoring
computers and field control station with a communication speed of 100Mbps;

 Profibus is used for the data communications between master field control station and I/O
sub-stations. The transmission medium use the shielded twisted pair wires and the
communication speed is 9.6k ~ 12Mbps (automatic adjustment);

 The communication speed of the industrial Ethernet is 100Mbps, the highest rate among all
network styles;

 The Industrial Ethernet can stably transmit large amounts of data at high speeds. This is a
great advantage to which other networks cannot compare;

 The use of TCP / IP protocol with best openness makes it easy to connect with other systems
and management networks.

Process Control Scheme

 Brine Purification System

The process control of brine purification system includes PID regulation of the raw brine flow,, liquid level
in the pressurizing tank and bittern flow, PID control of liquid level in the bittern front reactive tank and
interlock of filter liquid feeding pump.

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 PID control of bittern flow is used to regulate the
pneumatic valve at the bittern inlet so to control
the bittern flow to the set value. Any unstable
control of the bittern flow will be not conducive to
controlling the liquid level in the front bittern
reactive tank. By comparison between the
measured bittern flow value and preset value, if
the difference value is less than zero, then the
opening of pneumatic valve at the bittern inlet
should be reduced, and vice versa.

(Note: other PID regulation processes are the same as above.)

 Pump interlock: When the liquid level in the intermediate tank of raw brine is below the set
value, the filter feeding liquid pump should be stopped. When the liquid level in the
intermediate tank of bittern is below the set value, the filter feeding liquid pump should be
stopped.

原卤预处理 Raw brine pretreatment

工程师 Engineer

原卤中间槽液位 Liquid level in the intermediate tank of raw brine

原卤中间槽液位超限 Over limit of intermediate tank of raw brine

低限 Low limit

淮海盐化厂卤水净化系统 Brine purification system in the Huaihai salinzation

plant

原卤过滤器 Raw brine filter

溶液 Solution

原卤来自界外 The raw brine comes from the outside of battery

limit

NaOH 溶液去 2#折流槽 NaOH solution goes to 2# baffle tank

NaOH 来自槽车 NaOH comes from the tank car

原卤流量 PID 调节 PID regulation of raw brine flow

当前值 Current value

设定值 Set value

输出值 Output value

加热器 heater

1#折流槽 1# baffle tank

文丘里混合器 Venturitube mixer

预处理器 preprocessor

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 LK Series PLC Industry Solutions

加压容器罐液位 PID 调节 PID regulation of liquid level in the pressurizing

tank

汽水混合器 Water-steam mixer

设定 Setting

当前 Current

加压容器罐 Pressurizing tank

空气缓冲罐 Air buffer tank

压缩空气 Compressed air

压缩空气来自界区 Compressed air comes from the outside of battery

limit

至原卤后反应槽 To the back reactive tank of raw brine

来自冲堵水 From flushing and plugging water

去老卤系统 To bittern system

NaOH 溶液贮槽 Storage tank of NaOH solution

NaOH 溶液泵 NaOH solution pump

NaOH 计量泵 NaOH metering pump

至冷水桶 To the cold water bucket

至地沟 To trench

冷凝水来自老系统 Condensate water comes from the old system

前反应槽 Front reactive tank

加压泵 Booster pump

泥浆至地沟 Slurry goes to the trench

NaOH 溶液泵 NaOH solution pump

配制槽 Compounding tank

主菜单 Main menu

原卤预处理 Pretreatment of raw brine

老卤预处理 Pretreatment of bittern

过滤部分 Filtered part

趋势图一、二、三 Trend chart 1, 2, 3

当前报警 Current alarm

报警记录 Alarm logging

操作记录 Operating record

备用 standby

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 Co-production of Salt and Sodium Sulfate System

The process control of co-production of salt and sodium

sulfate system includes PID regulation of liquid level in the
seal water tank, PID regulation of liquid level in
EV302/EV303/EV304 evaporation tanks, PID regulation of
liquid level in salt slurry drum as well as the liquid level in
the saltpetre slurry drum.

 PID regulation of EV301 evaporation tank level is

to regulate the outlet pneumatic valve of
evaporation tank EV301 to control EV301
evaporation tank level to the set value. By comparison between the measured level value of
EV301 evaporation tank and pre-set value, if the difference is less than zero, the openness of
out let pneumatic valve for the EV301 evaporation tank should be reduced; if the difference is
greater than zero, then the outlet pneumatic valve openness of EV301 Evaporation tank should
be increased.

(Note: other PID adjustment processes are the same as above.)

过滤部分 Filtered part

原卤预处理 Raw brine pretreatment

工程师 Engineer

原卤中间槽液位 Liquid level in the intermediate tank of raw brine

原卤中间槽液位超限 Over limit of intermediate tank of raw brine

低限 Low limit

淮海盐化厂卤水净化系统 Brine purification system in the Huaihai salinzation

plant

压缩空气 Compressed air

去折流槽 To baffle tank

原卤过滤器 Raw brine filter

老卤过滤器 Bitter filter

至原卤过滤器界区 To battery limit of raw brine filter

至老卤过滤器界区 To battery limit of bitter filter

原卤中间槽液位 PID 调节 PID regulation of intermediate tank of raw brine

level

老卤中间槽液位 PID 调节 PID regulation of intermediate tank of bitter level

设定 Setting

当前 Current

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手动 Manual

泵联动 Pump interlock

阀联动 Valve interlock

自预处理器 From preprocessor

至地沟 To trench

生产上水 Water feeding to production

自澄清槽 From clatifying tank

自 Na2CO3 计量泵 From Na2CO3 metering pump

Na2CO3 溶液 Na2CO3 Solution

后反应槽 Back reactive tank

原卤中间槽 Intermediate tank of raw brine

过滤器进液泵 Filter liquid feeding pump

酸洗液进液泵 Liquid feeding pump of acid-washing solution

酸洗液贮槽 Acid-washing solution storage tank

老卤中间槽 Intermediate tank of bitter

老卤后反应器 Bitter back reactor

过滤静老卤贮槽 Filter bitter storage tank

过滤原盐水贮槽 Filter raw brine storage tank

主菜单 Main menu

原卤预处理 Pretreatment of raw brine

老卤预处理 Pretreatment of bittern

过滤部分 Filtered part

趋势图一、二、三 Trend chart 1, 2, 3

当前报警 Current alarm

报警记录 Alarm logging

操作记录 Operating record

备用 Standby

Coal Water Slurry

The coal water slurry (CWS) is the new technology developed in 1970s resulting from worldwide oil crisis,
which is used to substitute coal for oil. The technology is used for grinding coal, water and a small
amount of additives, and then mixing them with water evenly. In the presence of chemical additives, a

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coal-based fluid fuel similar to oil that is flowable comes out eventually. Its concentrations is generally 60
to 70%, its viscosity 1 ± 0.2Pa.s, the average particle size 50µm, and heat productivity from 18.8 to
20.1MJ/kg. The CWS has good mobility and stability which could be stored and transported like the
petroleum and has outstanding features of safety and non pollution. This clean fuel using coal as a
substitute for the oil well matches the present condition of our country.

Process Flow

A simplified process flow chart is shown in Figure1. The

CWS production flow mainly includes the monitoring of
crushing shop, slurry making shop, slurry storage shop,
and chemical feeding shop. Among them, the control of the
slurry making shop is the core of the whole control system.

图1 水煤浆工艺流程图

原煤破碎 Raw Coal Crushing

精煤缓冲仓 Fine Coal Surge tank

药剂车间 Chemical agent workshop

水 Water

稳定剂 Stabilizer

给水装置 Water Feeding Unit

给药装置 Chemical dosing Unit

球磨机 Ball Mill

合格 Qualified

不合格 Unqualified

储浆车间 Slurry Storing workshop

图1 水煤浆工艺流程图 Figure 1 CWS Process Flow Diagram

Raw coal crushed in crushing workshop is sent by the conveyor belt to the fine coal surge tank of slurry
shop. Stabilizer and water are pumped from chemical dosing shop to slurry making shop. Start feeding
devices to feed coal/water/chemical to a ball mill in proportions for grinding. The CWS produced is
measured by concentration analyzer. Qualified products are sent by screw pump to the slurry storage
shop, while unqualified CWS is sent to the inlet of ball mill for re-grinding.

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System Design

Based on the "centralized management and

decentralized control" mode, a good open
monitoring system is designed to be integrated
with process control, monitoring and computer
scheduling management. The automation control
system of CWS uses the LK Series PLC of
HollySys to monitor and control the process and
production equipment, including acquisition and
automatic regulation of field temperature, pressure,
flow, level signals; control of field control valves;
and control & operation monitoring of field motors
图 2 系统网络结构示意图
and converters. The system consists of 1 CCR, 2 master PLC control stations and 5 remote I/O stations.
Between CCR monitoring computers and PLC control stations, a high speed industrial Ethernet (TCP/IP
protocol) is used for connection in order to achieve the sharing of information and resources, which has
a sound control capacity, high reliability and easy & flexible expansion capacity. Between PLC control
stations and remote I/O stations, redundancy PROFIBUS-DP is used for data communication.

中央控制室 CCR

打印机 Printer

操作员站 Operator Station

UPS 电源 UPS

100Mbps 环形工业以太网 100Mbps Ring Industrial Ethernet

PLC 控制站（破碎间） PLC Station #1 (Crushing Shop)

PLC 控制站（制浆、装浆） PLC Station #1 (Slurry Making & Loading Shops)

图 2 系统网络结构示意图 Figure 2 Schematic Diagram of System Network

Architecture

Process Control Strategy

The zoning philosophy of the whole process automation system is based on composition of the system
and process flow of production.

 Coal Receiving Pit to Surge Tank

Surge tank level gage is equipped with the electric gate of high and low material level linkage. Also, it
may provide feed rates for operators. In case of any shutdown of the above equipments due to failure,
stop all the power equipment at the last level.

This workshop section includes the current monitoring of two crushers and storage scraper coal feeder,
status indication and control of power equipments, stock level monitoring of 3 bunker bins as well as the
monitoring of coal conveyer belt scale. The current monitoring, off-tracking and rope protection of coal
conveyer at the first and second levels are also included into the central control system.

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An inclined screw feeder has a frequency adjustment function and is provided with two converters
(6.6KW).

 Surge Tank Coal Conduit to Slurry Filter

First make sure that ball mill is allowed to start, providing pressure and temperature conditions can
meet the requirements of the unit.

Both remote automatic control and local control monitoring can be achieved to control
synchronization of the constant feeder with water supply automatic control and chemical dosing
automatic control.

 Slurry Filer to High Shear Enhanced Pump

 Start the linkage of a relevant electric slurry valve

 Level gage to the setting value – start in parallel other stability processing cylinders to
electric slurry valve

 Mixing/Stirring Tank to Slurry Loading

 The high level of dispersant storage tank to the setting value - stop 406 (408) pump; the low
level of dispersing agent storage tank level to the setting value - start 406 (408) pump; the low
level of dispersing agent dilution tank to the setting value - prohibit 406 (408) pump from
starting

 The high level of stabilizer storage tank to the setting value - stop 405 (407) pump; the low level
of stabilizing agent storage tank to the setting value – start 405 (407) pump; the low level of
stabilizing agent dilution tank to the setting value – prohibit 405 (407) pump from starting

 Add the level of dispersing agent dilution tank; the level monitoring of stabilizing agent dilution
tank while importing the data to CCR

 Add the interlock of firewater pumps

 Add the current monitoring of all screw pumps, metering pumps and the outlet pressure
monitoring of pumps

 Pumps 361 and 362 are used on emergency

standby

 Control of Ball Mill

The ball mill is the heart of the whole production line, so

the monitoring and control are particularly important.
Specific controls are below:

上料报警 Material loading alarm

输煤系统 Coal handling system

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配料系统 Batching system

制浆系统 Slurring system

自动控制 Automatic control

配料参数 Ingredient parameter

班组管理 Team and group management

流量曲线 Flow curve

控制参数 Controls parameter

系统返回 System returns.

设定 setting

实测 Actual measurement

速度 Speed

 Ball Mill Control

The ball mill in operation is very heavy. While running its front & rear bearings are suspended by high
pressure oil. Thus the successful monitoring and control of lubrication oil station is a prerequisite to
ensure the safe operation of ball mills. The ball mill operating current is very large, but its starting current
is even larger. Therefore, real-time monitoring via PLC, over-current & overvoltage protections and the
corresponding alarm system are required.

 Coal Feeding Control

A coal feed rate is dependent upon CWS concentration. The powdered coal in fine coal surge tank is
sent by the conveyor belt to force feeder, and then to ball mill. The conveyor belt here is equipped with
weighing device and its RPM is controlled by the inverter. PLC is used for acquiring weighing device
signals. The PID operation may output signals to adjust the inverter and control conveyor belt speeds,
thereby regulating coal feed rates.

 Water Feeding and Chemical Feeding Control

The same control method applies to water and chemical feeding processes. Use flowmeter to measure
water and chemical feeding rates, and after the PID operation, regulate electric valves to control flow
rates.

 Slurry Dumping Control

CWS is sent from the surge tank of ball mill outlet to slurry storage tank or to waste slurry tank.
Concentration analysis signals acquired by PLC are used to automatically control slurry storage tank
inlet solenoid valves, thereby diverting CWS.

A reverse starting and forward stopping control method is used in the whole control system.

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Oilfield Automation Measurement System

A crude oil metering station is used as a hub for measuring and collecting
crude oil from oil wells, which plays a very important role in oilfield production.
It realizes the automatic measurement and monitoring of crude oil metering
stations and has an important role in realizing the automatic monitoring of the
entire oilfield system and improving the accuracy of crude oil measurement
and production efficiency.

The HollySys’ LK Series PLC-based oilfield automation measurement is a comprehensive control

system integrated with many advanced technologies like configuration data software, database
management, computer network, information and communication technologies, and onsite acquisition. It
realizes the real-time data acquisition of oilfield process and allows operators in the control room to know
the production in the whole measurement area so as to exercise their scheduling management. The
system has good openness and free-scale expansion function. The system capacity can be expanded at
any time.

Description of Process Flow

A simplified process flow chart is shown in Fig 1. The system is composed of the three-way valve for
metering, separator, balance tank and crude oil tracing system.

 Description of Process Flow

Crude oil is transported by pipeline from oil well to metering

station. In the non-measurement state, corresponding
three-way valve of each well points to the working manifold
orientation and the crude oil is directly sent out through
working manifold. When it needs to measure the crude oil in
a certain well, the corresponding three-way valve of this well
should point to the orientation of metering manifold. Crude
oil goes into the separator from the metering manifold,
where the crude oil is measured. Through the balance tank,
measured crude oil flows into output manifold to be
transported out of it. 图 1 油田计量工艺流程图

图 1 油田计量工艺流程图 Figure 1 Oilfield Metering Process Flow Diagram

参数设置 Parameter setting

前进 Forward

历史 History

后退 Back

主菜单 Main menu

登陆 Log in

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报警 Alarm

趋势 Trend

报表 Report

油气外输 Oil gas transmission

平？汇管 Header

进 Enter

分离器 Separator

热水 Hot water

系统控制面板 System control panel

压力报警 Pressure alarm

气体报警 Gas alarm

计量时间 Metering time

气计量 Gas metering

油计量 Oil metering

含水率 Moisture content

来水管 Intake water pipe

回水管 Return oil pipe

中控室 Central control room

触摸屏 Touch screen

油阀 Oil valve

气阀 Gas valve

手动计量选择 Manual metering option

手动 Manual

自动 Auto

 Metering Principle

The crude oil metering of oil well is comprised of two sections, i.e., the mixture output (M3) and
volumetric water content (%). Mixture output V is calculated from the time T required by metering well for
completing the set separator height (50cm) according to the formula: V = δ / T; where, δ = 15,564,
measured coefficient (may be modified).

A crude oil production of oil well τ (t) cannot be directly derived from the above measured output
because there is a considerable part of water. So, to measure a crude oil output, the water content (vol%)
of crude oil corresponding to each well is required. The volumetric water content ξ (%) of crude oil is the
instantaneous water content value measured by moisture analyzer installed on the oil outlet pipeline of
separator, which is obtained by PLC weighting and averaging instantaneous water content values in

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statistical data. That is ξ = (V-τ / ρ) / V.

Finally, from the formula: τ = (1-ξ) Vρ, a crude oil production in τ (t) of well is obtained; where, ρ is the
density of crude oil.

System Design

As per the system control requirements and the actual field conditions, the following design of the
system is made:

The system is provided with a central control room (CCR) and field measurement stations in order to
realize the centralized control of system and local operations.

 The CCR is provided with monitoring computers on which run HollySys’ monitoring software
FacView. It is to achieve the monitoring and management of the entire system.

 A PLC system is located at field metering station to complete the data collection and program
control of the entire system. The PLC system selects HollySys’ LK series PLC. The LK has
complete module types and a flexible & excellent network communication function.
Furthermore, in order to realize the local operation of the system, a touch screen is installed at
the field metering station., Through this touch screen, users can complete the system
monitoring if the metering staion.

 Because of a long distance between the field station and central control room and taking into
account the feasibility of establishing the wireless communication network, GPRS wireless
communications networks are set up between each field metering station and CCR, so that the
communications between field stations and RRC can be achieved through wireless
communication networks.

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图 2 系统网络结构示意图

油田计量中央控制室 Oilfield Metering CCR

工程师站 Engineer Station
打印机 Printer
操作员站 Operator Station
数据服务器 Data Server
操作员站 Operator Station
打印机 Printer
UPS 电源 UPS
100Mbps 环形工业以太网 100Mbps Industrial Ethernet

路由器 Router

VPN 专线 Dedicated VPN Line

中国移动 GPRS 通讯网络 China Mobile’s GPRS Communication Network
LK 系列 PLC LK series PLC
计量站 Metering Station
图 2 系统网络结构示意图 Figure. 2 Schematic Diagram of System Network
Architecture

System Function
 Real-time Display of Production Data

Based upon the user’s needs, the system can create an overview map, working condition charts, trend
graphs, instrument bar graphs and alarm screens to real-time displays the field production data. These
frames can be easily switched to one another. ..In addition, the system can make the statistical
calculations of original production data and perform the real-time displays.

 Alarm Function

In cast that any unexpected circumstances occur or a person abnormally enters the metering room, the
system will automatically send alarm signals to the control room, including sounds and images, to notify
the control room personnel thereof, thus ensuring the safety.

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 Communications Status Detection and Monitoring Functions

It makes the real-time diagnosis of system communication status and line connections, so as to improve
communication reliability.

 Automatic Line Recovery Processing

In case of any interruptions in communication lines, the system auto recovery feature will ensure that
any messages sent at the time of interrupting the line are not lost.

 Query & Printing

In the light of user needs, you may carry out the classified query of field production data from real-time
database, such as unit data query and history alarm query; also, you may automatically generate and
print out various reports.

System Characteristics
 Simple structure, with stable and reliable running;

 Using the GPRS wireless communication network with a long communications distance and
free from a building shield;

 Realizing the automatic unattended measurement with high accuracy;

 The remote & field two-level control schemes make it flexible to satisfy the actual needs of the
users.

 Simple and vivid monitor screen displays make it convenient for the users to master the system
operating conditions at any time; and

 The system maintenance is simple and has good extendibility.

Water Resource

Water resources industry is an information-intensive industry with very long history. With the
development of computer technique, digital control technique and network communication technique,
industrial automatic control system has entered into a brand new era. New technique and equipment will
be adopted to modernize and intelligentize the equipment and management in hydraulic engineering
projects, which becomes the inevitable trend of historical development.

Gate
As one of the most basic projects in water resources system,
gate has played a very important role during flood control and
disaster relief. Besides meeting the requirement of water
demand of water resources department, gate has played
tremendous positive roles during flood control, protection of industrial and agricultural production,
safeguarding of people's lives and properties as well as environmental protection. With the purpose of
further improving the utilization efficiency of pump station, reducing the loss caused by flood and
improving the decision-making level of dispatch management, it is necessary to build an integrated

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automatic control information system of gate.

Gate automatic control system is mainly used to control the gate in hydraulic power plant, reservoir,
watercourse and water supply canal. The controlled gate can be flat gate, arc form gate, hydraulic gate
or quick acting gate. The system is composed of gate position sensor, control unit (PLC), signal
transmission cable and central control station. Single control, group control and off-site remote control
can be conducted upon the requirement of consumer as well as the characteristic of system. As for the
system, hardware equipment with high reliability and dedicated configuration software platform for
industrial control are required, which shall be high in reliability and simple in operation.

Pump Station

Pump station—the only man-made power source for water, which acts as
an important engineering measures, has played an irreplaceable role in the
reasonable dispatch and management of water sources. Meanwhile, pump
station has also played an important role in flood control, drainage of
stagnant water, drought control and disaster reduction, industrial and
agricultural water consumption and living water for urban and rural
residents. Moreover, pump station is also a large energy consumer for which energy conservation is as
important as water conservation. Therefore, the economic operation and optimizing management of
pump station has become extremely important.

Automation level is an important index to decide the operation and management level of pump station.
High automation level of pump station during operation and management as well as a perfect control
system can not only improve the safety, reliability and economical efficiency of pump station during
operation but also save the manpower resource and provide a reliable basis for maintenance of the
engineering.

Hydropower
Hydropower is the second large constituent of electric power generation.
Compare with fossil-fired power generation, hydro energy is a renewable
energy source, which has the advantages such as high environmental
benefit, no harmful gas/dust/ash, high generation efficiency as well as low
generation cost, therefore, it is an ideal power generation mode. Meanwhile, hydroelectric generation
undertakes a comprehensive utilization function in flood control, irrigation, shipment, etc. Therefore,
most of the countries in the world give priority to the development of hydropower which is the power
developing direction in the future.

The automatic control system in hydraulic power plant is mainly composed by hydroelectric generating
set control system, switchyard control system, public equipment control system and gate automatic
control system. Monitoring, data acquisition, control and adjustment of the production process of
hydraulic power plant can be achieved by means of open and modularized structural design. Thus,
monitoring and protection function for electrical equipment such as unit, transformer and circuit as well
as auxiliary equipment of oil, gas and water systems in hydraulic power plant can be achieved.

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Gate Monitoring System

Integrated automatic control information system of gate is mainly to detect the upstream and
downstream water level of gate, gate load, open and close status and
opening degree of gate, automatic acquisition and transmission of
image information via computer monitoring system, so as to control
remotely the opening and closing of gate, automatic control of gate
as well as system interlock in the control center. Working condition of
the gate and the surrounding environment can be understood through
real-time image.

The advantages of gate control system solution, which is based on LK series PLC produced by Hollysys
Company, include: high real-time, quick response speed, safe and reliable, powerful function, etc. This
will provide a powerful guarantee to promote the automation and informatization level of dam and gate,
improve the management level of water resources system, perfect the quick response system of water
resources system and establish effective disaster prevention system.

System Configuration

The system is mainly divided into two parts: central control room (monitoring center) and on-site control
device of gate. The monitoring center is composed of control computer, system control software platform,
computer network platform and application software. On-site control device of gate is composed of local
control unit (LCU), on-site monitoring instrument and information transmission channel.

Based on the communication of optical network, LAN will be established between each terminal and
central station (management center) to fulfill the data communication. Optical fiber has the advantages
such as high reliability, stable data transmission and low maintenance charge. It is a reasonable scheme
to implement reliable data transmission remotely.

Figure1. Automatic Control System Diagram of Gate

打印机 Printer

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操作员站 Operator station

工程师站 Engineer station

UPS 电源 UPS power supply

100Mbps 工业以太网 100Mbps industrial Ethernet

闸门现地控制单元 Local control unit of gate

LCU is usually installed in gate hoist house or the distribution center of system. It is composed of
programmable controller, intelligent gate measuring and control instrument, control apparatus, logic
protection circuit, operation button, status indicator lamp, current and voltage indicator gauges, forming a
complete set in one equipment cabinet. LCU is connected to gate position sensor, load sensor,
mechanical limit, interlock protection, motor of hoist and incoming wire of three-phase AC power supply
via terminal blocks. LCU can control the start-stop apparatus of gate, make sure the opening degree of
gate in real-time via opening meter, confirm the load of gate via loading instrument, set the opening
degree of gate automatically, improve the automatic control level and reduce the artificial error based on
the hydrologic and hydraulic calculation and hydrological data. Installment of protective devices can
ensure the unexpected condition happened during implementation is handled in time. Unattended
automatic control of gate will be achieved by combining the remote image control system.

LCU has the functions as follows:

 Display function: digital display the parameters such as gate position, load, stroke setting
value, load two-stage alarm setting value, grid voltage and operation current as well as varous
operation status indicating, such as lifting and descending.

 Parameter setting: parameters such as stroke value, upper and lower limiting values and load
two-stage alarm setting value can be set via buttons.

 Gate operation: gate can be lifted or descended to the appointed position via buttons.

 Safety precautions: multiple protection functions such as digital and electronic limit, mechanical
limit, overload, overtime operation, over-current of gate hoist and interlock can guarantee the
safe and reliable operation of gate.

 Communication function: parameters can be modified remotely and the principle of the last
modification effective shall be followed; upload the real-time procedure parameter and
operation status, receive and conduct remote control command, lift or descend the gate to the
appointed position precisely.

System Function

Upper level computer is the command and control

center of the system. It can conduct network
interconnection with superior management center,
operate and modify the technological parameters via
upper level computer and communication command
system of PLC. PLC is the control center of the system
which can control the normal operation of the whole

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system independently.

引滦入津工程自动化监控系统 Yinluan Automatic Control System

隧洞分中心 Sui Dong sub-center

黎河分中心 Li He sub-center

于桥分中心 Yu Qiao sub-center

潮白河分中心 Chao Baihe sub-center

尔王庄分中心 Er Wangzhuang sub-center

宜兴埠分中心 Yi Xingbu sub-center

水质监测系统 Water quality monitoring system

历史数据查询 Historical data query

报警记录查询 Alarm record query

操作记录查询 Operation record query

报表数据查询 Report forms data query

系统管理菜单 System management menu

九王庄进水闸监测站 Monitoring station of Jiu Wangzhuang inlet gate

计算机名称 Computer name

本机运行任务 Operation task of the unit

数据服务 Data service

报警服务 Alarm service

趋势服务 Trend service

时间服务 Time service

报表服务 Report forms service

监视服务 Monitoring service

剩余硬盘空间 Residual hard disk space

剩余系统资源 Residual system resource

剩余物理内存 Residual physical memory

操作站负荷率 Load rate of operation station

主菜单 Main menu

水文监测 Hydrologic monitoring

闸后水位 3.56 米 Water level behind gate: 3.56m

1#、2#、3# 闸门 1#, 2#, 3# Gate

九王庄进水闸 Inlet gate of Jiu Wangzhuang

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马营节制闸监测站 Monitoring station of Ma Ying check gate

鲍丘河倒虹监测站 Monitoring station of Bao Qiu River inverted siphon

宝坻取水口监测站 Monitoring station of Bao Di Water Intake

潮白河泵站监测站 Monitoring station of Chao Baihe Pump Station

泵站周围闸门 Periphery Gates of Pump Station

潮白河倒虹监测站 Monitoring station of Chao Baihe inverted siphon

青龙湾倒虹监测站 Monitoring station of Qing Longhe inverted siphon

预留 Reserved

工作模式 Working Mode

闸门开度 Opening degree of gate

开度设定 Opening degree setting

开/关/故障 Open/ Close/ Failure

开闸 Open Gate

关闸 Close Gate

停止 Stop

 Data Acquisition and Processing

This function includes the acquisition of real-time data, necessary data pre-processing and storing the
data in real-time data base in certain format. Based on the difference of properties of signal, it can be
divided into analog quantity, switching value and impulse digital quantity, whose acquisition and
processing methods are different from each other.

 Acquisition and Processing of Analog Quantity

This kind of real-time quantity includes electric analog quantity, non-electric analog quantity and
temperature quantity. Electric analog quantity refers to the electric semaphore such as voltage, current,
frequency and power, power factor. Non-electric analog quantity mainly refers to the semaphore such as
pressure, flow, water level and displacement.

 Acquisition of Switching Value

Acquisition of switching value includes interrupt

switching value and non-interrupt switching value.
Interrupt switching value signal includes all kinds of
fault signals, position signals of circuit breakers and
isolating switches, operation status signals of pumps
and equipments, position signals for manual or
automatic selection.

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引滦入津工程自动化监控系统 Yinluan Automatic Control System

隧洞分中心 Sui dong sub-center

黎河分中心 Li he sub-center

于桥分中心 Yu qiao sub-center

潮白河分中心 Chao baihe sub-center

尔王庄分中心 Er wangzhuang sub-center

宜兴埠分中心 Yi xingbu sub-center

水质监测系统 Water quality monitoring system

历史数据查询 Historical data query

报警记录查询 Alarm record query

操作记录查询 Operation record query

报表数据查询 Report forms data query

系统管理菜单 System management menu

报警摘要 Alarm summary

模拟量 Analog quantity

开关量 Switching value

SOE 报警 SOE alarm

设备报警 Equipment alarm

系统警告 System warning

报警摘要 Alarm summary

报警禁止表 Alarm forbidden list

历史摘要 Historical summary

日期 Date

时间 Time

点名 Name of Point

点说明 Description of Point

报警级别 Alarm level

离开时间 Departure time

确认时间 Confirmation time

潮白河泵站 1#机组故障 Failure of Chao Baihe pump station 1# unit

设备故障报警 Equipment failure alarm

隧洞进口液位 water level at Sui Dong Inlet

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前毛庄液位 Front Mao Zhuang water level

入开泵站压力 Pump station pressure of Development Zone

坝上液位 Dam water level

潮白河倒虹进口液位 Inlet water level of Chao Baihe inverted siphon

高高限报警 High-high limit alarm

低限报警 Low limit alarm

高限报警 High limit alarm

页号 Page No.

预定义报警 Predefined alarm

恢复 Restore

报警确认且未恢复 Alarm confirmed and not restored

报警恢复且未确认 Alarm restored and not confirmed

报警被禁止 Alarm forbidden

报警确认且已恢复 Alarm confirmed and restored

 Operation Security Monitoring

 Real-time monitoring conducted within the whole plant and parameter on-line modification

 Parameter off-limits alarm record

 SOE record

 Fault status display record

 Trend analysis and judgment

 Operation Guidance

 Monitoring during startup and shutdown of unit

 Operation guidance of primary equipment

 Control and Adjustment

Operators can control and adjust the control objects via

display and keyboard in operator station.

 Production Management

 Real-time control of operation condition of gate

can be conducted in central control room

 Operation, alarm event and real-time

parameter report forms of all control objects
within the whole plant can be recorded and

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 LK Series PLC Industry Solutions
displayed on LCD in Chinese format, and printed by printer.

 Manage, analyze, count the data that acquired on-site, generate report forms and printout.

引滦入津工程自动化监控系统 Yinluan Automatic Control System

隧洞分中心 Sui Dong sub-center

黎河分中心 Li He sub-center

于桥分中心 Yu Qiao sub-center

潮白河分中心 Chao Baihe sub-center

尔王庄分中心 Er Wangzhuang sub-center

宜兴埠分中心 Yi Xingbu sub-center

水质监测系统 Water quality monitoring system

历史数据查询 Historical data query

报警记录查询 Alarm record query

操作记录查询 Operation record query

报表数据查询 Report forms data query

系统管理菜单 System management menu

溢洪道监测站 Monitoring station of spillway

登录用户 User name

调度操作员 Dispatching operator

本机运行任务 Operation task of the unit

数据服务 Data service

报警服务 Alarm service

趋势服务 Trend service

时间服务 Time service

报表服务 Report forms service

监视服务 Monitoring service

剩余硬盘空间 Residual hard disk space

剩余系统资源 Residual system resource

剩余物理内存 Residual physical memory

操作站负荷率 Load rate of operation station

主菜单 Main menu

大坝安全检测系统 Security detection system of dam

暗渠进口监测站 Monitoring station of culvert inlet
州河节制闸监测站 Monitoring station of river check gate

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 LK Series PLC Industry Solutions

于桥电厂水质监测 Water quality monitoring of Yu Qiao power plant

调压井监测站 Monitoring station of surge tank
暗渠出口监测站 Monitoring station of culvert outlet
坝下放水洞监测站 Monitoring station of water discharge channel that under the
dam
水情自动测报系统 Water regimen automatic measuring system
视频实时监控 Video monitoring in real-time
1#-8# 闸门 1#-8# Gate
溢洪道闸上水位 Upper water level of spillway gate
溢洪道闸下水位 Lower water level of spillway gate
工作模式 Working mode
远程 Remote
闸门开度 Opening degree of gate
开度设定 Opening degree setting
开，关 Open, close
故障 Failure
开闸，关闸 Open gate, Close gate
停止 Stop

 System Maintenance and Setting

Real-time database and historical database can be maintained in real-time, including adding, deleting,
modifying, querying of database record as well as the backup of data in database.

Users can set the working environment of system upon their needs, hobbies and interests. Operation
environment of system can be set by setting the basic parameters of on-site station and functional
parameters such as data acquisition and processing, communication and control. The system is
provided with instant help and operation of guidance document, which includes self-diagnosis, operating
instruction and helptext.

System Characteristics
 Safe & Reliable and Advanced & Practical System

Matured and advanced distributed computer control system is adopted for the purpose of system design.
Based on the centralized management of information as well as scientific operation, danger of control
will be distributed and thus the reliability of system will be improved. LK series PLC acquires all kinds of
on-site data which will then be transferred to central control room by high speed network for the purpose
of monitoring and managing. Similarly, control command from host computer of central control room is
transferred to the measurement & control terminal by the above mentioned high speed network so as to
monitor and control every unit distributedly.

 Distributed Architecture Schematic Design

Generally, distributed remote group-gate control system controls the opening and closing of gate and
operation of water pumps in real-time and transmits the image and status data (include phenomenon
data and control command) of the gate that monitored in real-time. Based on the above requirements,
reliable transmission architecture will be adopted in order to guarantee the rapidity and consistency of

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data transmission, real-time of image transmission and reliable implementation of control strategy.
Remote and distributed control system usually adopts master station-substation architecture and some
large scale systems will adopt multistage substation. Fiber-optic communication has big market shares
based on its advantages such as high reliability, stable data transmission and low maintenance cost.

 Information Layer-management and Authority Control Classification

The system is designed as a fully distributed and open type distributed control and management system
that integrates computer technique, automatic control technique, network communication technique and
image display technique based on the functional principle of safety, reliability and economy. As for
logical structure, layered structure is adopted and the whole control system is divided into three layers:
first, production dispatching layer; second, intermediate monitoring and management layer and third,
on-site measurement and control layer. Information transmission and resource sharing is carried out by
special industrial Ethernet or by hiring other communication network.

 Good Openness and Expandability

Design of the whole management system adopts open network architecture, standard data acquisition
and processing system so that upgrading, extension and interconnection of multi-media management
system is convenient. Equipments adopted shall consider the upgrading and updating and during
upgrading, the original hardware equipment and software investment shall be protected to the utmost. It
has the characteristics such as few configured parameters, little adjustment, high degree of automation,
convenient usage, simple operation, reasonable and practicable.

Control System of Pump Station

Generally, the pump station (such as water delivery pump station, sewage pump station) is equipped
with electromechanical device systems such as power, electric,
detection, etc. They have complicated control logic, strict
management requirement and huge system architecture. Computer
control system of pump station is an integrated automation system
that combines monitoring, measurement, control, protection and
management together. It is mainly used to conduct effective
monitoring and control for pump unit, electrical system, public
oil/water/gas systems, gate control system, excitation system and DC system, so as to guarantee safe,
reliable and economic operation and achieve the goal of “Unattended operation, few person on duty”.
Moreover, operation data and status of pump station can be submitted to high management by computer
networks in real-time.

The control system of pump station, based on LK series PLC produced by HOLLYSYS Company,
adopts reliable multi-task control software FacView and PowePro advanced programming software so
as to build a stable, reliable and ream-time control and management system. It achieved the control and
operation of pump station system, data acquisition and real-time, correctness, integrity and unity of
information.

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System Configuration

Computer control system of the pump station adopts layered and open system with pump station level
and LCU level arranged. Automatic control system of the pump station is composed of one control room
and eleven local control units. Core equipment of local control unit is LK series PLC which is produced
by HOLLYSYS Company. It acquires the operation condition, status and parameter of ten pump units
and one set of auxiliary equipment respectively, and conducts distributed control according to the
operation specification and economical operation condition. Control room of pump station conducts
centralized management to the control system of whole pump station. Data communication between
control room control computer and on-site PLC control station is proceeded by high speed and real-time
industrial Ethernet with star-type structure, communication rate of 100Mbps and optical fiber as
transmission medium.

Figure1. Structural Diagram of Control System of Pump Station

泵站中央控制室 Central control room of pump station

大屏幕 Large screen

打印机 Printer

操作员站 Operator station

UPS 电源 UPS power supply

工程师站 Engineer station

通信计算机 Communication computer

冗余数据服务 Redundancy data service

总调度中心 General dispatching center

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LK 冗余系统 LK Redundancy system

100Mbps 环形工业以太网 100Mbps ring industrial Ethernet

1#-10# 泵机组现地控制单元 LCU of 1#-10# Units Pump Station

公用系统现地控制单元 LCU of Common Service System

 Control Room of Pump Station

Control room of pump station is equipped with two sets of host computers as operator stations, one set
of engineer station, one set of communication processing computer, one set of audio alarm device, one
set of network switchboard and photovoltaic conversion device, one set of A3 black& white network laser
printer, one set of GPS clock system and one set of control panel in central control room. Two operator
stations operate in hot standby mode reciprocally so that maintenance and management of database of
culvert pump station control system can be realized. During normal condition, one will be the host
computer to accomplish the monitoring and control work. The other will be in standby status for normal
control. When main station fails or quits, the standby station will promote to main station manually or
automatically to accomplish the control task.

 Local Control Unit (LCU)

There are eleven sets of local control units for culvert pump station, among which ten sets of LCU are for
pump units (one set for each pump unit:) and one set of LCU is for public equipment. Core equipment of
LCU for every pump unit is LK series PLC which is produced by HOLLYSYS Company. A set of
12”colorized touch screen is adopted as man-machine interface equipment. Moreover, a set of
microcomputer based relay protection device for main pump motor, a set of microcomputer temperature
routing inspection and protection device（48 points） and a set of multi-function intelligence watt-hour
meter are installed. The above mentioned devices communicate with PLC.

Pump assembly PLC is equipped with manual and automatic closed-loop blade angle regulating and
control equipment (including air switch and contactor), manual control button, handle, power supply,
relay and digital indicating instrument. Digital indicating instrument is used to display measurement value
of water level, pressure, oil temperature of angle modulation mechanism, blade angle, etc. PLC has
Ethernet interface and carries out data communication with upper level computer in control room of
pump station by using 100Mbps industrial Ethernet and the communication medium is optical fiber.
Pump assembly PLC is located in main workshop of pump station.

System Functions
Functions of the automatic control system include
monitoring, control, interlock and alarm of operation
parameters, electric parameters and operation state of
every pump unit and auxiliary equipment as well as report
form printing. By using a series of communication link, the
required data acquisition, data communication, sequence
control, time control, loop adjustment and upper level

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monitoring and management of the whole pump station will be accomplished. Meanwhile, it is also
responsible for the communication connection between computer control system of pump station and
the remote dispatching center.

引滦入津工程自动化监控系统 Yinluan Automatic Control System

隧洞分中心 Sui Dong sub-center

黎河分中心 Li He sub-center

于桥分中心 Yu Qiao sub-center

潮白河分中心 Chao Baihe sub-center

尔王庄分中心 Er Wangzhuang sub-center

宜兴埠分中心 Yi Xingbu sub-center

水质监测系统 Water quality monitoring system

历史数据查询 Historical data query

报警记录查询 Alarm record query

操作记录查询 Operation record query

报表数据查询 Report forms data query

系统管理菜单 System management menu

暗渠泵站 1#泵监控图 Control drawing of culvert pump station 1# pump

恒水位 Constant water level

单机控制 Single unit control

测试状态 Test status

大,小 Big, small

开,关 Open, close

叶角调节 Blade angle adjustment

1#轴流泵 1# axial flow pump

1#-3# 阀 1#-3# Valve

励磁主回路电源 Excitation main loop power supply

串口通讯 Serial port communication

励磁装置 Excitation equipment

PLC 故障 PLC failure

机组保护 Unit protection

开机允许 Startup permit

开机过程 Startup process

开机完成 Startup completed

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停机过程 Shutdown process

事故停机 Emergency shutdown

停机完成 Shutdown completed

1# 机组 1# Unit

叶角度数 Degree of blade angle

度 Degree

 Data Acquisition

The system will acquire all kinds of real-time data of every local control unit inside the whole pump
station, check the effectiveness of data and store in the database. The data will be used for upgrading of
display screen, control and adjustment, record retrieval, operation guidance and fault analysis

 Safety operation monitoring

Colorized TFT display, which is used to display the operation condition of pump station, is equipped on
the operator control console in control room of pump station. The monitoring range includes status
monitoring, trend analysis, out-of-limit checking, SOE record and accident review of equipment in pump
station.

 Operation condition of unit

 Operation condition of auxiliary equipment of unit

 Position of circuit break, isolating switch and

earthing switch

 Operation condition of circuit and bus

 Operation condition of public equipment

 Operation condition of auxiliary power

 Other important parameters

引滦入津工程自动化监控系统 Yinluan Automatic Control System

隧洞分中心 Sui Dong sub-center

黎河分中心 Li He sub-center

于桥分中心 Yu Qiao sub-center

潮白河分中心 Chao Baihe sub-center

尔王庄分中心 Er Wangzhuang sub-center

宜兴埠分中心 Yi Xingbu sub-center

水质监测系统 Water quality monitoring system

历史数据查询 Historical data query

报警记录查询 Alarm record query

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操作记录查询 Operation record query

报表数据查询 Report forms data query

系统管理菜单 System management menu

暗渠泵站计算机监控系统 Computer control system of culvert pump station

分中心名称 Name of sub-center

本机运行任务 Operation task of the unit

数据服务 Data service

报警服务 Alarm service

趋势服务 Trend service

时间服务 Time service

报表服务 Report forms service

监视服务 Monitoring service

剩余硬盘空间 Residual hard disk space

剩余系统资源 Residual system resource

剩余物理内存 Residual physical memory

操作站负荷率 Load rate of operation station

主菜单 Main menu

北排河倒虹监测站 Monitoring station of Bei Paihe inverted siphon

2#闸和入塘节制闸 2# gate and Tanggu check gate

明渠泵站监测站 Monitoring station of open channel pump station

暗渠泵站监测站 Monitoring station of culvert pump station

变电站监测站 Monitoring station of substation

1#闸监测站 Monitoring station of 1# gate

入塘，入汉泵站 Pump Stations of Tanggu and Hangu

入聚酯，入开泵站 Pump Stations of Shihua and Development Zone

入扬，入港泵站 Pump Stations of Yixian yuan and Dagang

安全运行天数 Number of safe operation days

机组监控图 Control diagram of unit
辅机监控图 Control diagram of auxiliaries
变电站监控图 Control diagram of substation
泵站剖面图 Cross-section diagram of pump station
水位趋势显示 Water level trend display
流量趋势显示 Flow trend display
数据查询及报表 Data query and report forms
历史报警及查询 Historical alarm and query

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巡视设置 Routing inspection setting

1#-10# 机组 1#-10# Unit
主窗口 Main window

 Control and Adjustment

Operator can operate and adjust all control objects of computer and equipment of computer control
system via operator station. Control and adjustment of monitoring object include startup and shutdown of
unit, opening and closing control of outlet valve of unit, operating and disconnecting of circuit breaker
and isolating switch, automatic sequence switching operation and misoperation-proof and safety
interlocking, control of public equipment and auxiliary equipment of pump station, setting of the
corresponding limits of authority and modification of the setting value and limit value under the enabled
condition of limits of authority, query of production procedure, display or print the relevant record/report
form/picture.

According to the setting value of flow, number of units to be

startup or shutdown as well as the optimal combination can be
ensured based on the water level of collecting basin and
working condition of unit. Also, closed-loop regulation and
open-loop guidance can be realized. Dispatch and
optimization of water are under the condition of fulfilling the
operation and safety constraint condition and according to the
general principle such as fulfilling of water supply plan, flow
balance, minimum power consumption (short-term goal and
the long-term goal is minimum electric charge) and highest combined efficiency. Based on the optimal
criterion, make sure the number of units and unit No. to be put into operation, including optimization of
number of unit in every pump station, working condition and opening degree of every regulating gate and
realize the optimal operation of the whole system.

引滦入津工程自动化监控系统 Yinluan Automatic Control System

隧洞分中心 Sui Dong sub-center

黎河分中心 Li He sub-center

于桥分中心 Yu Qiao sub-center

潮白河分中心 Chao Baihe sub-center

尔王庄分中心 Er Wangzhuang sub-center

宜兴埠分中心 Yi Xingbu sub-center

水质监测系统 Water quality monitoring system

历史数据查询 Historical data query

报警记录查询 Alarm record query

操作记录查询 Operation record query

报表数据查询 Report forms data query

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 LK Series PLC Industry Solutions

系统管理菜单 System management menu

暗渠泵站剖面图 Cross-section drawing of culvert pump station

分中心名称 Name of sub-center

本机运行任务 Operation task of the unit

数据服务 Data service

报警服务 Alarm service

趋势服务 Trend service

时间服务 Time service

报表服务 Report forms service

监视服务 Monitoring service

剩余硬盘空间 Residual hard disk space

剩余系统资源 Residual system resource

剩余物理内存 Residual physical memory

操作站负荷率 Load rate of operation station

主菜单 Main menu

北排河倒虹监测站 Monitoring station of Bei Paihe inverted siphon

2#闸和入塘节制闸 2# gate and Tanggu check gate

明渠泵站监测站 Monitoring station of open channel pump station

暗渠泵站监测站 Monitoring station of culvert pump station

变电站监测站 Monitoring station of substation

1#闸监测站 Monitoring station of 1# gate

入塘，入汉泵站 Pump Stations of Tanggu and Hangu

入聚酯，入开泵站 Pump Stations of Shihua and Development Zone

入扬，入港泵站 Pump Stations of Yixian yuan and Dagang

 Fault Analysis and Management

It is capable of the function such as accident analysis and

automatic processing for equipment in pump station. All
operation events, alarm events and report forms of
equipment in pump station can be recorded, displayed on
LCD and printed. The print record is divided into timed print
record, random print record of accident and fault, called-on
print record and other operation mode. The record report will
use Chinese and international symbol for displaying and
printing as required.

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 LK Series PLC Industry Solutions

引滦入津工程自动化监控系统 Yinluan Automatic Control System

暗渠泵站流量棒图 Flow histogram of culvert pump station

流量 Flow

主窗口 Main window

隧洞分中心 Sui Dong sub-center

黎河分中心 Li He sub-center

于桥分中心 Yu Qiao sub-center

潮白河分中心 Chao Baihe sub-center

尔王庄分中心 Er Wangzhuang sub-center

宜兴埠分中心 Yi Xingbu sub-center

水质监测系统 Water quality monitoring system

历史数据查询 Historical data query

报警记录查询 Alarm record query

报表数据查询 Report forms data query

系统管理菜单 System management menu

2006 年 7 月 1/8/15/22/29 日 1st/8th/15th/22nd/29th, July 2006

主窗口 Main window

 Statistic, Tabulation and Print

It is convenient to generate and modify forms, query and maintain the database. Report forms at any
time of past can be generated freely. Printing includes timed print and called-on print. Called-on print
includes real-time print and historical print, automatic print during accident and fault. The forms to be
printed include statistic form of operation record (startup-shutdown time and frequency of unit, tripping
and closing time and frequency of circuit breaker), statistic form of accident and fault, report forms of
SOE record, daily/every ten days/monthly/yearly statistic form of pumping quantity, historical report
forms, and time-sharing measurement report form of water quantity, etc.

 System Self-diagnosis and Self-restoring

The system is capable of self-diagnosis. During on-line operation, hardware and software within the
system will conduct self-diagnosis operation so that modules in the faulty section will be pointed out.
Based on the requirement of availability, the system is also capable of self-restoring.

Monitoring System of Hydraulic Power Plant

Hydropower is the second large constituent of power generation. Compare

with fossil-fired power plant, hydro energy is a renewable energy source
which has the advantages such as high environmental benefit, no harmful

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 LK Series PLC Industry Solutions

gas, dust and ash, high generation efficiency as well as low generation cost, therefore, it is an ideal
power generation mode.

Automatic control system, which is the foundation of informatization and automation, has played a very
important role during production and operation of the whole hydraulic power plant. The monitoring
system, based on LK series PLC of HOLLYSYS Company, adopts controller with high performance and
reliability and combines with high speed Ethernet and on-site bus network so as to form a large-scale
distributed control system. The system has the characteristics such as flexible configuration, simple
operation and convenient maintenance and is suitable for the monitoring of newly-built hydraulic power
plant, upgrading of monitoring technology of the built hydraulic power plant and dispatching
automatization system of cascade hydraulic power plant.

System Design

According to the control object, the automatic control system of hydraulic power plant mainly includes
control system of hydroelectric generating set, control system of switchyard, control system of public
equipment and automatic control system of gate. Monitoring, acquisition, control and adjustment can be
realized via an open and modularized structural design. Moreover, control and protection of electrical
equipments such as unit, transformer and circuit as well as auxiliary equipment of oil/gas/water systems
in the whole plant can be accomplished.

Computer control system, based on LK series PLC of HollySys, is a distributed real-time process control
system that based on high speed industrial Ethernet and on-site bus network. Design of the system is
divided into three layers:

 Station-level monitoring layer: includes main and standby servers operator station, engineer
station, communication processor, print server and other equipments.

 Communication layer: it is a bridge between spacer-layer and station-level monitoring layer

and also a confluence between assigned command and uploaded data.

 Spacer-layer: spacer-layer is responsible for data acquisition and execution of remote control
and remote adjustment command sent by the background. It mainly includes local control unit
(LCU) of unit, local control unit of public equipment, local control unit of switchyard and front
communication set, etc.

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 LK Series PLC Industry Solutions

Figure 1. Automatic Control System Diagram of Hydraulic Power Plant

中央控制室 Central control room

操作员站 Operator station

网络打印机 Network printer

数据管理站 Data management station

打印机 Printer

工程师站 Engineer station

UPS 电源 UPS power supply

100Mbps 环形工业以太网 100Mbps ring industrial Ethernet

通信站 Communication station

GPS 对时系统 GPS time-hack system

大屏幕 Large screen

培训仿真站 Training and simulation station

Oncall 站 Oncall station

省调 Provincial Dispatch Center

网调 Power Grid Dispatch Center

In addition, automation system of hydraulic power plant is equipped with GPS clock synchronizer,
Chinese audio alarm device, uninterrupted power supply (UPS), large screen projector, remote
monitoring terminal and operator's control console. After the comparison of technological economy,
users can select the configuration plans with superior cost performance according to the demand
condition of actual monitoring function.

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 LK Series PLC Industry Solutions

System Functions

The system is capable of the functions such as acquisition of operation state and parameter of main
equipment in real-time, security detection of every control point and monitoring point in hydraulic power
plant, off-limit alarm, SOE record, analysis of accident and fault audio alarm, etc. This plan can realize
economic operation, automatic generation control and automatic voltage control, automatic sequence
start-up and shutdown control of hydro-turbine and generator, switching operation of important electrical
equipments such as circuit breaker and isolating switch as well as other control functions. Meanwhile,
the system can be networked and receive dispatch command, and automatic closed-loop control will be
completed by control system of station. As the control core of the whole plant, the control system is
responsible for the communication function of network, water regimen measurement and industrial
television system besides monitoring function.

 Upper Level Control Function

Upper level computer of the system is capable of

acquiring and processing the real-time status of
hydraulic power plant and real-time operation
parameters, monitoring, adjusting of operation
parameters of controlled object, alarming and accident
recording, SOE recording, remote control record,
status query of historical data, report form processing
and printing, accident reviewing, calculation statistics,
displaying the operation state and parameter of
equipment in real-time, audio alarm and other functions. Meanwhile, the system can communicate with
synchronizer directly and read the clock reading, conduct time calibration to every sub-system on the
hour so that the clock of the whole computer control system remains the same. Thus, accuracy of
accident review can be guaranteed. Moreover, operation can be conducted according to water level or
the given active、reactive load curves and communication with electrical dispatching center is possible so
that communication between the power plant and dispatching center will be accomplished.

水轮机 Hydroturbine

尾水管 Water tail pipe

滤油机 Oil filter

排至集水井 Drained to collecting well

主阀 Main valve

开环运行 Open-loop operation

调速器 Speed governor

其余看不清楚

 Data Management

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As for all kinds of real-time data such as analog quantity

(unit, main transformer and U/I/F/P/Q/ cosφ of circuit,
electrical degree, pressure of oil/gas/water), switching
value (location of circuit breaker, emergency signal,
working state signal, etc) and temperature, upper level
computer of system can conduct digital filtering,
engineering unit conversion and judgment of logic
correctness. Then, the data will be divided into remote
measurement (YC), remote signaling (YX), electrical
degree (YM) and put into the corresponding database file for the purpose of real-time display and
promoting of events and operation by different image. Scanning module of the system software
refreshes the dynamic data in real-time and stores all the received data in hard disk on the hour. During
operation of system, data file with date will remain on the hard disk of upper level computer and these
data files will be stored in the historical database for the purpose of querying of operation parameter and
status. Data quantity can be 10years or determined upon the requirement of users.

 Dynamic and Real-time Control and Adjustment

The system is capable of calculating the optimal output of generator based on the water level of reservoir
and mathematical model and sending the data and command to local unit. Based on the received data
and command, local unit will adjust the active and reactive output of generator to the setting value
automatically so as to accomplish the dynamic and real-time adjustment. Remote control (YK) and
remote adjustment (YT) data file will be generated after the adjustment of system. These data files carry
with day markings and are stored in the historical database on hard disk for the purpose of querying.

 Automatic Generation Control (AGC)

Automatic power control operation, including three modes:

power control mode controlling the unit directly, given total
active power and given daily load curve of the whole plant.
Computer monitoring system is to realize the AGC when it
operates in the two latter modes.

 Automatic startup and shutdown control of unit

 Automatic adjustment of active power

 Remote Operation

Remote operation of startup and shutdown of generator,

generator circuit breaker, circuit breaker of main
transformer, line-breaker, circuit breaker of auxiliary transformer and other equipments can be
conducted by the system. The whole procedure of remote operation can be monitored in real-time.

 Accident & Fault Alarm and Review

Accident prompt message will be displayed on screen by the system when accident and fault happen.

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Meanwhile, the operator on duty will be informed about the position of accident and fault. System and
local control unit can handle the accident and fault quickly and accurately, record the relevant data
before and after the accident as well as the time of accident,
and, generate accident review record. Accident review
record can be displayed and printed in the form of data and
diagram for the purpose of analyzing.

 Sequence of Events Record

The system can record all the events (such as all kinds of
off-limits signal, accident signal, fault signal, remote
operation) that related to the equipments with certain
sequence in detail and generate data file for the purpose of
querying and printing.

报警页面 Alarm page

趋势显示 Trend display

趋势名称 Trend name

单位 Unit

当前值 Current value

量程 Range

综合生化池 Comprehensive biochemical reaction basin

综合生化池浊度 Turbidity of comprehensive biochemical reaction basin

综合生化池液位 Water level of comprehensive biochemical reaction basin

趋势左移一屏 Left shift of trend

综合池趋势 Trend of comprehensive basin

鼓风机频率反馈 Frequency feedback of air blower

回流泵频率反馈 Frequency feedback of reflux pump

其余看不清楚

 Event Trend Record and Analysis

The system can analyze the trend of parameters such as stator temperature, bearing temperature and
oil temperature of main transformer. If the changing rate of temperature trend exceeds the setting value,
alarm signal will be given.

Timed print, called-on print, accident print, screen print and other print methods are provided in the
system. Take advantage of the printing function of upper level computer, the required information can be
printed at any time.

 Self-diagnosis

The system has the functions such as self-diagnosis and fault tolerance, and the self-diagnosis

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report will be typed into the database. The monitoring system can automatically test the health condition
of intelligent device on every local unit as well as the whole network communication system. In case any
problem appeared, fault location will be shielded automatically and alarm will be given. After
trouble-shooting, the shield point will be removed automatically. The system is also capable of
self-restoring and retrying as well as remote diagnosis.

Transportations

Urban rail transit is the effective way to solve traffic jam and protect
ecology environment in modern cities, which is used widely in urban
transportation all over the world. Rail transit has been built or being built in
many cities in our country, as an inevitable trend to solve urban traffic
problems. Rail transit is a complicated and enormous system which
concerns hundreds of specialties. All its electromechanical control system
includes CONTROL technology, COMPUTER technology and NETWORK
technology and other modern science technologies. All these developing technologies have become the
technological basis for solving the integration problems in rail transit control system.

The typical systems in all electromechanical control systems of urban rail transit are Automatic Train
Control (ATC), Environmental Monitoring and Control System (EMCS), Fire Alarm System (FAS),
Supervisory Control And Data Acquisition (SCADA), Depot management system (DMS), Automatic Fare
Collection (AFC) system, Platform screen door System (PDS), Communication System and Closed
Circuit Television system (CCTV), etc.

 Environmental Monitoring and Control System (EMCS)

The EMCS of subway is designed to monitor and manage subway

ventilation and air-conditioning system as well as electromechanical
equipment being used directly by passengers, which is an indispensable
and important component of subway. Such electromechanical equipments
as lighting, water supply and drainage, guiding, platform screen door,
escalator, etc are used directly by passengers, whose operation condition
has a strong influence on service quality of subway. The EMCS
monitoring and managing operation of above mentioned equipments is in an important position during
subway operation. Environmental Monitoring and Control System with English abbreviation EMCS is
called BAS in Chinese subway specification. BAS system is a typical integrated system, which has three
basic characteristics of integrated system: open system, application requirement and interface.

 Supervisory Control and Data Acquisition for Electric Power (SCADA)

Called as SCADA system or telecontrol system, Supervisory Control and Data Acquisition for electric
power is developed on the demand of remote status monitoring and remote control for power supply
system equipments (e.g. circuit breaker and isolating switch). It carries out real-time control and date
acquisition for main substation, combined substation, step down substation and OCS switch
equipment, and it monitors the operation condition of power supply system equipment so as to indentify
and handle all kinds of accidents and warning events, which plays an indispensible role in improving the
reliability, safety and economic benefit of the power grid, reducing the workload of dispatcher, realizing

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the automation and modernization of power dispatch and raising the effectiveness and level of the
dispatch.

The system consists of local area network, master and standby server, master and standby operator
computer, maintenance computer, data & file computer and signal system adjusting computer, etc. In
mode of centralized management and distributed control, the automation system of substation consists
of control signal panel (including master control unit and LCD), lower level monitoring unit installed in
each switch cabinet and communication network in the station. Each lower level monitoring unit is
managed by master control unit and its data is exchanged through communication network in the station.

 Depot Management System (DMS)

DMS is a monitoring system independent of station, which comprehensively and effectively monitors and
manages the electromechanical equipments in buildings and areas located within depot, including
maintenance storeroom, master material storeroom, office building, motor building, bachelor apartment,
dinning room, entrance guard, fire control center, base maintenance area, traction substation, signal
equipment room, vehicle cleaning room, main substation and electromechanical equipments in other
areas such as air-conditioning and ventilation equipment, water supply and drainage equipment,
elevator, indoor illumination, waste water treatment system, car washing equipment, etc.

EMCS System of Subway

In recent years, with the rapid development of social economy and sharp
increase of urban population in our country, many large cities prefer rail
transit due to its mass transportation, rapid, safe and punctual
characteristics. Due to its own uniqueness, the operation process of rail
transit requires enormous electric power equipments to ensure the
normal operation of environmental temperature control, transportation
operation, communication signal, disaster prevention and warning, water
supply & drainage systems, etc.

Based on application solution of Environmental Monitoring and Control System (EMCS) LK series PLC
of Hollysys Company, the EMCS fully reflects the adaptability to the monitoring system of large scale
computer, the high reliability, excellent network expansion ability and good openness, etc..

Environmental Monitoring and Control System (EMCS) composes

central-station-local three levels control system, which allows itself
to monitor and manage fully and effectively all the
electromechanical equipments in each station of whole rail line,
ensures effective, energy-efficient and optimum operation status of
station equipments. In case of fire or accident conditions, control
station equipments will conduct disaster relief mode to make sure
the safety of passengers and normal operation of equipments. Main
monitoring subsystem or object of system includes fire warning system, ventilation equipments of tunnel
and platform, air-conditioning system, lighting system, water supply and drainage system, platform
screen door system and other electromechanical equipments.

3 System Structure

As shown in figure 1, the whole Environmental Monitoring and Control System (EMCS) consists of

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local station area network which includes three subsystems – ECS (Environmental Control System),
BAS (Building Automation System) and PIDS (Passenger Information Display System).

Figure 1 Structure of EMCS system network

ATC 系统 ATC system
通讯控制器 Communication controller
监控工作站 Monitoring working station
报表打印机 Report forms printer
事件打印机 Event printer
BAS 服务器 BAS server
FAS 系统工作站 FAS system working station
OA 系统 OA system
其它子系统工作站 Other subsystem working station
其它服务器 Other server
中央局域网 Central local area network
操作控制中心（OCC） Operation control center (OCC)
三山街站 San Shanjie station
张府园站 Zhang Fuyuan station
新街口站 Xin Jiekou station
地铁骨干网 Subway backbone network
南京站 Nanjing station
监控工作站 Monitoring working station
打印机 Printer
车站控制室 Station control room
光纤以太网环网 Optical Ethernet looped network
车站南侧环控电控室 Loop electric control room in the south side of station
车站北侧环控电控室 Loop electric control room in the north side of station
冗余 PROFIBUS-DP 总线 Redundancy PROFIBUS-DP bus line

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通风机房 Ventilator room

冷水机房 Cooling water machine room
照明配电电梯 Lighting distribution escalator
给排水 Water supply and drainage
配电照明 Distribution lighting
符号说明 Description of symbols
OCC 控制中心 OCC operation control center

SCR 车站控制室 station control room

FAS 火灾报警系统 Fire alarm system
IBP 集成后备面板 Integrated back-up panel
LCP 就地控制面板 Local control panel
pgMT 编程维护工作站 Program maintenance working station
BAS 环控系统 Environment control system
MCC 马达控制中心 Motor control center
R 路由器 Router
S 交换机 Switch

 ECS subsystem includes PLC controller (Redundancy configuration), I/O module equipment,
etc, which mainly monitoring the ventilation system of tunnel, station air-conditioning big/small
scale system, air-conditioning water system and platform screen door, etc.

 BAS subsystem includes PLC controller, remote I/O, which mainly monitoring the lighting
system, automatic escalator, and water supply & drainage system, etc;

 PID subsystem includes PLC controller, I/O module, etc, which mainly monitoring the station
guidance sign.

System Functions

EMCS system implements two-level management and

three-level control for equipments. The two- level
management refers to central-station level management,
with central level having the highest management right.
Meantime, the three-level control means
central-station-local control, with local control processing
the highest operation control level.

四号线少年宫站（405）： Line No.4, Children’s palace station (405)

隧道系统原理结构 Principle and construction of tunnel system
用户 user
管理员 administrator
级别 level
系统工程师 System engineer
管理 Management
图表 Diagram

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工具 Tool
调试 Debugging
帮助 help
未确认 Not confirmed
日期 Date
时间 time
车站名称 Name of station
报警等级 Level of alarm
描述 description
少年宫 Children’s palace
普通报警 Ordinary alarm
故障报警 Failure alarm
FAS 手动 FAS manual
活塞风亭 Piston kiosk
排风亭 Air exhaust kiosk
风亭 kiosk
下行 down
上行 Up
区间 Interval
至市民中心站 To citizen central station
车档隧道 Bumping block tunnel
正常 normal
设备手动 Equipment manual
灾害模式 Disaster mode
系统控制 System control
车站概貌 Station overview
隧道系统 Tunnel system
大系统 Large scale system
小系统 Small scale system
冷水 Cold water
给排水 water supply and drainage
照明 lighting
电扶梯 Escalator
屏蔽门 Shielding door
其它设备 Other equipment
主控 Master control
星期二 Tuesday

 ECS Subsystem

ECS subsystem is designed to implement automation management for ventilation and air-conditioning
equipments, satisfy the requirements for subway operation environment.

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Many equipments in ventilation system are used as fume

extractors during fire disaster. In normal condition, these
equipments implement control and monitoring according
to the requirement of environment control operation mode
by ECS subsystem. In case of fire, through the fire
command from station level FAS system, the ECS
subsystem will turn these equipments into pre-setting fire
operation mode to ensure the priority of FAS system
control command.

四号线少年宫站（405） Line No.4, Children’ palace station (405)

大系统图 Large scale system diagram
用户 User
管理员 Administrator
级别 Level
系统工程师 System engineer
管理 Management
图表 Diagram
工具 Tool
调试 Debugging
帮助 Help
未确认 Not confirmed
日期 Date
时间 time
车站名称 Name of station
报警等级 Level of alarm
描述 Description
少年宫 Children’s palace
普通报警 Ordinary alarm
高水位报警 High water level alarm
FAS 手动 FAS manual
正常 Normal
设备手动 Equipment manual
时间表编辑 Schedule editing
灾害模式 Disaster mode
系统控制 System control
新风亭 New kiosk
排风亭 Air exhaust kiosk
温风室 Warm air chamber
静压室 Static pressure chamber
站台送风 Air delivery of platform
站厅送风 Air delivery of station office
站台回排风 Air exhaust of platform

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站厅回排风 Air exhaust of station office

通道排烟 Fume exhaust of tunnel
车站概貌 Station overview
隧道系统 Tunnel system
大系统 Large scale system
小系统 Small scale system
冷水 Cold water
给排水 Water supply and drainage
照明 Lighting
电扶梯 Escalator
屏蔽门 Shielding door
其它设备 Other equipment
主控 Master control
星期二 Tuesday

ECS subsystem sets Integrated Backup Panel (IBP) in station control room. In case of train obstructed
and fire, it will implement emergency mode control to ventilation system equipments in tunnel, ventilation
equipments and fume extractors in public area of station.

The emergency mode control of ventilation air-conditioning small scale system is available on station
level monitor or maintenance station of small scale system equipment monitoring room.

ECS subsystem monitors the operation status of platform screen door in maintenance station of
equipment monitoring room and conducts failure warning.

 BAS Subsystem

BAS subsystem implements station-local two-level control

for station lighting system according to emergency lighting,
economic lighting, work lighting and advertisement lighting,
etc. The local control is set in lighting distribution room.
The control and operation gives priority to station level
control, which implements station level monitoring
activities for each type of lighting and carries out control
according to the schedule based on the service time of
subway.

四号线少年宫站（405）： Line No.4 Children’s Palace station

车间西端小系统结构原理图 Principle and construction diagram of small scale system in the
west of station
用户 user
管理员 Administrator
级别 Level
系统工程师 System engineer
管理 Management
图表 Diagram
工具 Tool
调试 Debugging

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帮助 help
未确认 Not confirmed
日期 Date
时间 Time
车站名称 Name of station
报警等级 Level of alarm
描述 Description
少年宫 Children’s palace
普通报警 Ordinary alarm
高水位报警 High water level alarm
FAS 手动 FAS manual
排风道 Air exhaust duct
送风道 Air delivery duct
正常 normal
设备手动 Equipment manual
模式 Mode
时间表编辑 Schedule editing
系统控制 System control
气瓶间 Gas cylinder room
蓄电池室 Battery room
照明配电室 Lighting distribution room
清扫工具室 Cleaning tool room
垃圾间 Dustbin room
备品库 Spare parts warehouse
站南端 South of station
站北端 North of station
系统选择 System selection
信号值班室 Signal duty room
电池间 Battery room
信号机械室 Signal machinery room
低压配电室 Low voltage distribution room
工务用房 Work room
屏蔽门室 Shielding door room
车站概貌 Station overview
隧道系统 Tunnel system
大系统 Large scale system
小系统 Small scale system
冷水 Cold water
给排水 Water supply and drainage
照明 Lighting
电扶梯 Escalator
屏蔽门 Shielding door
其它设备 Other equipment
主控 Master control
星期二 Tuesday

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In normal condition, the automatic escalator of station is controlled locally, with BAS subsystem
implementing central-station level monitoring for the operation status of each automatic escalator. In
emergency condition, the automatic escalator is stopped urgently in station control room.

The waste water pump, sewage pump, rain pump and section waste water pump are automatically
started and stopped according to high and low water level. The BAS subsystem monitors the operation
status of all pumps and sends warning messages that related to equipment failure and dangerous water
level. The electric butterfly valve of feed water pipe is automatically started and stopped by BAS
subsystem in equipment monitoring room, according to pre-set schedule, with its operation status being
monitored.

 PIDS Subsystem

The equipment monitoring room of guidance system controls the first, second and fourth types guiding
lighting box and third guiding lighting box according to normal operation, emergency condition or fire
situation.

Automation of Subway Substation

Subway power supply system provides electric energy for the

operation of subway. Subway power supply provides electric energy
not only for the operation of subway vehicle, but also for environment
control, lighting, signal and operation management system and all
facilities in the whole subway system. The safety and reliability of
subway power supply system guarantee the normal operation of
each system.

Adopting automation design of substation, because there are a lot of substations and equipments, in
additional with perfect comprehensive functions and the exchanging message in subway is in great deal.
Furthermore, it requires rapid transmission speed and high accuracy. In comprehensive automation
system of subway, the monitoring system is the key part to ensure a reliable operation of the whole
system. The automation system of subway substation adopts Hollysys Company's LK series PLC ,
which can completely meet the requirements of subway power supply and monitoring. All PLC hardware
of LK series is in industrial grade and it is reliable during operation. In addition, PLC modularization
design of LK series, hot plug with electricity and convenient wiring characteristics enable a convenient
maintenance and replacement of system.

Components of Automation System of Subway Substation

Through combining and optimizing the function and design of substation’s secondary equipments
(including measuring instrument, signal system, relay protection, automatic device and remote control
device, etc.), using advanced computer technology, PLC technology, communication technology and
signal processing technology, the comprehensive automation of substation realizes the automatic
function of automatic monitoring, measuring, control microcomputer protection, dispatching and
communication for main equipments and transmission/distribution line in whole station.

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The substation of subway adopts layered distributed functional division plan. The system has three
layers in longitudinal direction, namely as management layer of substation, network communication
layer and
interval

equipment layer. The system structure is shown as figure 1.

Figure 1 Automation System Structure of Subway Substation

地铁控制中心 OCC Subway operation control center (OCC)
地铁骨干网 Subway backbone network
路由器 Router
监控工作站 Monitoring working station
打印机 Printer
车站控制室（SCR） Station control room
光纤以太网环网 Optical Ethernet ring network
变电站电控室 Electric control room of substation

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LK 系统 PLC PLC of LK system

冗余控制器 Redundancy controller
FAS，BAS 等系统 FAS,BAS system
冗余 PROFIBUS-DP 总线 Redundancy PROFIBUS-DP bus line
远程 Remote
线路纵差保护装置 Longitudinal differential protection device of line
变压器保护测控装置 Transformer protection, measurement and control device
直流屏 DC screen
750V 电量保护测控装置 750v electric quantity protection, measurement and control device
750V 非电量保护测控装置 750v non electric quantity protection, measurement and control device
0.4V 保护测控装置 0.4v protection, measurement and control device
变压器温控装置 Transformer temperature control device
线路保护测控设备 Line protection, measurement and control equipment

Adopting PLC of Hollysys Company’s LK series, the main monitoring part in substation management unit
has redundancy function to realize PROFIBUS-DP network redundancy, increase the reliability of
communication between main controller and remote I/O. The power module also adopts Redundancy
configuration. Power supply adopts Redundancy configuration and two circuits DC power are input. This
will guarantee that if one of the circuit is power-off, the system can runs safely without disturbance so as
to improve the reliability.

As local protection device function becomes more and more powerful, the remote control and
telesignalling function can be realized by communication with protection device. The PLC of LK series
supports multiple communication protocols, so that it can easily communicate with the equipment of the
third party. The longitudinal differential protection device of line in this system communicates with control
center PLC through MODBUS protocol to meet the technical requirement of control, measure and
protection of comprehensive automation system of substation.

System Functions

 Monitoring Function

The monitoring function includes data acquisition, sequence of events record (SOE), failure record,
operation control function, safety monitoring function, man-machine interface function, print function,
data processing and recording function;

 Microcomputer Protection Function

Microcomputer protection includes the protection of main equipments and transmission line of whole
station, which includes, in detail, main protection and back-up protection of high voltage transmission
line, main protection and back-up protection of main transformer, protection of reactive compensation
capacitors, bus protection, distribution line protection, selection of single-phase grounding line of partial
grounding system.

 Function of Voltage, Reactive Comprehensive Control

The automatic control of voltage and reactive power in substation is mainly accomplished by
automatically adjust the tapping point position of loaded transformer and automatically control the
switching of reactive equipment or control its operation condition. There are three types of control
methods which are shown as following: centralized control, distributed control and interaction distributed

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control.

 Under-frequency Load-shedding Function

The frequency of power system is an important index of electric energy quality. When power system
operates normally, the frequency must keep within 50±（0.1～0.2）Hz. If the offset of system frequency
is overlarge, generating equipment and electric equipment will be influenced badly. So when the active
power shortage occurs, it is necessary to turn off partial load immediately to reduce the active power
shortage so as to keep the system frequency at the normal level or within the allowance.

 Automatic Switch Function of Reserve Power Supply

In substation which power is supplied by two circuits, the power incoming line can be divided into two
kinds as working power incoming line and reserve power incoming line. The automatic switch device of
reserve power supply is such a device that can automatically and rapidly put the reserve power supply
into operation when working power is turned off due to failure.

System Characteristics

Based on PLC of LK series by Hollysys Company, the characteristics of automation system of subway
substation are as follows:

 LK has perfect self-checking function. In addition to monitoring each unit through

communication, the protection and monitoring modules of each unit have strong self-checking
function and these two kinds of modules monitors each other’s status simultaneously. And if
any abnormal condition happens, it will warn in time so as to increase the reliability of system
during operation.

 Adopting LK Redundancy system, it is available for power redundancy, CPU redundancy,

Ethernet and bus line redundancy.

 Provided with multiple communication interface such as Redundancy Ethernet interface,

Redundancy PROFIBUS-DP bus line interface, RS485 and RS232 interface.

 Resolution ratio of SOE record reaches 100us.

 Adopting normal open and normal close double position contact for status messages of
switches and isolator, judging its validity by using software

 Adopting PLC instead of conventional RTU for monitoring system; uploading the data collected
by each intelligent module to communication controller through site bus line

 Adopting computer simulation alarm window instead of conventional alarm window, displaying
message according to layers of different voltage grades

 Simplifying the design of anti-mal-locking, using hardwiring between important equipments to

realize interlock function, comprehensive automatic software having logic judgment function,
considering the accumulated operation and maintenance experience, interlock will not be
conducted in background software

 For transient state deflection signal, adopting self-holding method after processed by software.
The signal will not disappear without manual confirmation

Depot Management System (DMS)

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DMS is a monitoring system independent of station, which comprehensively
and effectively monitors and manages the electromechanical equipments in
buildings and areas located within depot, including maintenance storeroom,
master material storeroom, office building, motor building, bachelor
apartment, dinning room, entrance guard, fire control center, base
maintenance area, traction substation, signal equipment room, vehicle
cleaning room, main substation and other areas such as air conditioning and ventilation equipment,
water supply and drainage equipment, elevator, indoor illumination, waste water disposal system, car
washing equipment, etc.

System Construction

DMS adopts PLC of LK series by Hollysys Company to control equipments and the system construction
adopts distributed control and centralized management method. Local area network of monitoring layer
and control layer of DMS is formed by connecting controllers and IBP panel controllers in each area into
depot control center through Redundancy industrial level Ethernet exchanger. Meanwhile, the depot
control center is the center of depot electromechanical equipment monitoring center and fire warning
command center. The system construction of DMS is shown as following figure.

Figure 1 System Construction of DMS

IBP 控制盘 IBP control panel
消防及设备控制室 Fire and equipment control room
车辆段控制中心 Depot control center
服务器 Server
辅助 PLC 控制器 Auxiliary PLC controller
操作员站 Operator station
打印机 Printer
维护工作站 Maintenance work station
FAS 接口 FAS interface

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100Mbps 光纤冗余环形工业以太网 100Mbps optical redundancy ring industrial Ethernet

工业以太网交换机 Industrial Ethernet switch
通信控制器 Communication controller
其他设备或控制系统 Other equipment and control system
LK 冗余控制器 LK Redundancy controller
I/O 控制柜 I/O control cabinet
电机楼 Motor building
物资总库 Master material storeroom
检修库 Maintenance storeroom
主变电所楼 Main substation building
门卫及消防控制中心 Entrance guard and fire control center
停车线 Stop line
焊接车间变电所 Substation of welding workshop
物业平台下停车列检线 Train parking and inspecting line under the platform
洗车库 Vehicle cleaning room

 Redundancy LK PLC controller and DMS monitoring work station are installed for depot guard
room and fire control room to monitor depot electromechanical equipments. Communication
interface equipments connecting escalator and intelligent lighting systems are set in depot
guard room and fire control room to realize data communication with related systems.
Integrated backup panel (IBP) is set in fire fighting room and equipment control room. LK
auxiliary PLC controller, which is set in integrated backup panel, is designed to receive control
command of panel buttons, displaying the operation mode status on the panel through
indicating lamp. Data communication interface connecting FAS main warning computer is set
in PLC integrated backup panel which is emergent backup in case of fire. It is available to
realize coordinated control function of FAS warning and DMS.

 Setting DMS maintenance working station in depot control center

 Setting communication controller in equipment room to realize communication interface

treatment with other equipment or control system

 Setting UPS Uninterruptible Power Supply in fire room and equipment control room to supply
power centrally for system equipments in this area

 Setting remote I/O control cabinet at the concentrated area of the equipments being controlled
to monitor and control site equipments through connecting Redundancy PROFIBUS-DP site
bus line to PLC controller in each area

Monitoring Management Mode

 Normal Operation Mode

Under normal operation condition, DMS monitors operation status of each equipment, receives warning
signal, sends operation status messages and tested environment messages of equipment to fire and
equipment control room, receives all kinds of monitoring commands from fire and equipment control
room and transform the operation mode of equipment.

 Fire Operation Mode

In case of fire at depot, DMS receives fire warning signal from FAS system, stops non-fire fighting

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apparatus, controls relevant fan to enter smoke control state to discharge smoke effectively.

 Mode Control

Including automatic control, manual control and IBP panel control

System Functions

 Monitoring Function

DMS is able to monitor and record the operation status and parameter of ventilation and
air-conditioning system, water supply and drainage system, escalator and all controlled equipments.
The status message and parameter message of equipment are displayed on monitoring screen of DMS
monitoring working station; the operator monitors the status of all electromechanical equipments
through monitoring screen of monitoring working station.

 Control and Adjustment Function

DMS monitoring system is able to monitor and control ventilation and air-conditioning system, water
supply and drainage system, escalator system and various electromechanical equipments, give an
alarm for failure status. DMS monitoring system has PID adjustment and control function, logic control
function and mode control function.

 Alarm Processing Function

DMS is able to display the failure status of main equipment and send out warning messages, which has
the function such as audible and visual alarm, automatic ejection of warning screen, warning
confirmation and processing function. The real-time alarm displays high water level and filter screen
blocked alarm, etc.

 Display, Print and Record Function

DMS is able to record and display the data of various sensors. For various messages, it is able to carry
out real-time record and query, establish equipment management database, automatically generate
various statistical statement as necessary, periodically print data statement (daily statement, weekly
statement, monthly statement, etc.)

 Protection Measures and Self-diagnosis Function

DMS has protection measures which open different operation authorities for different level’s operators
and it is capable of on-line maintenance and self-diagnosis function.

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Gas

Pipeline transmission is one of the major transportation methods for

natural gas, and a unified sealing gas transmission system has formed
from oil and gas wellhead to end users, going through mine gas
gathering, cleaning, compressor station, gas distribution station and
regulating-metering station, etc. According to transportation distance,
operation mode and transportation purpose, gas transmission pipeline is
generally classified into three categories: the first is the mine site pipeline under the internal
management of oil and gas fields, often referred to as mine gas gathering pipeline; the second is the
trunk gas transmission pipeline under the jurisdiction of a pipeline transmission company , often referred
to as long-distance gas transmission pipeline; the third is the urban gas transmission pipeline invested,
built, operated and managed by the former city gas company or other gas companies, often referred to
as urban transmission and distribution pipeline network.

Long Distance Transportation Pipeline

A long distance transportation pipeline is generally composed of gas
transmission trunk, initial station, middle gas transmission substations, trunk
intercepting valve chamber, middle gas receiving station, pigging station,
stations across obstacles (rivers, railways, water conservancy, etc.), end
station (or city gate station), city gas storage & distribution station and
compressor station.

Urban Transmission and Distribution Pipeline Network

Urban Natural Gas Transmission and Distribution Network is composed of city gate station, city
high-pressure pipeline network, high and medium pressure regulator station, medium pressure trunk
pipeline network, medium pressure secondary trunk pipeline network and courtyard pipeline network.

Gas SCADA System

Gas distribution dispatching management system completes the monitoring,
dispatching and management tasks of the pipeline network and all the process
stations. After the system is put into operation, operators can complete the
monitoring and operational management upon the pipeline network in the main
dispatching control center, backup control center and regional control station.

The operation mode of the SCADA system includes centralized monitoring and control by the
dispatching center, automatic/manual control in all the process stations, automatic/manual control of
single station equipment, and automatic/manual control of station subsystems.

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 SCADA system of long distance gas
transmission pipeline

 City gas SCADA system

 Gas metering and remote meter reading

system

 Monitoring of LPG evaporation and gas

mixing station

 Monitoring of LPG bottling and canning

stations

 LNG station control system

 Monitoring of CNG gas filling station

 Monitoring of natural gas storage station

 Video monitoring of natural gas stations

 Monitoring of large gas application facilities

 Gas Geographic Information System（GIS）

 Integrated system of gas supply service

center
 SCADA System of Long Distance Gas Transmission Pipeline

The long distance gas transmission pipeline system consists of initial station, transmission substations,
intermediate compressor station, pigging station, valve chamber and cathodic protection station. The
automation control system of natural gas pipeline project adopts a Supervisory Control and Data
Acquisition (SCADA) system which makes the computer as the core. The system can complete the
monitoring, dispatching and management tasks upon the whole gas pipeline in the dispatching control
center, and thus, the stations throughout the whole pipeline can achieve a control and management level
of unmanned operation with someone on duty. The SCADA system mainly consists of three major parts,
namely the dispatching control center, station control system (SCS) and data transmission and
communication system.

 Dispatching control center：Based on the scale of the SCADA system, the chief dispatching

control center, backup dispatching control center or regional dispatching control center can be
set up to monitor, dispatch and manage the whole pipeline through the data acquisition and
control of the PLC system in each station as well as the monitoring and managing the pressure,
temperature, flow, density, equipment operating status and other information of the pipeline
system in process;

 Station control system

（ SCS）：According to the distribution of stations in the pipeline network,

station control systems of different sizes (SCS) are set up in the initial station, end station,
transmission substations, intermediate compressor station, pigging station and intercepting
valve chamber, cathodic protection station and others. The station control systems are the
remote monitoring stations of the SCADA system, which implement the commands of the main
dispatching control center, complete the data acquisition and processing in the station as well
as interlocking protection, continuous control and monitoring the running status of process
equipment, and also upload various collected data and information to the dispatching control
center;

 Data transmission and communication system：It completes data communications between

station control systems and dispatching control center; in general, industrial optical fiber
Ethernet is used, and optical fiber is laid along with long distance gas transmission pipeline.
 LK Series PLC Industry Solutions

Configuration Diagram of SCADA System for Long-distance Gas Transmission pipeline

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 LK Series PLC Industry Solutions

主调度中心 Master Dispatching Center

操作员工作站 Operator Workstation
工程师工作站 Engineer Workstation
视频工作站 Video Workstation
网络打印机 Network printer
GIS 工作站 GIS Workstation
仿真工作站 Simulation workstation
投影仪 Projector
交换机 Switch
交换机 Switch
GIS 服务器 GIS Server
仿真服务器 Simulation Server
DLP 大屏幕 DLP Large Screen
UPS 电源 UPS Power Supply
历史服务器 History Server
磁盘阵列 Disk array
历史服务器 History Server
实时服务器 Real-time server
核心交换机 Core switch
光纤以太网交换机 Optical Ethernet Switch
WEB 服务器 WEB Server
办公局域网 Office LAN

备用调度中心 Standby Dispatching Center

操作员工作站 Operator Workstation
操作员工作站 Operator Workstation
工程师工作站 Engineer Workstation
视频工作站 Video Workstation
网络打印机 Network printer
交换机 Switch
WEB 服务器 WEB Server
UPS 电源 UPS Power Supply
历史服务器 History Server
磁盘阵列 Disk array
实时服务器 Real-time server
核心交换机 Core switch
光纤以太网交换机 Optical Ethernet Switch
光纤工业以太网（光纤随管道敷设） Optical Industrial Ethernet (laid together with
pipelines)
主控机 Master controller
打印机 Printer
视频工作站 Video Workstation
工业以太网交换机 Industrial Ethernet switch

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LK 冗余 PLC LK Redundancy PLC

远程 I/O Remote I/O
LM 小型 PLC(含 GPRS/CDMA 模块) Small PLC of LM （ containing GPRS/CDMA
modules）
硬盘录像机 Hard disc recorder
视频转换器 Video converter
摄像头 camera
光纤交换机 FC switch
UPS 电源 UPS power supply
首站 Initial station
分输站 off-take station
末站 End station
阀室 Valve chamber

Urban Natural Gas SCADA System

Urban gas system is composed of city gate station, city high-pressure pipeline network, high and
medium pressure regulator station, medium pressure trunk pipeline network, medium pressure
secondary trunk pipeline network and courtyard pipeline network. The SCADA system consists of three
major parts, namely dispatching control center, station control system and data transmission and
communication system.

 Dispatching control center：Based on the scale of the SCADA system, chief dispatching

control center, backup dispatching control center or regional dispatching control center can be
set to complete monitor all major stations in urban high and medium pressure gas network, and
remote intercepting valve chambers, as well as all the monitoring points in the medium
pressure pipeline network, and realize a series of tasks, such as pipeline network optimization,
development of transportation planning, and measuring control;

 Station control system

（ SCS）：According to the distribution of stations in the pipeline network,

station control systems (SCS) of different sizes are set up in the gate station, regulator station,
remote intercepting valve chamber, and monitoring points of the pipeline network. SCS is the
remote monitoring station of the SCADA system, which implements the commands of the main
dispatching control center, completes the data acquisition and processing in the station as well
as interlocking protection, continuous control and monitoring the running status of process
equipment, and also uploads various data and information collected to the dispatching control
center;

 Data transmission and communication system： It completes the data communications

between station control systems and dispatching control center and supports the wired (VPN
lines, fiber-optic communications, frame relay, PSTN dial-up, etc.) and wireless communication
(radio communication, GPRS, CDMA, etc.). It can select the best communication mode through
combining the costs and local resources.

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 LK Series PLC Industry Solutions

Configuration Diagram of Urban Natural Gas SCADA System

主调度中心 Master Dispatching Center
操作员工作站 Operator Workstation
工程师工作站 Engineer Workstation
视频工作站 Video Workstation
网络打印机 Network printer
GIS 工作站 GIS Workstation
仿真工作站 Simulation workstation
投影仪 Projector
交换机 Switch
交换机 Switch
GIS 服务器 GIS Server
仿真服务器 Simulation Server
DLP 大屏幕 DLP Large Screen
UPS 电源 UPS Power Supply
历史服务器 History Server
磁盘阵列 Disk array
历史服务器 History Server
实时服务器 Real-time server

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 LK Series PLC Industry Solutions

核心交换机 Core switch

路由器 Router
WEB 服务器 WEB Server
办公局域网 Office LAN

备用调度中心 Standby Dispatching Center

操作员工作站 Operator Workstation
操作员工作站 Operator Workstation
工程师工作站 Engineer Workstation
视频工作站 Video Workstation
网络打印机 Network printer
交换机 Switch
WEB 服务器 WEB Server
UPS 电源 UPS Power Supply
历史服务器 History Server
磁盘阵列 Disk array
实时服务器 Real-time server
核心交换机 Core switch
办公局域网 Office LAN
主控机 Master controller
打印机 Printer
视频工作站 Video Workstation
工业以太网交换机 Industrial Ethernet switch
LK 冗余 PLC LK Redundancy PLC
远程 I/O Remote I/O
LM 小型 PLC(含 GPRS/CDMA 模块) Small PLC of LM （ containing GPRS/CDMA
modules）
硬盘录像机 Hard disc recorder
视频转换器 Video converter
摄像头 camera
光纤交换机 FC switch
UPS 电源 UPS power supply
门站 Gate station
储配站 storage and distribution station
阀室 Valve chamber
工业用户 Industrial user
中中压调压站 Regulator station of medium-medium pressure
中低压调压站 Regulator station of medium-low pressure

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 LK Series PLC Industry Solutions

Dispatching Control Center

The main task of the dispatching control center is to perform the data
acquisition and control through PLC systems in each station as well as
monitor and manage the pressure, temperature, flow, density, equipment
operation and other information of the pipeline system in process. Its
computer system is set according to client/server structure and its operating
system uses UNIX (server) and Windows (client). The local area network is
100Mb/s high speed Ethernet. Its servers use distributed structure,, which are set separately according
to the functions so as to reduce the load on a single server. The servers adopt dual computer
hot-standby, while the LAN has Redundancy configuration with the operator workstation, simulation
workstation and engineer workstation, etc as the nodes on the LAN to share server resources. Its main
functions are as follows:

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 Dynamic display of process flow

 Alarm display, alarm management and

incident inquiry and print

 Real-time data acquisition and trend

display

 Archiving, management of historical data

and historical trend display

 Issue the pressure and flow settings to

stations within the pipeline network

 Generate and print the production

statistic report forms.

 Issue the dispatching and operation

commands

 Pipeline failure treatment, such as

pipeline leakage, and non-normal
shutdown of stations along the pipelines

 Issue ESD commands

 Confirm the control authority

 Implement the configuration application

software and user-generated application
software

 Security protection

 SCADA system diagnosis

 Provide the MIS system with data

 Configuration Diagram of the System in the Dispatching Control Center
调度控制中心 Dispatching Control Center
操作员工作站 Operator Workstation
工程师工作站 Engineer Workstation
视频工作站 Video Workstation
网络打印机 Network printer
GIS 工作站 GIS Workstation
仿真工作站 Simulation Workstation
投影仪 Projector
交换机 Switch
GIS 服务器 GIS Server
仿真服务器 Simulation Server
DLP 大屏幕 DLP Large Screen
UPS 电源 UPS Power Supply
 LK Series PLC Industry Solutions

历史服务器 History Server

磁盘阵列 Disk array
历史服务器 History Server
实时服务器 Real-time server
核心交换机 Core switch
光纤以太网交换机 Optical Ethernet Switch
办公局域网 Office LAN
WEB 服务器 WEB server
光纤工业以太网（随管道铺设） Optical Industrial Ethernet(laid together with the
pipelines)

Station Control System

The station control system (SCS) is a remote monitoring station of natural gas
SCADA system, which lays the foundation for ensuring the normal operation
of the SCADA system. For the long distance transportation pipeline, the
station control systems are generally set in the initial station, transmission
substations, intermediate compressor station, pigging station and valve
chamber, cathodic protection station, and end station; while for the urban
transmission and distribution network, the station control systems are generally set in the gate station,
regulator station, industrial users and valve chamber.

The station control system mainly consists of monitoring computer, programmable logic controller (PLC),
instrument and transmitter, as well as communication equipment. The PLC in the station control system
uses LK Series, which supports dual computer hot-standby, power redundancy, Ethernet and bus
redundancy, and communicates with third-party equipment in the station by use of standard MODBUS
communication.

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Configuration diagram of station control system

站控系统配置图 Configuration Diagram of Station Control System
(SCS)
站控系统（SCS） Station Control System (SCS)
至主控中心 To the master control center
打印机 Printer
操作员站 Operator Station
操作员站 Operator Station
打印机 Printer
工程师站 Engineer Station
光纤 Optical Fiber
100M 冗余工业以太网 100M Redundancy Industrial Ethernet
UPS 电源 UPS Power Supply
LK 冗余 PLC LK Redundancy PLC
冗余 PROFIBUS-DP 现场总线 Redundancy PROFIBUS-DP field bus
硬盘刻像机 Hard disk carved camera
摄像头 Camera

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 LK Series PLC Industry Solutions

远程 I/O Remote I / O
远程 I/O Remote I / O
远程 I/O Remote I / O
视频转换器 Video Converter

According to process parameters, the station control system in the initial station integrates following
functions and completes local and remote monitoring respectively.

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 LK Series PLC Industry Solutions

 Display the dynamic process flow

 Perform the data acquisition and processing upon the site process variables

 Monitor the running status of various process equipments

 Exchange the information with monitoring systems or intelligent devices of the third party via
communication interface

 Display various process parameters and other relevant parameters

 Display alarm list

 Monitor power equipments and related variables

 Test relevant variables of the cathodic protection station

 Provide a window for man-machine dialogue

 Upload data to the main dispatching control center

 Receive parameter setting and control commands sent from the dispatching control center

 Gas flow calculation

 Video surveillance

Municipal Engineering

Water Plant

Water plant is composed of the fist-stage pump station, chlorination room, air blower house, flocculation
sedimentation tank, filter, clean water tank and secondary pump station and others. Water source first
passes through the primary pump station (or water intaking pump station) to the water plant, and then
flows to the flocculation sedimentation tank after disinfection; after flocculation – sedimentation, it enters
the filter. The filter is an important part of the water plant, and is used to filter suspended solids in water.
In the process of filtering, it should realize the adjustment of constant water level in the filter and the filter
backwash (air impact – watering - gas-water mixture) as well as other functions. Then the filtered water
flows into the clean water tank. After disinfection, it will be delivered to the urban pipeline network via the
secondary pump station.

Fig 1 Process Flow Diagram of Water Plant

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 LK Series PLC Industry Solutions

水源 Water source
一级泵房 first-stage pump house
混合絮凝及平流沉淀池 Mixed flocculation and advection sedimentation
tank
滤池 Filter
清水池 Clean water tank
吸水井 Absorbing well
二级泵房 Second-stage pump house
自来水管网 Water pipe network
Filter is an important part of water purification process in a water plant. There are a variety of filter types,
and the ordinary rapid filter with quartz sand as the filter material has a long usage history. On this basis,
people have developed other types of rapid filters from different process sides. V-type filter is developed
on this basis by Degremont Company of French in the 1970s. It uses a coarser and thicker quartz sand
filter layer with uniform particles, adopts the surface sweep washing that does not enable the air and
water expanded on the filter layer to be backwashed and functions to filter water, and uses air
distribution of air cushion and special long-handled filter head for air and water distribution and other
processes. It has the features, such as good water quality, high filtration rate, long running cycle, good
backwash effect, energy efficiency and ease of automation and management.

Sewage Treatment Plant

A typical municipal sewage treatment process mainly includes mechanical treatment, biological
treatment, sludge treatment and other sections, as
shown in Figure 2. The system composed of
mechanical treatment and biological treatment
belongs to the second-stage treatment system with
BOD5 and SS removal up to 90% to 98%. The
treatment effect between the primary and secondary
treatment is commonly referred to as enhanced
图 2 污水处理厂工艺流程图
primary treatment, one-and-a-half-stage treatment or
incomplete secondary treatment, mainly including two categories— high-loading biological treatment
process and chemical process. The removal rate of BOD5 can be up to 45% to 75%. The secondary
treatment system with function of biological phosphorus and nitrogen removal is often referred to as the
advanced secondary treatment. In order to remove specific materials, the treatment system following the
secondary treatment is often called tertiary treatment, which includes chemical phosphorus removal,
flocculation filtration, and activated carbon adsorption, etc.

图 2 污水处理厂工艺流程图 Figure 2 Process Flow Diagram of Sewage

Treatment Plant
机械处理 Mechanical treatment
生化处理 Biochemical treatment
污泥处理 Sludge treatment

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 LK Series PLC Industry Solutions
 Section of Mechanical Treatment

The section of mechanical (primary) treatment includes the screen, sewage lift pump station, grit
chamber, primary setting tank and other structures to remove coarse particles and suspended solids; the
principle of treatment is to achieve solid-liquid separation by physical method, and to separate pollutants
from wastewater. This is a sewage treatment method in wide application. The mechanical (primary)
treatment is a necessary work for all the sewage treatment processes (though the primary setting tank is
omitted in some processes sometimes), the BOD5 and SS removal rates in the primary treatment of
urban sewage is typically 25% and 50% respectively.

 Section of Biochemical Treatment

Biological treatment is the core of the entire sewage treatment process, so the sewage treatment
process we call is particularly referred to this specific part, such as the oxidation ditch process, SBR
process, and A/O process, etc. Biochemical sewage treatment belongs to the secondary treatment and
is mainly to remove suspended solids as well as dissolved and biodegraded organic matters. At present,
most of the urban sewage treatment plants use activated sludge process. The principle of biological
treatment is to decompose organic matters and synthesize organisms through biological action,
especially the microbial action, and to change the organic pollutants into harmless gaseous products
(CO2), liquid product (water) and solid products rich in organic matters (also known as microbial
population or biological sludge); excessive biological sludges are separated in the sedimentation tank by
solid-liquid sedimentation and then removed from the purified sewage.

 Section of Sludge Treatment

The sludges in the section of biological treatment first go into the sludge pump station. Part of sludges
flow back to the section of biological treatment, and the part of the sludges (excessive sludge) are
transported quickly by sludge pump into the sludge concentration tank. After concentration in the sludge
concentration tank for a certain time, the supernatant fluid flows back to the collecting basin in the
sewage lift pump station; the concentrated sludges flow back to the another sludge conditioning tank,
and are lifted with a sludge lift pump to the sludge dewatering house. After the sludges are dehydrated in
a dewatering room, they are made into mud cakes and then sent out.

Currently, the common sewage treatment processes are A2/O process, oxidation ditch process, SBR
process, CASS process, CAST process, AB, biological contact oxidation process (BOC), biological
aerated filter process (BAF), and biofilm process, etc.

Recycling of Recycled Water

There are two main forms to treat domestic sewage: one is where there is a pipeline network of urban
sewage plant around, the domestic sewage flows into the pipeline network and is treated by urban
sewage treatment plant; the other is that domestic sewage that is unable to enter the pipeline network
will be treated by the sewage treatment facilities built on the spot; then, it will be discharged after
reaching the standard or go further processing to meet the purpose of water reuse. The latter form is
mainly discussed here.

The domestic sewage is taken as the water source. After appropriately treatment, it can be used as
mixed water with water quality between upper water and lower water, so it is called recycled water and

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the relevant technology is called recycled water technology. For the water shortage areas with fresh
water shortage and severe shortage of urban water supply, the use of the recycled water technology can
not only save water, but also make sewage harmless, so it is an important way of controlling water
pollution, and is also a new technology and new process being and to be focally promoted in the our
country.

 Recycled Water Source

Recycled water source includes cooling drainage water, shower drainage water, washing drainage water,
kitchen drainage water, toilet drainage water, and the water out of secondary setting tank in municipal
wastewater treatment plants. Generally, industrial wastewater is not used as a recycled water source,
and the sewage from infectious disease hospitals, tuberculosis hospitals and the radioactive sewage are
prohibited as the recycled water source. For residential buildings, the drainage water other than toilet
and domestic wastewater can be considered as a recycled water source; for large public buildings,
hotels, commercial and residential buildings and so on, the cooling drainage water, shower drainage
water, and washing drainage water are used as the recycled water source; the drainage water from
public canteens and restaurants has a high water pollution level and is complicated to get treated, so it
should not be used; because the drainage water from large laundry rooms contains a variety of
detergents, whether it can be a recycled water source will be determined by test.

 Recycling Process of Recycled Water

In order to treat the sewage into the water meeting water quality standards, it is generally required to be
treated in three phases:

(1) Pretreatment: in this phase, there are mainly two processing units— screen and regulating pool, and
the main role is to remove solid impurities and uniform water quality in the sewage.

(2) Main treatment: this phase is the key to treat recycled water, and the main role is to remove dissolved
organics in the sewage.

(3)Post-treatment: this phase gives the first place to disinfection and carries out deep treatment of outlet
water, so as to ensure that outlet water reaches the recycled water standards.

Heat Supply
Central heating is one of the urban infrastructures, and also a hallmark for
the city’s modernization level. The development of central heating has great
significance for energy conservation, environmental enhancement and the
improvement of people's living standards and has good social, economic and
environmental benefits; and thus, it is very urgent and necessary for the city’s
development and improvement in the field of central heating.

Urban central heating information management, dispatching and automation system collects heat supply
information from boiler rooms, heat transfer stations, geothermal wells, thermoelectric, thermal and other
aspects in the city, and performs the centralized monitoring, comprehensive analysis, coordination and
dispatching so as to improve the management level of the heat supply industry.

The urban central heating information management dispatching and automation system plays a very

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important role in ensuring the high-quality heat supply, safe operation, economic energy saving and
environmental protection of the heat supply system. Through the construction of the urban central
heating information management dispatching and automation control system, it will be able to collect all
the main information from the city's heat supply projects, perform the centralized monitoring,
comprehensive analysis, coordination and dispatching and improve the efficiency so as to change the
heat supply industry from extensive management to intensive management and promote the
improvement on the overall control level of the heat supply industry.

Figure 3 Diagram of Monitoring System for the Heat Supply Structure

管理层 Management level
调度中心 Dispatching Center
维修中心 Maintenance Center
运行管理 Operating Management
厂长室 Director Room
总工室 Chief Engineer Office
生安部 Department of Production and Safety
通过采用先进的企业互联网 Intranet 技术，把工 Use the advanced enterprise Internet technique,
况数据在企业范围内予以发布，授权用户就可以像 Intranet, to release the working data within the
互联网一下，不受时间和地域的现在，随时随地掌 enterprise, and the authorized users can grasp the

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握管网的运行工况。 operating condition of the network at any time

anywhere like the Internet
通信层 Communication Layer
市话网/宽带电话网 Local call network/ broadband telephone network
光缆/屏蔽双绞线 Optical Cable / shielded twisted pair
无限数传网 Unlimited data transmission network
有线、无线、电话拨号或多种的组网方式 Wired, wireless, dial-up or a variety of networking
modes
控制层 Control layer
换热机组 Heat exchanger unit
控制柜 Control cabinet
LK PLC 控制器 LK PLC controller
智能表 Smart meter
变频器 Frequency Inverter
以换热站 LK PLC 控制器为核心，实现就地自动控 Use the heat transfer station’s LK PLC controller
制、图形、数据、趋势就地显示，并能实现网上监 as the core to show the local automatic control,
控累积计算，量值比较及数据追补和数据保存。 graphics, data and trends, and achieve cumulative
calculation of online monitoring, comparison of
values and data supplement and data
preservation.
现场层 Field layer
热流量调节阀 Heat flow control valve
泵 Pump
电磁阀 Solenoid valve
流量计 Flowmeter
压力开关 Pressure Switch
温度开关 Temperature switch
压力变送器 Pressure Transmitter
热电偶 Thermocouple

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Water Plant

The water plant consists of primary pump

station, chlorination room, air blower
house, flocculation sedimentation tank,
filter chamber, clean water tank and
secondary pump station, etc. Water
source first passes through the primary
pump station (or water intaking pump
house) to the water plant, and after
disinfection, it enters the flocculation
sedimentation tank; after flocculation –
sedimentation, it goes into the filter. The
filter is an important part of the water plant,
and is used to filter suspended solids in 图1 水厂工艺流程示意图
water. In the process of filtering, it should
realize the adjustment of constant water level in the filter and the filter backwash (air impact – watering -
gas-water mixture) as well as other functions. Then the filtered water flows into the clean water tank.
After disinfection, it will be delivered to the urban pipeline network via the secondary pump station.

The water plant applies the automation control system which is mainly based on the LK programmable
logic controller (PLC) of Hollysys Company to realize the production control, operation, monitoring and
management. The system not only has reliable hardware equipment, but also has powerful, reliable,
user-friendly system software, application software, programming software and control software. Its
operating and maintenance costs are low, and it is easy to operate.

图1 水厂工艺流程示意图 Figure 1 Schematic Diagram of Water Plant

Process
源水 Source water
取水泵房集水井 Collecting well in the water intaking pump house
前消毒 Pre-disinfection
絮凝-沉淀-过滤-后消毒 Flocculation - sedimentation - filtration –
post-disinfection
清水池 Clean water tank
送水泵房 Water supply pump house
用水户 Water users
市区管网 Urban pipe network
出厂输水干网 Outlet water trunk network

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 LK Series PLC Industry Solutions

Automation Control System Design

In order to ensure safe and reliable control process of the water plant project and the continuity of
production, and to improve the level of automation, the automation control system with the combination
of the centralized and dispersed mode
mainly based on Hollysys Company's LK
Series PLC is used. It is mainly used for
the water plant's production control,
operation, monitoring and management.

The whole system consists of a central

monitoring station, six field control
stations (PLC1 ~ PLC6) and 8 PLC
substations (PLC2-1 ~ PLC2-8). The
central monitoring station is composed
of two central monitoring computers
(standby for each other), server,
large-screen projection system, GPRS
DTU, director office computers, engineer 图 2 自来水厂自动化控制系统示意图
office computers, and production
department computers. The field control station applies the programmable logic controllers (PLC), which
are used for the dispersed control of each process in the process system. These PLCs are separately
set in chlorine dosing room (PLC1), water purification room (PLC2), 8 filter chambers (PLC2-1 ~
PLC2-8), water pump house (PLC3), sludge dewatering house (PLC4), pure water preparation plant
(PLC5), and heat transfer room (PLC6). Among these controllers, PLC5 and PLC6 are provided in
complete set by the process equipment manufacturers. The central control room’s monitoring computers
with the director office computers, engineer office computers, laboratory computers, large screen
projector and other computers, switches, hub (HUB), or router constitute a 100Mbps industrial Ethernet.

中国移动 GPRS 通讯网络 China Mobile GPRS communication network

图 2 自来水厂自动化控制系统示意图 Fig 2 Diagram of Water Plant Automation Control
System
工程师站 Engineer Station
服务器 Server
厂长室 Director Room
生产部门 Production department
化验室 Laboratory
取水泵站 Water intaking pump house
中央控制室 Central Control Room
通信计算机 Communication Computer
打印机 Printer
中央管理计算机 Central management computer
中央管理计算机 Central management computer
打印机 Printer
GPD 电源 GPD power supply

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 LK Series PLC Industry Solutions

投影仪 Projector
100Mbps 环形光纤工业以太网 100Mbps Ring Fiber Industrial Ethernet
LK 系列 PLC LK Series PLC
加氯药间 Chemical and chlorine dosing room
净水间 Water purification room
送水泵房及变配电间 Water supply pump house and power distribution
room
污泥脱水机房 Sludge dewatering room
纯净水制备车间 Pure water preparation room
换热间 Heat transfer room
滤格 Filter screen
Industrial Ethernet is used between the central control room (operation station, engineer station) and
sub-control station (PLC), and it is a fiber optic ring network. The control station has no less than 40 units
of PLC, and communication baud rate is100Mbps. The communication between the two optical fiber link
modules adopts multi-mode optical fiber with a maximum distance up to 3000 meters. Data
communication is conducted by use of GPRS communication network between the water intaking pump
station and the central control room monitoring computers. The transformer substation monitoring
system is supplied with 10KV electrical equipment, and is connected to the automation control system
through MODBUS protocol.

Process Control Strategy

 Primary Pump Station

It is responsible to collect the status signals and data signals of the water intaking motor, electric butterfly
valves and field instruments and send the control signals to the devices above. By pre-assembling PID
regulating program, the motor’s operating frequency and the electric regulating valve’s opening are
regulated automatically.

 Chemical and Chlorine Dosing Room

It is responsible to collect the status signals and data signals of

the field devices and instruments and send the control signals to
them. The automatic operation of the chlorination and dosing
equipment is controlled through the automation control
program.

滤池工艺控制图 Filter Process Control Diagram

来自沉淀池 From sedimentation tank

进水管 Water inlet pipe

排水管 Water drain pipe

去回收水池 To water recovery tank

滤格 Filter screen

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 LK Series PLC Industry Solutions

计算机性能监测 Computer performance monitoring

反充气管 Backwashing gas tube

出水管 Water outlet pipe

去清水池 To clean water basin

反冲水管 Backwashing water tube

工艺监控图 Process monitoring diagram

鼓风机 Blower

风量 Air quantity

风压 Air pressure

来自清水池 From clean water basin

反冲洗泵 Bachwashing pump

控制的报警数量 Controlled alarm quantity

加药间 Chemical dosing room

加氯间 Chlorine dosing room

沉淀池 Sedimentation tank

滤池 Filter

清水池 Clean wate basin

送水泵房 Water supply pump station

报警 Alarm

趋势图 Trend chart

返回主画面 Return to main screen

其他看不清

 Sedimentation Tank

Mud is removed automatically according to the cycle of mud removal. The cycle of mud removal and the
time for mud removal valve to remove mud can be modified and set through the operator station.

 Filter

The filter is an important part of the water plant, and is used to filter suspended solids in water. In the
filtering process, the adjustment of constant water level in the filter, filter backwashing (air impact -
flushing - gas-water mixture) and other functions need to be achieved.

 Adjustment of Constant Water Level in the Filtering Process of the Filter

According to the setting value of water level, the opening of the outlet valve of the filter chamber is
adjusted to maintain the filter running at a constant water level.

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 Backwashing Control of the Filter

The backwashing of the filter is controlled by a public

PLC. When meeting the backwashing conditions, the filter
makes a backwashing request, and the PLC forms a request
queue for backwashing based on the priority of filters.

The control conditions for filter backwashing are mainly the

set time and the liquid level in the filter.

 Secondary Pump Station

The function of Secondary pump station is to acquire the

operating status and data signals of the field equipments and instruments, and automatically adjust the
motor operating frequency through pre-assembling PID conditioning program according to the actual
use of water by users. Then the purpose of constant pressure water supply can be achieved.

送水泵房 Water supply pump station

出厂水工艺参数 Plant water process parameters

计算机性能监测 Computer performance monitoring

变频速度给定 Variable frequency speed given

送水泵 Water supply pump

吸水井 Suction well

远方 Remote

就地 Local

出厂 Leave factory

设备运行时间 Equipment running time

控制的报警数量 Controlled alarm quantity

加药间 Chemical dosing room

加氯间 Chlorine dosing room

沉淀池 Sedimentation tank

滤格 Filter screen

清水池 Clean wate basin

送水系统 Water supply system

报警 Alarm

趋势图 Trend chart

返回主画面 Return to main screen

其余看不清

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 LK Series PLC Industry Solutions

Sewage Treatment Plant

Oxidation ditch process is a common sewage treatment

process. Oxidation ditch, also known as oxidation drain, gets its name
for the factor that its structure forms a closed ring ditch. It is a variant of
the activated sludge process. Because sewage and activated sludge in
the aeration ditches circulate constantly, it was called "circular aeration
tank" or "non-terminal aeration tank". The oxidation ditch has a long
hydraulic retention time with a low organic loading, and thus, it is in essence an extended aeration
system.

The automation control system mainly

based on Hollysys Company's LK
programmable logic controller (PLC) is
used in the sewage treatment plant, and
can fully meet the requirements of the
oxidation ditch sewage treatment
process to provide a high reliability, low
cost and more optimal control scheme.

LK programmable logic controller (PLC),

which was introduced by Hollysys
Company after a summary of fifteen
years of control system design and
Fig 1 Process flow chart of oxidation ditch process
implementation experience in
thousands of sets of projects, is a
product suitable for the field of medium and high-performance control. The CPU module integrates an
industrial processor (frequency up to 533MHz), and the instruction processing speed is up to
13ns. Compared with the traditional PLC, LK PLC has been fully integrated with the advantages of DCS
and PLC, and used high-performance analog processing technology, small structural design, open
industry standard, and common system platform, so the product not only has powerful features and
excellent performance, but also has higher reliability, better openness and ease of use.

污水 Sewage
粗格栅 Coarse screen
提升泵房 Lift pump house
栅渣外运 Gate residue shipment
细格栅 Fine screen
旋流沉砂池 Vortex grit chamber
栅渣外运 Gate residue shipment
砂外运 Sand shipment
泥饼外运 Mud cake shipment
污泥脱水间 Sludge dewatering room
贮泥池 Sludge storage tank
选择池 Selection tank

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 LK Series PLC Industry Solutions

氧化沟 Oxidation Ditch

二沉池及配水井 Secondary sedimentation tank and distribution well
出水 Outlet water
污泥泵房 Sludge pumping station
剩余污泥 Excess sludge
回流污泥 Return sludge

Design of Automatic Control System

The whole system consists of a central control room and three field PLC control stations. The field PLC
control station consists of programmable logic controller (PLC) system and detection instruments for the
decentralized control of each process of the sewage treatment plant; then, the central control room
(CCR) realizes the centralized management of the whole plant. The data communication between the
central control room and PLC control station applies the high-speed and real-time Industrial Ethernet in a
ring structure. The
communication speed is
100Mbps and the transmission
medium is optical fiber. The
central control station is located
at the complex building’s central
control room. There are three
field control stations, located at
the inlet water pump house (1 #
PLC control station), air blower
house (2 # PLC control station),
and sludge dewatering room (3 #
PLC control station), respectively;
they all apply the Hollysys
Company's LK Series PLC. Fig 2 Diagram of Automatic control system

中央控制室 Central Control Room

UPS 电源 UPS Power Supply
打印机 Printer
操作员站 Operator Station
操作员站 Operator Station
打印机 Printer
投影仪 Projector
100Mbps 环形光纤工业以太网 100Mbps Ring Optical Industrial Ethernet
LK 系列 PLC LK Series PLC
触摸屏 Touch Screen
UPS 电源 UPS Power Supply
提升泵房 PLC 控制站 Lift pump house’s PLC controller
LK 系列 PLC LK Series PLC
触摸屏 Touch Screen

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 LK Series PLC Industry Solutions

UPS 电源 UPS Power Supply

鼓风机房 PLC 控制站 PLC control station in blower room
LK 系列 PLC LK Series PLC
触摸屏 Touch Screen
UPS 电源 UPS Power Supply
脱水机房 PLC 控制站 PLC controller of dehydration room
The communication network in the whole plant is divided into two stages: the first stage is the central
control/field monitoring stage in which an industrial Ethernet optical ring network is used from the field
control station to the central control station; the second stage is the data transfer stage which serves as
the conventional I/O cable connection from the field control station to the device control box.

The automation control system in the sewage treatment plant are designed with three control modes,
namely, in-situ manual control of the field devices, remote manual control of the automation control
system, and remote automatic control of the automation control system. The level of the three modes is
manual control, remote manual and remote automatic in order from high to low.

Process Control Strategy

 Screen Control

Screen control adopts two modes, the time control and

level difference control. Normally, the screen operates
based on the pre-set time interval and duration. When
the level difference before and after the screen is
greater than the set value, the screen cleaner starts
working continuously. After the level difference is small
enough to meet the requirements, the screen cleaner
can restore the normal operation.

系统工艺流程图 System Process Flow Diagram

粗格栅及污水提升泵房 Coarse screen and sewage lift pump
厌氧池 Anaerobic tank
配水井 Distribution well
沉砂池 Grit basin
细格栅 Fine screen
粗格栅 Coarse screen
进水闸室 Water inlet gate chamber
六六河来水 Water intake from Liuliu he River
氧化沟 Oxidation ditch
污泥泵房 Sludge pump house
出水井 Water well
终沉池 Final sedimentation tank
去 1#厌氧池 To 1# anaerobic tank
均质池 Homogeneous tank
加药装置 Dosing device
投药计量泵 Chemical dosing metering pump
离心分离机 Centrifugal separator

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 LK Series PLC Industry Solutions

螺旋输送机 Screw conveyer

至六六河 To Liuliu he River
污泥投配泵 Sludge batching pump
工艺流程 Process flow
脱水机房 Dehydrator house
参数修改 Parameter modification
备用 Spare
Screen residue delivering presser works with the screen.

 Lift Pump House

According to the liquid level of the collecting basin, the speed of governor pump with frequency
conversion and the on/off of water pump are controlled automatically. According to the lowest level of the
collecting basin, the pump automatically stops, and the pump in dry operation is protected. The number
of starting each pump balances with the total number of operating hours. Through initial setting, the
operating time of each pump is equal. The control system monitors the pump’s operating process, and if
the pump gives failure warnings, a standby pump will be automatically put in place.

 Grit Chamber and Sand-water Separator

The grit lifting pump and other motors, and sand-water separator system in the grit chamber have their
own system and are controlled by the accompanied control boxes.

 Oxidation Ditch

The PLC regulates the operation and rotary speed of the rotary disk
according to the DO measured values of each channel and controls the
operation of the sludge scraping bridge for the propeller.

 Backflow and Excess Sludge Pump House

The time to open, close and operate the backflow sludge pump is
controlled by the PLC based on the concentration of the mixed liquid detected in the biological tank.

 Transformer Substation

The PLC is not involved in the control of transformer

substations, and communicates with automation control
system of the power station through the RS485 or other
interfaces.

 Sludge Concentration Tank

The agitators in the sludge concentration tank are in the

continuous operation, They are manually started and
stopped by the PLC or the field electrical control box.

细格栅及旋流沉砂池 Fine screen and revolving grit basin

选择厌氧池及氧化沟 Choose anaerobic tank and oxidation ditch
氧化沟 Oxidation ditch

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 LK Series PLC Industry Solutions

2B 沟溶氧 2B ditch dissolved oxygen

2B 沟水位 2B ditch water level
污泥浓度 Concentration of sludge
出水堰板开度 Outlet water flash board
厌氧池 Anaerobic tank
二号进水日积累（10 吨） No.2 water inlet accumulated per day (10 tons)
来自配水井 From distribution well
去二号终沉池 To No.2 final sedimentation tank
来自二号终沉池 From No.2 final sedimentation tank
二号回流日积累（10 吨） No.2 water backflow accumulated per day (10
tons)
一号进水日积累（10 吨） No.1 water inlet accumulated per day (10 tons)
来自一号终沉池 From No.1 final sedimentation tank
一号回流日积累（10 吨） No.1 water backflow accumulated per day (10
tons)
工艺流程 Process flow
粗格栅 Coarse screen
细格栅 Fine screen
脱水机房 Dehydrator house
参数修改 Parameter modification
时间修改 Time modification
备用 Spare

 Sludge Dewatering House

The sludge dewatering machine and its auxiliary machine are controlled by the control box of the sludge
dewatering machine. When the sludge dewatering machine works, the sludge pump, chemical feed
equipments, batching pump and other devices operate jointly.

 Air Blower House

In the air blower control system, the gaseous signal is the main control signal and the DO signal in the
oxidation ditch is the auxiliary signal. The system could automatically control the opening of control valve
according to the actual load and finally realize the control of the outlet water quality. The number of
starting each air blower balances with the total number of operating hours.

Recycling of Recycled Water

According to the interim measures for the management of urban recycled water facilities of the Ministry
of Construction, recycled water is defined as: part of domestic high grade grey water, after treatment and
purification, can meets the domestic reclaimed water indicators (CJ25.1-89) and can be reused within
a certain range. Recycled water is actually regenerated water with water quality between upper water
and lower water, and hence it is named "recycled water". Although the recycled water is not suitable for
drinking, it can be used for a number of occasions with low demanding for water quality. The recycling
objects for the recycled water are municipal reclaimed water, domestic reclaimed water and industrial

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 LK Series PLC Industry Solutions

consumers.

The recycling system for recycled water is an automation control system mainly based on Hollysys
Company's LK Series PLC. On the basis of the full use of existing resources and through a rational
system structure and powerful control function, all devices can be well controlled to run stably and
reliably and recycling of recycled water is safe and efficient.

System Design

Automatic control system for the recycling of recycled water consists of a central control room, three field
PLC control stations and their industrial Ethernet data communication network of high speed and
security. The central
control room is mainly
composed of 2 sets of
industrial control
computers, and a
projection display system.
It is used to monitor and
control each field PLC
control station through
the industrial Ethernet
which uses optical fiber
as the transmission
medium. The three field
control stations are the
rapid filter field control
station (PLC1 Station),
field control station in the Figure 1 Schematic Diagram of Automation Control System
aerated biological filter for the Recycling of Recycled Water
chamber’s (PLC2 Station),
and field control station in the inlet water pump house (PLC3 Station). The field control stations above
are responsible for monitoring the process-related electrical equipments and instruments in their
own structures and around, and transmitting the information required for the management to the central
control room in the office management building.

中央控制室 Central Control Room

UPS 电源 UPS Power Supply
打印机 Printer
操作员站 Operator Station
操作员站 Operator Station
打印机 Printer
投影仪 Projector
100Mbps 环形光纤工业以太网 100Mbps Ring Optical Industrial Ethernet
LK 系列 PLC LK Series PLC
触摸屏 Touch Screen

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 LK Series PLC Industry Solutions

UPS 电源 UPS Power Supply

快滤池 PLC1 控制站 Rapid filter PLC1 controller
LK 系列 PLC LK Series PLC
触摸屏 Touch Screen
UPS 电源 UPS Power Supply
曝气生物滤池 PLC2 控制站 BAF PLC2 controller
LK 系列 PLC LK Series PLC
触摸屏 Touch Screen
UPS 电源 UPS Power Supply
送水泵房 PLC3 控制站 Water supply pump house PLC3 controller

The system uses the principle of decentralized control and centralized management, and is composed of
the management layer of the central control room, the filed PLC control management layer, and the
management layer of field controlled equipment and instrumentation. Each field station of the control
system consists of Hollysys Company's LK Series PLC and color touch-screen. The upper computer and
PLC station are connected by use of optical industrial Ethernet, and the remote I/O stations of the field
PLC station are connected with PROFIBUS-DP industrial field bus.

Process Control

The main recycling process of the recycled water is as

follows: sewage from the secondary settling tank of the
sewage plant is lifted by the pump station and goes into
the aerated biological filter chamber for biochemical
treatment, The treated water after chemical and
chlorination feeding, enters the flocculation tank and
inclined tube sedimentation tank for filtering and
precipitation before flowing into the clean water tank.
Then the clear water is supplied by water pump station
to users. The dirty water in the procedure is continuously
microfiltered by the circulating pool and then enters the reverse osmosis tank for processing, and the
processed water flows into the clean water tank before it is used by users; the settled sludge is
discharged by the mud removal pump station to the secondary treatment plant’s sludge thickener.

确定 Confirm

删除 Delete

过程 Process

系统 System

指导 Guidance

操作履历 Operation history

配水泵设备 Water distributing pump

出水阀 Water outlet valve

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 LK Series PLC Industry Solutions

未关到位 Not closed fully

控制场所 Control places

现场控制室 Field control room

星期四 Thursday

设定画面 Setting screen

主画面 Main screen

画面一览 Screen list

窗口化 Windowed

报警辅导 Alarm direction

远程多光标 Remote multiple cursor

画面工具 Screen tool

功能 Function

系统 System

彩色 H/C Color H/C

编号 Serial number

搜索模式 Searching mode

最新画面 Latest screen

系统工具视窗 System tool window

关闭 Close

系统工具 System tool

密码设定 Password setting

级：用户 Level: user

版本信息 Version info.

专用键盘分配定义 Distribution definition of special keyboard

工厂时刻设定 Factory time setting

记录检索 Record retrieving

消息表示一览 Message indication list

对话框表示一览 Dialogue box indication list

CRT 系统异常 CRT system abnormal

终了工具 Ending tool

沉淀池 Sedimentation tank

7 号滤池 No.7 filter

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 LK Series PLC Industry Solutions

第0号 No. 0

水位 Water level

压差 Differential pressure

过滤 filtering

清洗 Cleaning

停止 Stop

设置密码对话框 Setting password dialogue box

设置级别：用户 Setting level: user

密码 Password

特权用户 Privileged user

系统管理 System management

设置 Setting

清水池 Clean water basin

监视用户 Monitoring user

回流调节池 Backflow adjusting basin

配水井 Distribution well

流入水 Flowing in water

排水 Drain

反冲洗水 Backwashing water

清水 Clean water

空气 Air

排气 Exhaust

滤池全体 Entire filter

1 号滤池 No.1 filter

 Aerated Biological Filter

 Control the filtering process in the filter and

backwashing process

 Monitor the DO content in the sewage, and

control the volume of aeration by detecting the
dissolved oxygen. Detect the differential
pressure between the upper and lower filtering
material on the biological aerated filter to
control the backwashing to start and stop

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 LK Series PLC Industry Solutions
 Flocculation, Inclined Tube Sedimentation Tank

 Control the operation of eight agitators of the flocculation tank

 Control the operation of the sedimentation tank scraper

确定 Confirm
删除 Delete
过程 Process
系统 System
指导 Guidance
操作履历 Operation history
配水泵设备 Water distributing pump
6#出水阀 6# Water outlet valve
未关到位 Not closed fully
滤池全体 Entire filter
星期四 Thursday
后加氯 Rear chlorine dosing
4 号清水池 No.4 clean water basin
吸水井 Suction well
受变电设备 Power transformer equipment
真空泵 Vacuum pump
出水阀 Water outlet valve
由滤站引来 Induced from dilter station
流量 Flow
至用户 To users

 Lift Pump House

 Control the on/off time of submersible pumps

and the startup number

 Monitor the manual/automatic, operating,

fault signal and level signal of submersible
pumps

 Water Supply Pump House

 Control the centrifugal pumps and electric

valves in the water supply pump house

 Manual/automatic, operating and fault

signals of centrifugal pumps

 Manual/automatic, fully open, fully closed and fault signals of electric valves

 Outlet pipe pressure

 Detect residual chlorine value, turbidity value, PH value and temperature of outlet water

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 LK Series PLC Industry Solutions

确定 Confirm
删除 Delete
过程 Process
系统 System
指导 Guidance
操作履历 Operation history
配水泵设置 Water distributing pump
6#出水阀 6# Water outlet valve
未关到位 Not closed fully
滤池全体 Entire filter
星期四 Thursday
控制场所 Control places
1 号配水压力 No.1 water distributing pressure
比例流量加氯机 Proportional flow chlorinator
轴流风机 Axial-flow fan
二期静态混合器井 Phase-2 static mixer well
一起混静态合器井 Phase-1 static mixer well
高压切换器 High voltage switcher
复合环加氯机 Compound loop chlorinator
4 号清水池（二期工程） No.4 clean water basin (phase-2 project)
2 号清水池 No.2 clean water basin

 CMF-RO Workshop

 Detect the residual chlorine value of inflow in CMF-RO workshop

 Rapid Filter

 Control the backwashing pump and backwashing fan

 Control chlorine tank filter and backwashing process

System Functions
 Collect process data and equipment operating status, automatically regulate the production
data, and control the operation of process equipment.

 The color monitor (TFT) displays the general process flow chart, sectional flow chart, power
supply system diagram, process parameters, and operating status of electrical equipments,
etc.

 According to the information collected, automatically create the database, save the process
parameters, electrical equipment operating status, alarm data and fault data, and automatically
generate the trend curve of parameters. Managers will make the analysis and research on
the process curve to further improve the process operating program and enhance the
production efficiency.

 According to the requirements of production management, print yearly, monthly, daily and
team operating reports and alarm reports, fault reports and process flow chart (color hard
copy.) Print the real-time alarm and fault.

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 LK Series PLC Industry Solutions
 Through the communication with the field control system of each sub-control station via the
industrial Ethernet, the computer system can diagnose various types of failures online.

Urban Pump Station

To reduce operating costs, and enhance the level of enterprise modernization and information
technology, the water supply dispatching and supervision system of urban pump station based on
Hollysys Company's LK Series PLC is mainly composed of FacView monitoring configuration software,
high-speed data communication network (VPN) and PLC system. The concept for the system
constitution is set up based on an open and modular architecture, and the system can flexibly and easily
conduct complex programming and configuration.

According to the running requirements for the water supply dispatching and supervision system of urban
pump station and fully considering the system's high reliability, availability, convenience, maintainability
and scalability, the control operation, data collection and information real-time accuracy, completeness
and consistency of the water supply dispatching system of the entire pump station are realized.

Design of Dispatching Monitoring System

 Overall System architecture

The project design adopts the world’s advanced control technology. A VPN (Virtual Private Network)
communication network is built among various pump stations and the central monitoring center to collect
and transmit real-time data signals and video signals of the automation control system in various pump
stations to the central monitoring center, and then, the central control center can conduct real-time
remote operation of the pump stations. The entire system is divided into upper computer monitoring
layer, PLC control layer, and field instrumentation layer and communication network.

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Figure 1 Diagram of Automatic Control System

泵站总调度中心 General station dispatching center

GPS 对时系统 GPS timing system
图像监控计算机站 Image monitoring computer station
数据服务器 Data server
打印机 Printer
操作员站 Operator Station
操作员站 Operator Station
大屏幕 Large screen
打印机 Printer
工程师站 Engineer Station
培训工作站 Training workstation
水务 MIS 网 Water MIS Network
网关计算机 Gateway Computer
UPS 电源 UPS Power Supply

打印机 Printer
操作员站 Operator Station
操作员站 Operator Station
UPS 电源 UPS Power Supply
GPS 对时系统 GPS timing system
100Mbps 环形光纤工业以太网 100Mbps Ring Optical Industrial Ethernet
LK 系列 PLC LK Series PLC
LK 系列 PLC LK Series PLC

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LK 系列 PLC LK Series PLC

打印机 Printer
操作员站 Operator Station
操作员站 Operator Station
UPS 电源 UPS Power Supply
GPS 对时系统 GPS timing system
100Mbps 环形光纤工业以太网 100Mbps Ring Optical Industrial Ethernet
LK 系列 PLC LK Series PLC
LK 系列 PLC LK Series PLC
LK 系列 PLC LK Series PLC
打印机 Printer
操作员站 Operator Station
操作员站 Operator Station
UPS 电源 UPS Power Supply
GPS 对时系统 GPS timing system
100Mbps 环形光纤工业以太网 100Mbps Ring Fiber Industrial Ethernet
LK 系列 PLC LK Series PLC
LK 系列 PLC LK Series PLC
LK 系列 PLC LK Series PLC
LK 系列 PLC LK Series PLC
1#-n# 泵站控监控系统 Monitoring and control system of 1#-n# pump
station

 Central Monitoring Center (Upper Monitoring Layer)

The central control center, located within the master control center of the system, is the core of
automatic information system in the entire pump station and is responsible for managing the monitoring
system’s database, and the production process dispatching. The field control station transmits data
through the communication network to the monitoring computer, and the system can automatically
complete the data storage, display, analysis, warning, and sharing. Meanwhile, the master control center
and sub-control center control the field pump stations under division of labor, and they could serve as the
backup for each other.

 PLC Control Station（ Field Control Layer）

The system sets a control station in each pump station to automatically monitor and control the operation
of all field pump stations. The PLC control station includes control cabinet, LK Series PLC controller, a
variety of I/O modules, operating touch screen, and video monitoring equipment and so on.

 Field Instrument Layer

The field instrument layer at the bottom of the system is the data source of entire system. It mainly
includes a variety of instruments for field data collection, which are responsible for data collection,
display and alarm, and are used to transmit the data to the PLC control station and central monitoring
center.

 Data Sharing and Data Security

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The system communication network is the key to achieve the system unity, stability, security and
integrity, and is the basis for the realization of the system functions. For this application, we use VPN
(Virtual Private Network) technology to combine all the pump stations and the monitoring center into a
virtual local area network. The pump stations using the transmission mode can achieve data
transmission, and can also transmit surveillance images.

Pump Station Control Strategy

The pump station is configured with many sets of

submersible pumps, and the pumps are controlled by
industrial/frequency switching. The control devices of the
pumps are equipped with manual, automatic and central
control methods and can achieve local manual control,
automation control of PLC system, and remote control of
central control room. The electrical part of the pump
starting device has over voltage, overload and other
protection functions, ensuring that the pumps could
operate stably in a safe environment.

萧山排水管理处泵站自动控制系统 Automatic control system of Xiaoshan drainage

management adimistrative office pump station

监视员级别 Level of supervisor

北京和利时系统工程股份有限公司 Beijing HollySys Co., Ltd

前进 Forward

历史 History

后退 Back

流程列表 Flow list

登陆 Log in

系统状态 System status

报警 Alarm

趋势 Trend

日志 Log

报表 Report form

管理 Management

打印图形 Printing graphs

污水 1#泵 Sewage 1# pump

参数设置 Parameter setting

控制状态 Control state

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运行方式 Running mode

运行状态 Running state

故障状态 Failure state

泵电流 Pump current

AB 相电压 AB phase voltage

功率因数 Power factor

压力 Pressure

日流量 Flow per day

进水泡液位 Inlet bubble level

瞬时流量 Instantaneous flow

月流量 Monthly flow

1#污水池 1# sewage tank

城北泵站 Chengbei pump station

潘水泵站 Panshui pump station

仙家河泵站 Xianjia he pump station

道源泵站 Daoyuan pump station

萧西泵站 Xiaoxi pump station

市心泵站 Shixin pump station

拱秀泵站 Gongxiu pump station

通南泵站 Tongnan pump station

泰和泵站 Taihe pump station

新街泵站 Xinjie pump station

城东泵站 Chengdong pump station

集控 Central control

宁围泵站 Ningwei pump station

燕子河泵站 Yanzi he pump station

美之园泵站 Meizhi yuan pump station

蜀山一号泵站 Shushan No.1 pump station

金城立交泵站 Jincheng pump station

通北泵站 Tongbei pump station

城北泵站 Chengbei pump station

长山旧泵站 Changshan old pump station

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长山新泵站 Changshan new pump station

建四泵站 Jiansi pump station

 Operating Control of Pumps

 Pump units take turns to operate to ensure the operation time of each pump is approximately
the same and avoid long time running for a single pump.

 Control mode: manual, automatic, and remote control

 Frequency conversion and constant level control strategy

 Control during the maintenance of frequency conversion cabinet

 Special Control of Pumps

When the system detects that the water level is below the lower limit or the pump has adverse
circumstances like overheating, overload, over-pressure, phase failure or frequency failure, the pump
will be forced to start and stop.

 Screen Machine Control

The operation of the screen machine is controlled by the time set by the PLC, namely, a time period is
set within the PLC (the time period can be set by the touch screen and remote controller), and the screen
machine clears off slag regularly according to the time period.

 Electric Valve Control

In any operating mode, the electric valve can be opened, closed and stopped under control.

 Hoist Control

According to the water level of the collecting basin, the hoist is on or off to control the wastewater
flow. The electric valve can be opened, closed and stopped manually or under the control of touch
screen or central control room. Meanwhile, it can also be remotely controlled under the automatic
operating mode.

 Communication Failure Control

When the communication between the PLC

system and the central control room is
interrupted, the PLC system will
automatically switch to the local automation
control to ensure that the pump station’s
control system can normally operate in the
unmanned state.

System Functions
 Pump Station Control System

 Communication and control

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 Monitoring and alarm

 Event handling

 Secondary development

 Database System Functions

 Data Storage

 Data Processing

 Specific Functional Modules

 Report function module

 Data query module

 Data charting

宁围泵站 Ningwei pump station

污水液位 Sewage level
雨水液位 Rainwater level
萧山经济技术开发区 Xiaoshan economic and technological
development zone
通北泵站 Tongbei pump station
长山新泵站 Changshan new pump station
长山旧泵站 Changshan old pump station
新街泵站 Xinjie pump station
城北泵站 Chengbei pump station
金城立交 Jincheng junction
美之园 Meiyi yuan
萧西泵站 pump station
市心泵站 pump station
燕子河 Yanzi he
城东泵站 pump station
拱秀泵站 pump station
通南泵站 pump station
仙家河 Xianjia he
道源泵站 pump station
泰和泵站 pump station
潘水泵站 pump station
单位 Unit
地址 Address
电话 Tel.

 Maintenance Function of Database Pump Station

In the maintenance interface of the pump station, users can add, delete, and modify the tables by
themselves. When the number of the pump stations is increased, users can easily add the database for
new pump stations.

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 User management

 Imaging System

 Information Sharing

The operating information of the monitoring system, pump station data management system, and image
system is offered through the Intranet network to each functional department of the company, corporate
decision makers and other departments or individuals with different access rights.

 Aided Management

Based on the historical records, the pump station data management system can allow the management
to dynamically analyze the running status of regional pump stations, so as to provide the basis for
management decisions.

Features and Advantages

 A solution integrated with the local and offsite data as well as disaster recovery application can
ensure the consistency of data to a maximum extent;

 Support homogeneous and heterogeneous disaster recovery modes;

 The level of disaster recovery increases in order, and the latter is based on the former;

 They can be implemented step by step, and the post-investment protects the front-end
investment;

 Solutions that can support manual/automatic disaster recovery can be chosen by users
according to actual needs;

Heat Source Plant

The Chinese economy in rapid development has put forward higher and
higher demands for energy and environmental protection. Using the
energy in a rational and efficient way is an effective way to protect the
ecological environment. The working environments of the auxiliary
systems (such as coal bunker coal, coal trestle, boiler slag removal
system) of heat source plant are usually harsh, and all kinds of devices
are placed in an environment with generally large dust and are in
decentralized operation, so the security, reliability and maintenance convenience of the control system
at work are highly required.

In the auxiliary system of the heat source plant, Hollysys Company's LK Series PLC is used to monitor
and automatically control the production equipments as well as the processes of the boiler auxiliary
system in the heat source plant The system is stable, functional and cost-effective, and can be flexibly
expanded and can meet the safe and efficient operation requirements of auxiliary system equipment,
thus providing users with a low-cost, high-reliability control solution.

Control System Design

The auxiliary system of the heat source plant consists of coal bunker coal handling system, trestle coal

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handling system, and boiler deslagging system. According to the process requirements of the heat
source plant and the existing overall layout, the entire auxiliary system is provided with three field PLC
control stations, which are separately used for centralized control, monitoring and management of the
trestle coal handling system, coal bunker coal handling system and boiler deslagging system,. In order to
achieve the overall layout of "focused monitoring and decentralized control", they are connected into the
boiler DCS control system of the heat source plant.

Figure 1 Control System Diagram of Heat Source Plant's Auxiliary System

热源厂锅炉 DCS 控制系统 DCS control system for heating plant boiler
UPS 电源 UPS Power Supply
打印机 Printer
操作员站 Operator Station
操作员站 Operator Station
打印机 Printer
工程师站 Engineer Station
热源厂 MIS 网 MIS network of heating plant
100Mbps 工业以太网 100M Industrial Ethernet
打印机 Printer
操作员站 Operator Station
操纵台 Console
UPS 电源 UPS Power Supply
1~6#胶带机 1~6# belt conveyor
1、2 除尘机组 1,2 Dedusting Unit
煤斗卸料器 Coal bucket unloader
碎煤机 Coal crusher
除铁器 Magnetic separator
煤仓输煤控制系统 Bunker coal handling control system
打印机 Printer
操作员站 Operator Station
操纵台 Console

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UPS 电源 UPS Power Supply

1~6#胶带机 1~6# belt conveyor
1、2 除尘机组 1,2 Dedusting Unit
煤斗卸料器 Coal bucket unloader
碎煤机 Coal crusher
除铁器 Magnetic separator
栈桥输煤控制系统 Trestle coal handling control system
打印机 Printer
操作员站 Operator Station
操纵台 Console
UPS 电源 UPS Power Supply
1~6#胶带机 1~6# belt conveyor
1、2 除尘机组 1,2 Dedusting Unit
煤斗卸料器 Coal bucket unloader
碎煤机 Coal crusher
除铁器 Magnetic separator
锅炉除渣控制系统 Boiler deslagging control system
Each field PLC control station is composed of a program-controlled cabinet, operator station and reserve
console; the program-controlled cabinet is Hollysys Company's LK Series PLC, CPU is LK210, and PLC
program-controlled cabinet is configured with 14 DI Modules LK610, with a 224 DI points; 7 DO Modules
LK710 are configured, with 112 DO points, and DO points are configured with DC24V small relay; 5 AI
modules LK411 are configured, with 40 AI points; two AO modules are configured, with 8 AO
points. Data communication is conducted between each PLC control station and operator station
through high-speed Ethernet network.

The PLC program-controlled cabinet is equipped with 2KVA UPS power supply. The external power
supply is from trestle coal handling one-channel MCC, and the power supply for the operator station is
drawn from UPS. The operator station is configured with P4 processor, 512M memory, 80G hard drive,
and 19-inch LCD display, coupled with a set of digital control software FacView.

Process Control Function

 Bunker Coal Handling System

The bunker coal handling system is responsible for collecting the status signals and data signals of belt
conveyors, dischargers and other devices, and sending control signals to the devices; also, it controls
and reads the working states of the belt conveyors in real time. The bunker coal handling system is
provided with two lines: a high-low level in the bunker is set for detection, and coal is transported
according to the level with an order of the dedusting unit × 4 → belt discharger × 4 →dedusting unit × 4
→ conveyor from the power plant. An operator station is configured and
can be used as a stand-alone system.

 Trestle Coal Handling System

The trestle coal handling system is responsible for collecting the status
signals and data signals of the frequency inverters in the belt conveyor,
belt scale, coal crusher, probability screen, screw feeder and other

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devices, and sending control signals to the devices above; also, it reads and controls the working state
of each belt conveyor in the materials conveyor system in real time. The trestle coal handling system is
provided with two lines: dedusting unit × 2 → electro-hydraulic discharger × 8 → belt conveyor× 2 →belt
scale→ coal crusher × 2 → probability screen × 2 →dedusting unit × 2 →electromagnetic de-ironing
separator→ screw feeder × 4.

PLC is used to perform the control works, and there is a display device showing the process of the coal
handling system; the PLC device is installed in a program control cabinet separately beside the console.
According to the selected control program, all the transportation devices can be started with time delay
in a direction against that of coal flow.

When the program is shut down, the devices delay 1 and a half minutes to stop along the direction of
coal flow; when any device fails in the process of operation, all the other devices ahead in the direction of
coal supply immediately stop, and the other devices behind delay stopping.

 Boiler Deslagging System

The boiler deslagging system is responsible for collecting the status signals and data signals of dust
collector, bucket elevator, bucket dust cleaner, slag cooler and other devices on top of the bunker, and
sending control signals to the devices above; also, it reads and controls the working state of the slag
cooler in real time. The boiler deslagging system is provided with four lines, and a level in the slag
bunker is set for detection, and slag is removed according to the high-low level in an order of the dust
cleaner on top of the bunker →bucket elevator →bucket chain cleaner 1 →bucket chain cleaner
2→bucket chain cleaner 1→ash cooler A, B. An operator station is configured and can be used as a
stand-alone system.

a. When the program starts, all the devices within the deslagging system delay starting in order against
the direction of slag flow;

b. When the program stops, all the devices within the deslagging system delay stopping in order along
the direction of slag flow;

c. When the program stops, that is, when any device fails during the operation, all the other devices
ahead of the device in the direction of deslagging immediately stop, and the other devices behind the
device delay stopping;

d. Automatic alarm: under a case, the on-site sound and light signal alarm starts automatically, under c
case, the accident parking alarm starts, and if the field devices stop successfully, the on-site sound and
light signal alarm stops;

e. Automatic detection: It detects whether all the devices within the deslagging system have fully
automatic control conditions of PLC, and shows why the devices can not be operated.

System Characteristics
 Distributed structure is used to facilitate expansion, with high reliability;

 High safety, and strong anti-jamming capability;

 The control system uses a combination of the programmed control, remote control and local
control;

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 When the equipment starts and stops manually, the upper computer can provide operational
guidance;

 All programmable logic, interlocking protection, control, and regulation (PID) can be completed
in the PLC, with no hard wiring;

 The upper computer directly shows measurement parameters of process flow diagrams,
control mode, device status, fault status, reports and others;

 The out-of-limit parameters, control object failure, state change, and control system failure are
displayed on the LCD in different colors, and meanwhile the audible alarm is given.

Monitoring of Heat-supply Network

Central heating is a measure for energy conservation and

environmental protection promoted by the country, and is the
direction of development for heat supply in the future; it has
advantages of high thermal efficiency, energy conservation, low
pollution, and good heating effect In general, it uses the power
plant’s waste heat. The heat-supply network monitoring system is
designed for the automation of heat network dispatching, and it is
integrated with human-machine interface, database management,
computer network, remote data communication, process control and signal detection and other
advanced technologies. Central heating is an important symbol for the modern management in the
regional heat supply .

The heat-supply network monitoring system based on Hollysys Company's LK Series PLC is used for
the monitoring, controlling and managing the entire thermal network and all the thermal stations in the
central heating system, and assisting the dispatching and duty personnel, so that the thermal network
can run in a secure, normal and energy-saving way, and can successfully complete the heat supply task.
The system has high performance, high reliability, flexible communications, and easy maintenance and
other features, and has provided the monitoring of urban heat-supply network with a high-performance,
practical and economical solution.

Heat-supply Network Monitoring System Design

Heat-supply network dispatching and monitoring system monitors, controls, interlocks and alarms the
process parameters, electrical parameters of each heat transfer station and the equipment operating
status, and prints reports; the data collection, data communication, sequence control, time control, loop
regulation and upper computer monitoring and management function necessary for the entire
heat-supply network are completed by using a series of communication chains between the dispatching
center and each heat transfer station. The entire system consists of dispatching monitoring center, data
communication network, and field PLC control station. The field PLC heat transfer station mainly
completes the real-time acquisition of temperature, pressure, flow, liquid level and other process
parameters of the primary and secondary network of each heat transfer station, and the real-time
reflection and control of the status of all operating devices; supported by the communication network, the
system through a network interface transmits the data that reflect the operating status of the heat

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transfer station to the dispatching monitoring center, and meanwhile receives the dispatching control
instructions sent by the dispatching monitoring center; the dispatching monitoring center is in charge of
receiving the data sent by the field monitoring equipment, and carrying on data storage, historical trend
analysis, alarm, report printing, etc. On this basis, it issues dispatching control instructions to all field
devices.

 Dispatching Monitoring Center

The heat-supply network monitoring center is mainly composed of data

server, operator workstation, engineer workstation, communications
gateway, analog display, Ethernet switch, firewall, printer, UPS power
supply and other components. For the small heat supply companies, a
data server can not be set, and the operator workstation works directly
as the data server; for the companies with a large heat supply system, if the number of heating stations
is over 50, it is proposed that a dedicated database server is used, and operators and management
personnel complete the monitoring work mainly through the operator workstation.

 Field PLC Control Station

A field PLC control station mainly consists of liquid crystal display operating terminal and control
system. The color LCD display mainly displays a variety of monitoring images and acquisition
parameters and receives the input information set by some parameters. The control system uses
Hollysys Company's LK Series PLC with high cost performance, including the CPU module, I/O module,
and backplane; the system is integrated with a variety of communication interfaces suitable for different
communications networks.

 Communication Network

The communication network is the hub to contact the heat-supply network monitoring system, and each
heat transfer station, heat source, and pipeline control node form a integrated whole through the
communication network system. In order to achieve the centralized monitoring, control, and dispatching
of operational data, a communication network connecting all monitoring points must be established. With
the rapid development of network technologies, the space for users to select becomes larger and larger,
and the services in various places provided by the Netcom, Telecom, Mobile and China Unicom are
quite different in terms of price and technologies. Therefore, the choice for a communication mode
should be carefully analyzed and compared combined with the actual situations, and the most suitable
communication mode will be ultimately selected.

Currently, when users are selecting the communication network, there are the following four options:

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1) Dial-up communication network: a modem is directly used to dial;

供暖监控调度中心 Heating monitoring dispatching center

UPS 电源 UPS Power Supply
打印机 Printer
操作员站 Operator Station
供暖公司 MIS 网 Heating Company’s MIS Network
中国网通通讯网络 China Netcom Communication Network
电话线 Telephone line
调制解调器 Modem
LK 系列 PLC LK Series PLC
换热站 Heat transfer station
图 1 拨号通讯方案系统图 Figure 1 System Diagram of Dial-up
Communications Scheme

 Advantages: simple network construction, small maintenance workload and low operation
cost,;

 Disadvantages: network instability, poor real-time, and meanwhile only one station reporting
the data.

2) Wireless communication network: radio stations use public wireless frequency band, and a radio
transmitter, receiving station is self-built;

 Advantages: low operating costs;

 Disadvantages: larger installation workload, unstable network, easily interfered and bad
instantaneity.

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Figure 2 System Diagram of Radio Communication Scheme

供暖监控调度中心 Heating monitoring dispatching center

UPS 电源 UPS Power Supply
打印机 Printer
操作员站 Operator Station
供暖公司 MIS 网 Heating Company’s MIS Network
数传电台 Data radio
LK 系列 PLC LK Series PLC
1#换热站 1# Heat Transfer Station
2#换热站 2# Heat Transfer Station
n-1#换热站 n -1 # Heat Transfer Station
n#换热站 n # Heat Transfer Station

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3) Mobile communication network: GPRS/CDMA networks;

Fig 3 System Diagram of GPRS Communication Scheme

供暖监控调度中心 Heating monitoring dispatching center
马赛克模拟屏 Mosaic simulated screen
UPS 电源 UPS Power Supply
工程师站 Engineer station
打印机 Printer
操作员站 Operator Station
数据服务器 Data server
网关计算机 Gateway computer
供暖公司 MIS 网 Heating Company’s MIS Network
100Mbps 工业以太网 100Mbps Industrial Ethernet
路由器 Router
VPN 专线 Dedicated VPN line
中国移动 GPRS 通讯网络 China Mobile GPRS communication network
LK 系列 PLC LK Series PLC
换热站 Heat Transfer Station

 Advantages: Easy to install, with strong anti-jamming capability, and easy maintenance, safe
against transmission distance restriction,

 Disadvantages: relatively high operating costs.

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4) Virtual private network, ADSL and other broadband technologies.

Fig 4 System Diagram of ADSL Communication Scheme

供暖监控调度中心 Heating monitoring dispatching center

UPS 电源 UPS Power Supply
工程师站 Engineer station
打印机 Printer
操作员站 Operator Station
数据服务器 Data server
网关计算机 Gateway computer
供暖公司 MIS 网 Heating Company’s MIS Network
100Mbps 工业以太网 100Mbps Industrial Ethernet
中国网通通讯网络 China Netcom communication network
LK 系列 PLC LK Series PLC
换热站 Heat Transfer Station

 Advantages: good instantaneity, simple installation, easy maintenance, and good network
security;

 Disadvantages: relatively high operating costs.

Control Strategies
The higher level of the heat-supply network monitoring system is the central dispatching room, that is the
central control room, and the lower level is several self-controlled heating stations; in general, the
self-controlled heating stations are mutually independent, and the central control room does not interfere
with the control of the heating stations to achieve decentralized control, thus eliminating the

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concentrated risks, and meanwhile enhancing the system’s flexibility and scalability. The central control
room and heating stations achieve wireless communications to monitor the operating conditions of the
heating station in the heating network. Through grasping the whole network’s operating parameters, the
thermal balance of each heating station is analyzed and judged, the most negative point of the pipeline
network running is checked, and the heat balance between heat source and heat load is predicted and
adjusted; as for the problems involved in the heating network in operation, the central control room
issues a dispatching order to the heating station or heat source to achieve optimal operation. In addition,
the central control room can also manage the heating network files and complete the statistics, archiving,
reporting of the operating data and has other functions. The self-controlled heating stations play the role
of connecting the preceding and the following in the heat-supply network monitoring system, and will in
time collect, transfer and on-site display the parameters that reflect the working states of the heating
network and heating stations and devices. It will perform operations automatically according to the
requirements of the best operating conditions, and its working principle includes the following aspects:

 Regulating and Control System for Heat Supply

Heat supply is regulated and controlled by a temperature compensator. The temperature compensator
generates the target value of the supply water temperature or the average return water temperature of
the secondary network according to the outdoor temperature (temperature sensor), and commands the
primary network’s electric control valve to act. When the electric control valve is opened large, the
primary network’s flow increases; when the electric control valve is closed small, the primary network’s
flow decreases. Through the change in the primary network’s flow through the heat exchanger, the
secondary heat supply to users is regulated.

 Automation Control System of Secondary Circulating Pump

As for the indirect connection mode of heat supply between heating stations, the hydraulic conditions of
the primary network and the secondary network do not affect each other. The operating parameters of
the secondary network’s circulating pump are generally selected according to the designed heat load; for
the heating system of users whose heat metering is separately conducted for each household, the
secondary network has the operating function of variable flow. Even for the heating system of common
users, in actual operation, as the heat load changes, and the circulating pump’s variable flow is
regulated, a lot of heat energy can also be saved. In addition, whether the indoor heating system of
users has a single pipe or double pipe system, the best way to regulate is based on the quality, that is,
with the changes in outdoor temperature, the water temperature is not only regulated, but also the
system flow is regulated, so as to virtually eliminate the system’s level imbalance and vertical
imbalance.

 Water-replenishing Constant Pressure Automation Control System

Water-replenishing constant pressure system functions to prevent the secondary network from being
empty, and to ensure that the system runs under the provided constant pressure. This function is
completed through the frequency conversion speed control cabinet. The system pressure signal is from
the pressure sensor on the constant pressure sample by-pass device, and when this pressure is below
the set pressure, the frequency conversion speed control cabinet directs the water-replenishing pump to
speed up replenishment; when the system pressure is higher than the set pressure, the frequency

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conversion speed control cabinet directs the water-replenishing pump slows down replenishment; when
the system pressure exceeds the limit pressure, the bypass valve on the pressure relief bypass device is
opened to drain water and relieve pressure.

 Heat Metering System

The heat metering system consists of a supply and return water temperature sensor, and a flow meter
and integrator installed for primary backwater. The heating station is set with a thermal metering device,
which not only provides the future implementation of meterage by heat with metering means, but also
provides an important basis to account technical and economic indicators of various heating stations and
guide heating operation with the "heat and flow" as an important operating parameter.

 Self-protection Function of Self-controlled Heat Transfer Station

The self-controlled heat transfer station requires unattended working mode, and operating personnel
only inspect it regularly; the automation control system of the heating station has the following
self-protection functions as required:

 Power phase failure, three-phase imbalance, and motor overload protection.

 Power outage protection, automatic start upon power on.

 Water tank lack of water, and the heat supply system waterpower over pressure and under
pressure protection.

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Building Materials

There are a large number of enterprises in the building materials industry in China, with smaller size and
lower degree of automation. For instance, 70% of cement production still uses vertical kiln, with
backward technology and high energy consumption. PLC is mainly applied in production equipment
control and production line control in the building materials industry, such as pulverizer, raw meal mill,
clinker mill and converter which are used in cement production, roll table, cutting machine and hacking
machine which are used in glass production, cement production line and glass fiber production line, etc.
Due to its technological development and cost advantage, large-scale PLC is widely applicable for
cement production line and glass production line. Currently large-scale PLC plays a leading role in
automatic control of the building materials industry.

The building materials industry is one of important business areas of HollySys. For years, the company
has been paying close attention to the industry development and gathering a group of experts who
master productive technology and have a good knowledge production management, researching how to
raise the automation & informationization level, reduce energy consumption and improve efficiency.
Having experienced the practice of hundreds of project sites, now the company is able to offer an
omni-directional integration of management & control solution from lower production control to top
corporate management.

Cement

Cement industry is an important material industry in China. Since the

reform and opening up, cement industry has developed rapidly and
formed an integral industrial system which consists of R&D, geological
exploration, equipment manufacturing, production and processing,
marketing services, international trade and so on, and product quality,
together with product grade, has improved to some extent, basically
meeting the needs of national economy and social development.
By purpose, cement products can be divided into general cement, special cement and characteristic
cement, among which general cement consists of ordinary Portland cement, Portland cement, Portland
slag cement, Portland pozzolana cement, Portland fly-ash cement and composite Portland cement.

Glass Fiber

Glass fiber is an inorganic non-metallic material with excellent performance,

which is produced with natural ore as raw material. After the scientific
calculation and reasonable matching to the ingredients of all the materials,
it goes through the processes of grinding, homogenization, high-heat
founding, wire drawing, winding and weaving, and forms into various final
products. Glass fiber is characterized by high strength, high elasticity modulus, low elongation, electrical
insulation and corrosion resistance, etc. It usually serves as reinforcing material, electrical insulation
material and insulation material in composite materials and is widely used in all areas of the national
economy.

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Currently, the production processes of glass fiber in China include crucible wire-drawing and tank
furnace wire-drawing.

 Crucible Wire-drawing

 As the traditional process, Crucible Wire-drawing make the natural mineral into glass ball, and then
melt wire-drawing with glass ball for production, which is featured by small production scale,
uncontrollable process parameters, bad stability of product quality..

 Tank Furnace Wire-drawing

The tank furnace wire-drawing can be completed by only one step from the raw material of natural
mineral to the final product, with high yield and low energy consumption. Its advanced wire-drawing
technology, treating compound technology, drying technology and post-processing technology, coupled
with a package of advanced assorted equipment, guarantee the production of high-quality glass fiber
products. Generally, tank furnace wire-drawing adopts developed automatic control systems, with stable
product quality, low production cost as well as high productivity.

Cement Clinker Production Line

China is a big cement-producing country. In recent years, there is

a high-speed growth in both supply and demand, making great
contributions to the continuous and rapid development of national
economy. State Economic and Trade Commission proposes in the
Tenth Five-year Plan of cement industry that it will be the
international trend for the industry that production equipment tend
to be large-scale, the production process tend to be automatic and
intelligent with focus on scale efficiency and energy conservation & consumption reduction .

Excellent automatic control system is essential for the development of cement industry. The cement
clinker production control system, which is based mainly on LK series PLC of HollySys, realizes the
monitoring and automatic control to the process and production equipment of cement plants. The system
is featured by stable performances, complete functions, high cost-performance and flexible expansion,
greatly improving the production efficiency and stability of cement production.

Process Description
Generally, the process of cement production can be briefly summarized as “two grindings and one
calcining” which means that grind the materials into raw meals, calcine raw meals into clinkers, and then
grind the clinkers into cement.

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 Materials grinding: the crude

materials are mixed with materials in
sandstone library, limestone library, steel
slag library and fly ash library by
constant proportion through the mixture
system and then be delivered into the
raw meal mill for raw-meal preparation
via transfer system and then the
prepared raw meal enters into the
homogenization library.

 Clinker calcining: the raw meal in the

homogenization library is sent into the preheater for preheating through the constant feeder,
and then it is sent into the ring kiln system for calcining into clinker.

 Cement grinding: add an appropriate amount of plaster, admixture or additive to the clinker
and then grind it into cement.

Cement Production Process

石灰石破碎 Limestone shattering

石灰石预均化堆场 Pre-homogenization heap of limestone

辅原料进厂 Supplementary raw materials entering

破碎机 Shattering machine

配料计量 Ingredient measurement

原料集尘 Dust collection of raw material

原煤入场 Run coal entering

煤堆场 Coal heap

煤粉集尘 Dust collection of coal dust

煤磨 Coal mill

去回转窑 To the rotary kiln

去分解炉 To the decomposing furnace

电收尘 Electrical dust precipitation

预热器 Air heater

喂料计量 Feed measurement

生料均化库 Raw meal homogenization library

熟料库 Clinker mill

原料磨 Raw material mill

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增湿塔 Humidifier tower

回转窑 Rotary kiln

冷却剂 Refrigerant

石膏入场 Plaster entering

水泥集尘 Dust collection of cement

水泥磨 Cement mill

碾压机 Mangle

水泥库 Cement bunker

港口库 Port storehouse

装船机 Ship loader

汽车散装 Bulk car

火车散装 Bulk train

散装水泥船 Bulk cement ship

包装机 Sack filler

汽车袋装 Bagged car

System Design

According to the process requirements and the site situation of cement production, the entire system
consists of two monitoring computers, one engineer station and four field control stations. The core
network of the control system adopts 100M ring industrial Ethernet.
Monitoring Computer

The main functions are to draw up the dynamically controlled flow chart, dynamic trend chart; start and
stop the equipment, control the circuit operation and change the parameters; real-time alarm and print;
record, display, print reports and historical data. It can present the configuration information to the
management staff by way of the computer screen in text, picture, alarm, etc. The operator can fulfill the
control on production line using keyboard and mouse as the input end, carry out the setting of various
configuration and control parameters, the invocation of picture, the starting and stopping of the
equipment, etc.

 Field Control Station

The main control functions are as follows: sequential control, analog control, logic control and I/O
monitoring. Four LK PLC filed control stations in the plant are separately located in the raw meal mill,
kiln outlet, kiln hood and cement grinding control room. The process control information of all the control
stations and PROFIBUS-DP slave station is sent to the central control room by industrial Ethernet,
where the analog control and logic control to the production process is achieved.

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Figure 1. Control System Diagram of the Lime Rotary Kiln

打印机 Printer
1#监控计算机 No.1 monitoring computer

2#监控计算机 No.2 monitoring computer

工程师站 Engineer station

交换机 Switch

环形光纤以太网络 Ring optical Ethernet

冗余工业以太网络 Redundancy industrial optical Ethernet

LK 系统主站 Main station of LK system

冗余 DP 总线网络 Redundancy DP bus network

生料 PLC 控制站 PLC control station for raw meal

窑头 PLC 控制站 PLC control station for kiln top

窑尾 PLC 控制站 PLC control station for kiln bottom

粉磨 PLC 控制站 PLC control station for grinding

Process Flow Control

According to the process flow of cement production, the control system can be divided into the following
several independent and interrelated parts and the control functions of each part are as follows:

 Raw Meal Grinding

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 Automatic control of belt weighs meter for raw meal dosing.

 Closed-loop automatic control of the load and output of the raw meal mill.

 Closed-loop automatic control of the outlet temperature and the inlet cold-hot valve of the raw
meal mill.

 Start-stop control of unlock and interlock of the grouping device and its protection.

 Calcination into Kiln Bottom

 Automatic control of timed charge and discharge of the raw meal homogenizing silo.

 Closed-loop automatic control of the weight of weighing bin and discharge at the bottom of the
homogenizing silo.

 Closed-loop automatic control of the outlet temperature of the evaporation cooler and the jet
water volume (or backwater volume).

 Automatic timed blocking and pre-alarming of the pre-heater at the kiln bottom.

 Closed-loop automatic control of the outlet temperature of calciner and coal quantity at the kiln
bottom.

 Start-stop control of unlock and interlock of the grouping device and its protection.

 Calcination into Kiln Top

 Closed-loop automatic control of the pressure of burner hood and the speed of exhaust fan (or
the exhaust valve opening) at the kiln top.

 Closed-loop automatic control of the pressure of grate cooler and its speed.

 Manually automatic control of the ash bucket unloading of the grate cooler.

 Start-stop control of unlock and

interlock of the grouping device and
its protection.

 Cement Grinding

 Automatic control of belt weighs

meter for cement dosing.

 Closed-loop automatic control of the

load and output of cement mill (globe
mill).

 Start-stop control of roll squeezer

and its protection.

 Start-stop control of unlock and interlock of the grouping device and its protection.

 Start-stop control of dilute oil station and its protection.

System Characteristics
 Combination of Sequential Control and Process Control

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The cement production process equipment has large single-machine capacity, strong production
continuity and high demand of speed and coordination as well as a great deal of analog quantity
treatment and PID adjustment of circuit. Large PLC of LK fully integrates the characteristics of PLC and
DCS, which can completely meet the requirements of sequential control and process control. Compared
to DCS system, it has better cost performance.

 The System Adopting Redundancy Ctructure, with High Safety

The system adopts operator station (server) redundancy, network redundancy (P.S. all the
communication network adopts Redundancy 100M optical fiber network) as well as the redundancy
structure design of CPU redundancy and power redundancy at the field control station to greatly improve
the security for the system.

 High Anti-interference Capability

The cement plant widely uses the strong disturbance source such as the transducer. The internal circuit
of the large PLC of LK achieves a good electromagnetic shield. At the same time, the input and output
channels take such measures as channel separation, digifax separation and optical isolation, which
effectively ensure the reliable operation of the system.

 Open System

The cement production field has a wide range of equipments, and the communication protocols provided
by the equipment supplier also vary a lot. Large PLC of LK uses the industrial Ethernet which most
widely used and most open, PROFIBUS-DP bus network, supporting software such as DDE, OPC,
ODSC and SQL as well as abundant API programming interfaces. In addition, the system also supports
multiple forms of interface such as Modbus / TCP protocol, Modbus RTU protocol and free port
interfaces, which is very convenient for the system expansion.

Lime Rotary Kiln

Lime rotary kiln technique is to first send the transported raw material of
limestone to silo. Then they are moved out by the vibrating feeder under the
silo, transported by the band conveyor to the screening building for screening.
The oversize whose size is over 18mm is transported to rotary kiln for
calcining while the undersize whose size is smaller than 18mm is temporally
stored in a storage tank and moved out later by truck.

The oversize is sent to storage bin at the top of pre-heater. Then through delivery pipes, limestone
(dolomite) is distributed to a vertical pre-heater for pre-heating. The pre-heated materials are pushed out
by hydraulic push-rod, and return to rotary kiln through transfer slide. After materials go trough burning
process and decompose in rotary kiln, hot flue gases come into the pre-heater. The flue gases are
vented into atmosphere by dust remove blower after pre-heating the limestone and de-dusting via belt
dust remover. The well-roasted limestone comes into a vertical cooler with cold air being sent into its
bottom to cool off, and then they are moved to collecting hopper by vibrating feeder. The cold air in the
cooler is heated while cooling off material, and gets into the kiln through burner hood as the secondary

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air for the fuel to burn. The rotary kiln uses coal gas as fuel.

The lime outside kiln is screened by a vibrating screen on finished product silo. The undersize whose
size is smaller than 3mm comes into fragmental limestone silo, and then it is loaded on a truck and
moved out later while the oversize whose size is bigger than 3mm is sent into lime silo by a band
conveyer.

Control System Design

Based on the mode of ‘centralized management and decentralized control’ coupled with digitalized and
informationized project ideology, focused on the construction of enterprise information system with
‘integration of management and control’, establish a monitoring system integrating process control,
monitor and management, which is advanced, reliable, efficient, safe and convenient for extension, to
complete the monitoring and automatic control of the whole technological process and all processing
equipment.

In order to ensure the safety, reliability and production continuity of the whole system, improve automatic
level, and adapt to the requirements of the rotary kiln process, and considering the high demand for
hardware condition of the system as well as the previous conditions, such aspects as excessive I/O
survey points with the system, we adopt a computer control system using HollySys LK as the core, with
centralization and decentralization combined, which consists of central control room, field PLC control
station and distant I/O station.

Figure 1 Control System Diagram of Lime Rotary Kiln

打印机 Printer
操作员站 Operator station

工程师站 Engineer station

UPS 电源 UPS power

LK 冗余系统 LK Redundancy system

冗余 PROFIBUS-DP 总线 Redundancy PROFIBUS-DP bus

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原料工段 PLC 控制站 PLC control station of the material section

1#窑体和成品工段 PLC 控制站 PLC control station of No.1 kiln body and the
product section

2#窑体 PLC 控制站 PLC control station of No.2 kiln body

 Central control room: set monitoring computers and printers, which in charge of monitoring,
managing, storing historical data and printing report forms for the technological parameters,
electric parameters and equipment running status of the rotary kiln; set another gateway
server, which in charge of the access control between industry-control networks and managing
network within the enterprise.

 Field PLC control station: consists of CPU module LK207 and I/O module and keeps
communication with central control station through high speed real-time industrial Ethernet.

 Remote I/O station: consists of slave station port module LK231, I/O module, electronic belt
scale and transducer, and keeps data communication with field PLC control station through
Profibus-DP field bus.

This rotary kiln control system is formed by three sets of LK systems. One set of LK control station and
distant station is used for controlling material section, water cycling and air compressor station, one is
used for controlling 1# kiln and finished product section, and the other is used for controlling 2# kiln.
Main station CPU is located in main field room and three sets of PLC system are communicated with
upper monitoring system, to achieve ‘centralized management and decentralized control’.

Adjustment and Control of Rotary Kiln

As for the process flow of rotary kiln, the materials are

continually fed to the bottom of the kiln by feeder. As the
kiln body rotating, materials are moving to the top the
kiln slowly. In the process of moving from bottom to top
of the kiln, first they are pre-heated by pre-heating zone,
and then they are roasted in the 900~1100 high
temperature zone. After that, well roasted materials fall
into the underneath cooler through a dropping pipe from
the top of kiln.

 Adjustment of Mixed Gas and Air

The proper proportion of mixed gas and air is the key adjustment to guarantee the temperature for kiln
roasting, so that the volume of gas and air can be dynamically adjusted according to parameters like
output, heating value, etc.

Flow rate limit alarm, out-of-limit alarm, undisturbed switching, nonlinearity PID adjustment and data
storage. This system runs reliably with low failure rate, which makes the burning to be more rationale
and secures roast temperature, largely lowering the unit consumption of gas, improving working
conditions and increasing safety.

1#回转窑工艺流程图 Process Flow Diagram of No.1 Rotary Kiln

煤粉制备 Coal dust preparation

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料浆班累计 Shift accumulation of slurry

熟料班累计 Shift accumulation of clinker

料浆月累计 Monthly accumulation of slurry

熟料月累计 Monthly accumulation of clinker

来浆 Slurry coming

回浆 Slurry returning

给定 t/H Given t/H

熟料 Clinker

执行器 Performer

尾喂阀门 Tailing valve

窑尾风阀 Air valve at the kiln bottom

一次风阀 One-time air valve

高压风阀 Air valve of high pressure

中压一室 No.1 room of medium pressure

中压二室 No.2 room of medium pressure

收尘排风 Dust collection and air discharge

开度 Opening degree

系统总揽 System overview

1#窑工艺 Process of No.1 kiln

1#窑煤磨 c Coal mill of No.1 kiln

2#窑工艺 Process of No.2 kiln

2#窑煤磨 Coal mill of No.2 kiln

趋势图 Trend chart

报警查询 Alarm query

退出 Exit

 Automatic Control of Kiln Bottom Temperature and Negative Pressure

In the normal production of rotary kiln, negative pressure is always kept within it, which is required to be
kept above 2mmH2O column. The inside temperature control is largely affected by the strength of the
negative pressure. Excessive negative pressure will lead to draft increase within the kiln, the clearing of
the powder inside and the lowering of the burning efficiency; too low negative pressure will result in a
smaller differential pressure between inside and outside of the kiln, the smoking of the kiln top and
bottom, and the deteriorating of the operation environment. Also, waste gas inside the kiln will flow

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slower, causing a turbid kiln inside and causing the temperature to be out of control. By adjusting the
temperature of kiln bottom, the temperature will be generally stable.

 Quantitative Control of Material Feeding

To guarantee the roasting quality, feeding quantity of rotary kiln is required to be stable, even and
continuous. Only stable, even and continuous feeding quantity assures a steady heat engineering
system and stabilized roasting quality.

Rotary kiln belongs to the great inertia production equipment. Material moving speed in kiln has great
influence on roasting quality and productivity of rotary kiln. If roasting materials are moving too fast, the
materials stay in kiln for short time and cannot get well heated, resulting in the bad roasting quality;
otherwise, moving too slow will cause a increasing loss in roasting and lower the productivity of rotary
kiln. Moving speed of material are related with inclination of kiln body, the dimension of ID(interior
diameter) of kiln body, rotational speed of kiln body, centre angle between material layer section of inner
kiln and kiln centre and other factors.

The adjustment of technological parameters inside kiln is the key to the production level of the whole kiln,
which include rotational speed of kiln, gas flow rate, first and second wind flow rate, draft fan hydraulic
coupling opening, cold blast sliding valve and etc. The performance indexes of all the technological
parameters well reach the requirement.

Based on LK, the rotary kiln control system can achieve the automatic control with the operation and
monitoring of kiln body device and auxiliary equipment in control room, the starting and stopping of
electrical equipment, the monitoring of device parameters, the closed loop adjustment of the controlled
parameters,, the system alarm control, the production process alarm as well as data storage via
human-machine interface, further achieving automation in both production and management of rotary
kiln to greatly reduce the labor intensity of workers, improve the automatic level of enterprise and
productivity, and save energy rationally.

Tank Furnace Wire-drawing for Glass Fiber

The glass-wool production line consists of the systems such as the

kiln, fiber forming, curing oven and cool line molding. The entire
production process is complicated. Meanwhile, the use of liquid gas
and heavy oil has particularly high demand for security, so the
production line has very high requirements for the automatic control
system. Based on PLC of LK series of HollySys, the automatic
control system for glass fiber uses redundancy structure to meet
security requirements. Its analog input and output modules and
sophisticated PID processing can fully meet the monitoring, control and management needs and provide
a high-performance, high reliability, economical solution for the glassmaking industry.

Process Description

The tank furnace wire-drawing of glass fiber is developed on the basis of crucible wire-drawing. A variety
of raw materials are mixed by different proportions and delivered into the furnaces and melt into liquid
glass, which flows into the platinum &rhodium alloy bushing on the branch after being clarified and
cooled. The drain board is full of holes numbered from 100 to 4000, from which glass is pulled out by

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drawing machine; the glass fiber is formed in this way.

There are many kinds of melting processes for glass materials, such as the crucible melting, tank
furnace melting and Pochet melting, among which the tank furnace melting is the international
mainstream technology. The heat source of the melting part
generally uses heavy oil or natural gas while the combustion air
is the air and pure oxygen. Electric boosting acts as auxiliary
heating and increases the production.

As for energy efficiency, pure oxygen is used for combustion to

reduce 40% heat bought away by the exhaust.. In addition it can
substantially cut down NOx emission. At present, metal heat
exchanger and waste heat boiler are frequently used to recycle
heat.

化学药品 Chemicals
硅酸盐 Silicate

混合搅拌 Stirring and mixing

含金属废弃物 Metal waste contained

固体 Solid

窑炉 Kiln

玻纤拉丝 Wire-drawing for glass fiber

烟气 Flue gas

烟气处理系统 Flue gas treatment system

已过滤水 Filtered water

洗涤水 Scouring water

过滤 Filtering

System Design

The whole control system is divided into such three sub-control stations as material, tank furnace melting
and fiber forming. The control objects include valves, transducers and motors. The two computers of the
operator station in the control center are redundancy systems, connected with the three sub-stations of
the system through the Redundancy and ring-shape industrial fiber optic Ethernet, and the
communication speed rate is up to 100Mbps. The sub-station of the system is connected with the
fielding I/O sub-station through the Redundancy PROFIBUS-DP field bus network, allowing the system
to become an organic unity.

 Monitoring Center

Located in the central control room, monitoring center consists of the monitoring computer, Ethernet

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switch, printer, and uninterruptible power supply (UPS) and other equipments. Among three monitoring
computers, one works as the engineer station and the other two works as the Redundancy operator
stations, acting as hot standby for each other.

 Sub-control Station of System

As the control core for the whole system, the sub-control station function as the logical operations,
mathematical operations, data collection, device control, system communication, etc. The system adopts
Redundancy configurations, including power redundancy, CPU redundancy and communication network
redundancy and the failure of each part wouldn’t cause system downtime, meeting the requirement for
stable and continuous operation of the system extensively.

 I/O Sub-station

Taking advantage of the strong PROFIBUS-DP network of the large PLC of LK of HollySys, the field I/O
sub-station is deployed in different areas. I/O sub-station mainly includes I/O control cabinet,
communication interface module, various I/O modules, etc. I/O sub-station is not responsible for data
processing or logical operation, and it is only responsible for field data collection and signal interface, etc.
Also it is responsible for sending the collected data to the respective sub-control station through the
PROFIBUS-DP network and for receiving the equipment instructions from the sub-station to complete
the operation of the equipment.

图 1 系统网络结构图

图 1 系统网络结构图 Figure 1 System Network Architecture Diagram

工程师站 Engineer station
打印机 Printer
监控计算机 Monitoring computer
交换机 Switch

环形光纤以太网络 Ring optical Ethernet

冗余工业以太网络 Redundancy industrial Ethernet

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LK 系统主站 Main station of LK system

冗余 DP 总线网络 Redundancy DP bus network

配料控制站 Control station for dosing

池窑溶化控制站 Control station for tank furnace melting

纤维成形控制站 Control station for fiber forming

Process Flow Control

From process perspective, automatic control of tank furnace wire-drawing is distributed in 4 sections,
separately material, tank furnace, channel and drain board.
The 4 sections will be introduced as follows.

 The Material Part

 Conduct weighing to the materials with precision of

0.1%.

 Control the sequence and timing of the material

process.

 The Melting Part

The control objective is to stabilize the thermo-technical

parameters of the tank furnace. The main control parameters are:

 Loop control on flame space pressure of the tank furnace (the furnace pressure)

 Temperature control on lame space of the tank furnace (the furnace temperature)

 Glass level control

 Channel and Drain Board Part

 Keep the glass metal at the temperature which is needed for forming by controlling the control
valve of LPG.

 Control the movement of the drawing machine and pull the glass fiber from the drain board.

 Other Control

 Logic control: mainly including the starting and

stopping of equipment, alarm interlock, the shift to
manually operation and nought output of PID, the
small hopper of tank furnace feeder and so on.

 Analog quantity control: fuel heating, venting flow of

combustion air, air ratio control of fuel atomization.

 Statistics: the full tube of drawing machine, the total

number of cylinders, full tube rate and fuel

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consumption.

 Control Index

 Flame space temperature of unit furnace ±3

 Channel glass metal temperature ±1

 Bushing temperature ±0.5

 Glass level ±0.3mm

 Pressure of the melting end ±2.0Pa

System Characteristics
 Combination of Sequential Control and Process Control

The processing equipment for cement production is complicated, including the control as the starting
and stopping of equipment, safety interlock and small hopper of tank furnace feeder, as well as the
analog control such as oil heating, combustion air venting flow and ratio control of fuel atomization air.
Large PLC of LK integrates the characteristics of PLC and DCS fully, which can completely meet the
requirements of sequential control and process control. Compared to DCS system, it has more favorable
cost performance.

 High Processing Precision of Analog Quantity

The fuel used for the production of glass fiber is liquid gas and heavy oil. The mixing ratio of fuel and
combustion air must be strictly controlled, and any imbalance may result in instability with the process
condition and even the danger of explosion. Therefore the system has high demand of the analog input
and output together with the precision of self-controlled circuit. The analog input and output of large PLC
of LK can be up to 16-bit, 0.2% precision, while the system integrates the optimized loop control
algorithm, completely meeting the control demand of the system.

 High Safety of the System

Glass wool production is characterized by continuous production and batch production: the furnace
production (fusing of glass metal) is a continuous, uninterrupted process and any interruption of the
process may result in unpredictable consequences and losses, so the system has high demand for the
reliability of the control. The control system featured with large PLC of LK has the functions of misuse
prevention, alarm, logic interlock and so as to ensure safe and reliable operation of the system.

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Energy Resource

In recent years, the demand and supply of energy resource and power in china become quite tight, and
power generation industries in china and abroad have paid great attentions to the development and
utilization of biomass resources which are rich in resources, renewable, strong and helpful for the
improvement of environment and sustainable development, so the biomass power generation industry
came into being.

The main raw materials of biomass power generation are agriculture, forestry and industrial waste, and
municipal solid waste can also be used as raw materials. These materials are burned directly or gasified
for power generation. In general, biomass power generation industry has a bright future.

First, in the renewable energy generation, compared with small hydropower generation, wind power
generation and solar power generation and other intermittent power generation methods, biomass
power generation has the advantages of high power quality and reliability, so it can be used as a
supplement to the above power generation methods and it has high economic value; second, under the
goal of building a moderately prosperous society, the rural energy structure dominated by traditional
biomass use has turned to modern direction and biomass power generation is an important way for this
transformation; third, there are rich biomass power resources for effective development and utilization,
urgent to get increased in value and promote economic development. The amount of biomass resource
in China is equivalent of 700 million tons of standard coal. With the activities of returning farmland to
forest and planting new carbon forest, it is estimated that by 2020 the amount of biomass energy
resources will be equivalent of up to 9 to 10 million tons of coal, holding a pivotal position in China
energy resources; fourth, biomass power generation technology is relatively mature.

At present, the straw power generation, biogas generation and biomass gasification are main power
generation methods with certain space for development and are being vigorously developed.

Straw Power Generation

Straw, which includes corn stalks, wheat straw, rice straw, straw of oil crops, beans, wheat crop residues,
grains straw, cotton stalk, etc., is an energy source whose consumption is only lower than those of coal,
oil and natural gas, accounting for 14 % of total energy consumption in the world. Relevant studies from
international Energy Agency indicate that straw is a low-carbon fuel and its sulfur content and ash
content are lower than those of the coal which is heavily used at current, all these features making it a
very clean and renewable energy.

In straw power generation, straw is burned directly to transform biomass energy in straw into heat and
electricity power. The process equipments mainly consist of combustion furnaces, feeders, feed belts,
steam turbine generators, thermal cycling devices, dust cleaning pools and control systems, etc. The
feeders feed materials from the bottom of the combustion furnace. After the first combustion, second
combustion and water spraying for accelerating heat transfer, Biomass achieves the full conversion to
heat and drives steam turbine generators to generate electricity with steam.

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Biogas Power Generation

Biogas is a rich and inexpensive biomass energy resource, and biogas power generation not only solves
the electricity problem in remote mountain area, but also provides an effective way for easing the tension
situation of shortage of commercial electrical energy supply. With renewable energy gets more and more
attention, biogas power generation system will have a good development prospects.

Biogas power generation is a new technology of energy comprehensive utilization that combines
environmental protection and energy saving. It processes a large number of organic wastes in industrial,
agricultural or urban life (for example: lees liquid, livestock manure, municipal waste and sewage, etc.)
with anaerobic fermentation technology to produce biogas and use the biogas to drive methane
electricity generator units, and it can make full use of the afterheat of biogas generator units for biogas
production, thus making integrated thermal efficiency reach about 80%, significantly higher than the
normal power generation efficiency of 30 to 40%, and users can gain significant economic benefit.

Wind Power Generation

The principle of wind power generation is that the kinetic energy of air flowing
is applies on the impeller, and the kinetic energy is transformed into
mechanical energy to drive the impeller for rotation. If the impeller shaft and
the generator shaft are connected, the generator will be driven to generate
electricity.

Wind power generation is currently the most mature technology, and the most
promising large-scale development of renewable energy. As energy supply is
getting tighter and environmental pollution becomes more serious, the
development of wind power generation is highly valued by all parties.

Control system is the nerve center of modern wind turbine generators. Modern wind turbine generators
are unattended. Blowers are generally started automatically when wind speed reaches about 3 - 4 m / s
and they provide rated power when wind speed is about 14m/s. Then, as the wind speed increases, wind
turbine generators are controlled to generate electricity in the vicinity of its rated power, until the wind
speed reaches 25 m / s when it will be automatically shut down. The Survival wind speed of the modern
blower is 60-70 m / s. The speed range of the wind commonly referred to as 12 hurricanes is only
32.7-36.9 m / sec. Fan control system will control the wind turbine generator system according to wind
speed and wind direction, so as to make the system operate in a stable voltage and frequency and
automatically connected to and disconnected from the grid. The control system will also monitor the
operating temperature of the gear boxes and turbine generators, oil pressure of the hydraulic system
and send alarm signals for any abnormal conditions and shut down turbine generators automatically
when necessary.

Solar Energy
Solar energy generally refers to radiant energy of sunlight. Inside the sun,
the fusion reaction of "hydrogen" transforming into "Helium" releases
enormous energy and keeps radiating energy to aerospace and this energy
is solar energy. Solar cells can transform the energy in sunlight into
electricity; solar water heaters can heat water with the heat in sunlight and

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use the heated water to generate electricity and complete seawater desalination with solar energy. Now,
solar energy is not very popular, as there are some problems in solar power generation, such as high
cost, low conversion efficiency, etc, but the solar cells are applied to providing energy source for
man-made satellites.

Straw Power Generation

The rapidly developing Chinese economy calls for increasing demands in

energy and environment, burning straw for power generation is an effective
way for full use of energy and protecting the environment. In Power straw
plants, LK Series PLC of Hollysys Company -based automated feeding
systems is used to monitor and automatically control the straw feeding
system process and production equipment of thermal power plants. The
feeding system is stable, functional and cost-effective, flexible expansion, and has been successfully
applied in the straw feeding system fields of many thermal power plants.

Process Flow Description

The straw power plant uses straw as raw material, which will be broken and bundled, and the feeding
system uses the bale loosing machine to complete the second breaking of straw fuel that has been
processed and then transfers the dispersed fuel on the belt machine. The belt machine will transfer the
dispersed straw into the steam boiler heating system for full combustion, so that the recycled water in the
steam boiler are converted into steam to drive the steam turbine generator to rotate, then the kinetic
energy are transformed into electrical energy. The overall feeding system includes two parts: the raw
material dispersion of the bale loosing machine, and the material handling of the belt machine.

 Raw Material Dispersion System of Bale Loosing Machine

The bale loosing machine consists of pressure roller, guide roller, conveyor roller, primary side bale
loosing machine and secondary side bale loosing machine.

After straw fuel is sent into the bale loosing machine, it is crushed by pressure roller firstly, the crushed
fuel is sent into conveyor roller through guide roller, then sent into the primary side bale loosing machine
for loosing operation through the guide roller, after loosing operation, and finally the fuel is sent into the
secondary side loosing bale machine for the second loosing operation through the conveyor roller.

 Belt Machine Material Handling System

After the second loosing operation, the straw fuel is sent into the belt machine through the bale loosing
machine. The fuel goes from 0# belt machine→ 1# belt machine → 2 # belt machine→ 3 # belt machine,
and is sent into the heating furnace by 3 # belt machine for combustion.

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PLC Control System Design

Straw power plant control system is divided into

three-level structure: production management level,
field-level control level and local control level. The
control system uses high-speed Ethernet (TCP / IP
protocol) as the connection tool to achieve
information and resource share. In these levels,
the priority of the local control is the highest, the
priority of the field control level is the second, and
the priority of the production management level is
the lowest. The field control station formed by the LK
Series PLC is at the field control level of the system,
and it is connected to the original DCS system of the 图1 自动化控制系统结构图

power plant.

打印机 Printer

操作员站 operator station

厂级局域网 Plant-level LAN

打印机 Printer

操作员站 operator station

以太网交换机 Ethernet switch

L.K 冗余系统 L.K Redundancy system

原料分散系统 PLC 控制站 PLC control station of raw material dispersion

system

燃料输送系统 PLC 控制站 PLC control station of fuel transferring system

图 1 自动化控制系统结构图 Figure 1 Structure Diagram of Automatic Control

System

 Production management level: The system is in the control room of steam boiler and steam
turbine generator cogeneration system, and composed by the original DCS control system.
The monitoring computers collect operational status and process parameters for the main
process equipment and production and display these status and parameters. The PLC control
station on the feeding and conveying system is connected to the communication server of the
DCS system via serial port communication and the data of the PLC control station is
transferred into I/O server of the DCS by the communication server. The monitoring software
running on the I/O server displays the data and sends control commands.

 Field control level: i.e. PLC control level, the system consists of LK large PLC, and uses the
redundancy structure of CPU dual CPU hot standby, so the whole system can operate stably
and reliably. Its function is to read the operating parameters of the bale loosing machines and
belt machines in the feeding system and control the operation of the devices in the control

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system according to the instructions issued by the production management system. Data for
collection includes operating states, feedback current and fault signals of transducers of
various components in the bale loosing machine; operating states, feedback current and
on-line detection switch signals of the belt machine. The field control level system accepts the
dispatch of the production management level system, but its operation does not depend on the
production management level system. If the monitoring computer fails or is not in use or a
failure occurs in the communications network, the control station can still work normally and the
whole process will not be affected.

 Local control level: the devices are switched to the manual field status to achieve local manual
control of devices. The priority of local manual control is the highest, and it is mainly used in
equipment commissioning and maintenance stages.

The feeding control system in the straw power plant collects transducer signals and data signals that are
responsible for controlling pressure roller, guide roller, feed roller, primary side bale loosing roller and
secondary bale loosing roller and sends control signals to the above devices; reads and controls the
working state of the belt machines in the material handling system in real time, including the start/stop
control on belt unit A / B and the anti-tear, slip, blocking material, deviation, pull rope and other on-line
detection switches.

System Functions

The feeding and transferring system of the straw power plant connects the PLC control station to the
original DCS system to achieve monitor and control of the process and data processing, storage,
analysis and report printing and other tasks.

 Process Display: Displays the process, while all device statuses, process parameters and the
details of the control loops are collected and displayed selectively.

 Setting Value Display: including the settings of all necessary parameters, control methods,
adjustable parameters, and other interlocking values, alarm values and so on.

 Alarm Display: including real-time alarm and alarm history. The system can diagnose various
types of faults online, find the fault position and send alarm signals, including process data
alarm, equipment failure alarm and system failure alarm, and provide different alarm screens
according to different alarm information and disable alarm signals when the failure is
confirmed.

 Report Form Displaying and printing: DDE technology is applied to allow users to directly
use the Excel to prepare report forms. With Excel's powerful functions, users can prepare a
variety of report forms freely: report forms can be real-time data report forms or historical data
report forms.

 Historical Data Storage and Retrieval: Important historical data are stored online and the
maximum storage period is 10 years. Historical data can be retrieved via historical reports or
historical trend curves.

 Control: In remote monitoring computers, users can carry out remote control manually, i.e.
using the mouse, keyboard to control the PLC to start/stop the equipments in the field.

 Operation Record: Operation to critical equipment and modifications to important parameters

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are automatically recorded, including the name of the operator who logs on the system, the
operation to the equipment, the time of the operation and the parameter values before and
after the modification, so as to facilitate management and accident analysis.

 System Security Management: The system is set in multi-user and multi-regional mode, and
all types of users have their own user names and passwords corresponding to different levels
of security, which determines the scope of observation, the functions can be used and the
parameters can be modified. Up to 8 user levels and 8 region levels can be set up in the
system.

Biogas Power Generation

Biogas burning power generation is a biogas utilization technology that

emerged with the development of comprehensive utilization, and it is a
new comprehensive technology of energy source utilization combining
environmental protection and energy saving. It processes a large number
of organic wastes in industrial, agricultural or urban life (for example: lees
liquid, livestock manure, municipal waste and sewage, etc.) with
anaerobic fermentation technology to produce biogas, and then uses the
biogas to drive methane electricity generator units. It can make full use of the afterheat of biogas
generator units for biogas production, thus making integrated thermal efficiency reach about 80%,
significantly higher than the normal power generation efficiency of 30 to 40%, and users can gain
significant economic benefit.

LK Series PLC of Hollysys -based automatic control system and Redundancy hot standby CPU
configurations are used in biogas power generation, greatly improving the stability, reliability and security
of operation of biogas power generation and making system maintenance more convenient and efficient.
The system has been applied in a biogas power generation project in Beijing, achieved perfect operation
conditions so far, hence are well received by the users.

Process Flow Description

Landfill gas power generation system is divided into four parts: collection system, exhaust system,
purification system and power generation system.

The collection system consists of well pipe, well head,

pipeline network and the condensate water collector and
other components.

The exhaust system uses a Roots blower to complete

vacuum extraction, and the landfill gas in negative pressure
state is withdrawn from the collection wells .The amount of
exhaust can be regulated by a valve and the exhaust
pressure is regulated by the Roots blower to obtain a stable
gas production.

图1 沼气发电工艺流程图

降雨 Rainfall

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气井 Gas well

过滤 Filter

垃圾填埋场 Refuse landfill

渗滤液排出管 Percolate discharge pipe

沼气收集管 Methane gas collection pipe

风机与过滤系统 Blower and Filter System

沼气发电机组 Biogas generator unit

变压器 transformer

去电网 To grid

图 1 沼气发电工艺流程图 Figure 1: Biogas Power Generation Process Flow

Diagram

The purification system includes condensate water separators and dust filters, etc, the former are mainly
used to remove moisture in the biogas, the latter are mainly used to remove granular pollutions to avoid
them entering into the power system and causing wear. After initial purification, the biogas is guided into
the pressurized blower, and after pressure increase, the biogas enters into the cooler for further filtering
by the coalescer filter, and the filtered biogas goes into the gas turbine generator through two filters and
burns to generate electrical energy.

Power generation system will send the electrical energy to the grid.

Automatic Control System Design

Automatic control system for biogas power

generation can provide monitoring, control,
interlocking, report printing for the process
parameters, electrical parameters and
equipment operating status of biogas treatment
system and biogas power generation system,
and use a series of communication chains to
complete data collection, data communication,
sequence control, time control, loop regulation,
upper level monitoring and management, etc.
图2 自动化控制系统结构图

中央控制室 Central Control Room

打印机 Printer

操作员站 Operator Station

操作员站 Operator Station

工程师站 Engineer Station

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UPS 电源 UPS Power Supply

100 Mbps 冗余工业以太网 100 Mbps Redundancy Industrial Ethernet

LK 冗余系统 LK Redundancy system

冗余 PROFIBUS-DP 总线 Redundancy PROFIBUS-DP bus

沼气处理 PLC 控制站 PLC control station of biogas treatment

发电机组 PLC 控制站 PLC control station of Generator Units

图2 自动化控制系统结构图 Figure 2 Structural Diagram of Automatic Control

System

The system consists of a central control room and two field PLC control stations (located at the biogas
treatment system and biogas power generation system).The field PLC control stations are composed by
LK Series PLC systems and detection instrumentations, to provide distributed control for biogas power
generation process; and the monitoring& management will be carried out by upper level computers in
the central control room. The data communication between the upper level computers and the PLC
control stations is achieved by high-speed, real-time industrial Ethernet whose speed is 100Mbps and
the transmission medium is shielded twisted pair.

The field PLC control stations use dual CPU hot standby redundancy structure. PLC devices collect field
signals and communicate data with the control and monitoring computers via industrial Ethernet. The
control mode is "whole open and whole distributed".

The control system is divided into three levels: management level (central control room), control level
(PLC control station) and field level.

System Functions

 Display Function

PID chart with multiple windows, alarm screens, trend maps, guiding screens, control screens,
parameter modification screens, fault diagnosis screens, dynamic screens, and other monitoring
screens.

 Security Function

An operator password and a system password are set up. When equipments are in operating state, all
Windows hotkeys are disabled to lock the free lock on and out of the system. The operating state is
recovered automatically when the system is powered on.

 Historical Data Management

Access gap and methods of all collection data can be set freely.

 Print Report

Provide timing, alarm and random printing according to user-defined report formats.

 Event Record

Events and internal clock can be distinguished and managed in time sequence, and can be displayed

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and printed timely.

 Database Interface and Data Communication

Real-time data with openness can be accessed by any task and the database exchanges data with the
task. The system has the function of reproduction and distribution, that is, distributing information to
other common database applications, and also supporting SQL, ODBC or OLE DB applications. All data
can be represented by symbols, such as: VALVE, MOTOR, etc. When necessary, every change of
variables can be monitored and processed.

 Control and Operation Function

Objects on the screen can be switched on or off or their values can be increased or decreased via
mouse clicking according to configuration, and loop response time is less than 2 seconds.

The control system uses the combination of program control, remote control and local control. For the
electric valves, pneumatic valves, pumps, blowers and other control objects, in addition to remote control
the control room, local operation methods are also adopted.

For the program control, the five operation methods of the system are automatic operation,
semi-automatic operation, step operation, key operation and local manual operation. In manual mode,
when the operator starts/stops motors, opens/closes valves and other equipments, LCD screen provides
operational guidance.

When a field equipment fails and affects the advance of the program control, the operating personnel
can carry out skipping operation if relevant constraints are met.

When devices are in local operation modes, the operations of upper level computers are invalid.

Wind Power Generation

With growing tensions in energy supply and more serious environmental pollution, the development of
wind power generation is more highly valued by various parties. Wind power generation is a technology
that transforms wind energy into mechanical energy and then transforms the mechanical energy into
electrical energy. The electric control system of wind power generation is a key component of the blower
and it directly affects the performance and efficiency of the entire wind power generation system.

At present, wind power generation farms mainly use synchronized wind turbine generator units at MW
class, and each blower has its own control system. The master control system is used to collect data,
and through calculation, analysis, determination, it controls unit's operation status (starting, idling to
speeding up, synchronization and power generation, shutdown, maintenance) and a series of control
and protection actions: yawing, braking and starting and stopping of lubricating oil pump. A single wind
turbine generator can be controlled automatically without manual intervention.

LK large PLC based-wind power control system can make full use of the various performance
advantages of LK PLC, so that various control performance of wind turbine generator units can be
maximized.

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Design of Master Control System

Master control system is the nerve center of modern wind

turbine generators. LK large PLC-based master control
system of wind turbine generators can control the power
generation system according to wind speed and direction,
so that the generators operate at stable voltage and
frequency, be automatically connected to and
disconnected from grid, and monitor the operating
temperature of gear boxes and turbine generators, oil
pressure of hydraulic system, and provide alarm signals
for any abnormal situation that has occurred, and
automatically shut down the turbine generators when
necessary. It can also ensure safe and reliable operation
of wind turbine generator units to achieve maximum
utilization and the highest energy conversion rate of
natural wind, and provide electric energy with good quality
to the grid.

图 1 主控系统解决方案
图 1 主控系统解决方案 Figure 1 Master Control System Solution

Currently, the lower level computer of the monitoring system in china is the controller of the wind turbine
generator. For each wind turbine, even without the participation of the upper level computer, it can also
work safely and correctly. So, relative to the entire control system, the lower level computer control
system is a subsystem and it can handle failures of wind turbine generator units separately to ensure the
security and stability of wind turbine generator under a variety of abnormal conditions. As the master
controller of the control system, LK PLC controls the synchronization and disconnection from grid by
detecting the grid parameters, wind conditions, the field temperature parameters, and carries out yawing
and pitching action according to wind conditions to optimize the control, thus enhancing the operation
efficiency and power quality of wind turbine generator units.

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LK large PLC based master control system realizes monitoring and controlling upon slave stations by the
master control station by high-speed field bus network among the master control station, nacelle station,
pitch equipment, converter equipment and water-cooled equipment, hence to achieve overall monitoring
and control of wind turbine generator units.

 Hollysys master wind power control system consists of power supply module, CPU module, I/O
modules, special function modules, backplane, communication network, HMI panels and PC
for debugging.

 The tower station uses local high-speed I/O as the master controller, and it connects to HMI
through open field bus protocol of MODBUS TCP;

 The nacelle station uses LK PLC remote I/O, and it receives control instruction from the master
control station via PROFIBUS-DP field bus and the communication media is optical fiber;

 A field bus (e.g. PROFIBUS-DP, CANopen, etc.) protocol is used as the communication
protocol between the nacelle station and pitch system.

 The nacelle station is mainly to complete in I/O signal acquisition, such as wind direction, wind
speed measurement, various temperature signals measurement, yaw control and exchanging
data with pitch system;

 LK PLC's CPU module is installed at the station of the bottom of the tower and is mainly used
for the control of wind turbine generators, such as synchronizing or disconnecting from the grid,
exchanging data with nacelle stations and converters, and exchanging data with the central
monitoring computer, etc.;

 Human-machine interface is used for setting various parameters, monitoring of data and
curves, and record of faults.

 The Ethernet switch sends data of each wind turbine generator unit to the central monitoring
system via optical fiber. The ring topology communication structure between wind turbine
generator units increases system reliability.

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Figure 2 Schematic Diagram of Master Control System Function

机舱站控制器功能 Nacelle station controller function

风速、风向测定 Wind speed and wind direction measurement

发电机转速测定 Generator rotating speed measurement

液压系统控制 Hydraulic system control

齿轮箱控制 Gear box control

高速轴刹车控制 High-speed shaft brake control

偏航系统控制 Yaw control system

发电机控制 Generator Control

润滑系统控制 Lubrication System Control

塔底主站数据交换 Data exchange of tower station

变桨系统数据交换 Pitch system data exchange

UPS 供电 UPS Power Supply

机舱振动监控 Monitoring for nacelle vibration

扩展 I/O Extended I/O

风力发电机组机舱控制柜 Control cabinet of wind turbine generator unit

nacelle

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光纤介质 Optical fiber

风力发电机组塔底站控制柜 Control cabinet of wind turbine generator unit

tower station

本地高速 I/O Local high-speed I / O

风电专用主控制器 Dedicated master controller of wind power

generation

HMI 就地监控系统 HMI local monitoring system

塔底站控制器功能 Controller function of tower station

控制柜温度控制 Temperature control of control cabinet

UPS 供电 UPS Power Supply

安全链输入 Input of the security chain

三相电数据采集 Three-phase electrical data acquisition

变流系统数据交换 Data exchange of converter system

HMI 通讯 HMI communication

SCADA 通讯 SCADA communication

机舱站数据交换 Data exchange of nacelle station

软件调试 Software debugging

System Characteristcs

The control device that uses LK PLC as the main station and nacelle station has the following
characteristcs:

 The open link between HMI and the tower controller uses an open bus protocol, making the link
between the touch-screen and the master controller simple and reliable, realizing local control
and monitoring of wind turbine generator efficiently.

 The master controller uses the optical fiber as the communication medium, and uses
PROFIBUS-DP network or industrial Ethernet connection to a central monitoring computer to
facilitate the remote control of a single wind turbine generator. It is characterized by diversity of
network topology structure, stable signal transmission, long stability transmission distance and
high transmission speed.

 Excellent anti-interference ability. All components of LK PLC are designed in accordance with
industry-standard strictly and can work stably in complex industrial environment, and they have
passed electromagnetic compatibility of national authorities testing and CE, UL certification.
The communication network uses optical fiber or shielded twisted pair to fight against external
interference effectively.

 All the master stations, slave stations and communication of the central monitoring computer
use open field bus protocol to provide excellent system compatibility.

 The debugging and maintenance of the system is easy. As the master controller is in the

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bottom of the tower, the control and monitoring functions of the nacelle station and pitch
system are achieved by the CPU of the controller at the bottom of the tower to provide
maximum convenience for the debugging and maintenance of the system.

 In the configuration provided, each type of signal is reserved with a margin of 10% to facilitate
system expansion.

 Excellent environmental adaptability. Wide temperature tolerance, enables the system to start
smoothly even when the temperature is -25 ; exellent three-proofing process, namely, salt
fog-proof, moisture heat-proof and fungal-proof, hence, the system is suitable for the wind
turbine generators working at desert, flats and offshore.

 Expert modules applicable for wind power are equipped, such as high-speed frequency
measurement module LK620, fiber optic communication module LK233, electric quantity
collection module LK420, etc. for completing the acquisition and communication of the wind
power signals.

Solar Energy

Solar energy generally refers to radiant energy of sunlight. Inside the

sun, the nuclear reaction of "hydrogen" transforming into "Helium"
releases enormous energy and keeps radiating energy to aerospace,
and this energy is solar energy. The solar water heating system heats
water with the heat of sunlight. At present, a large area of solar hot
water system in china is composed of header collector arrays, storage tanks, pump valves and other
components, and these components form once-through, natural circulation and forced circulation
systems. The above circulation systems can provide hot water under all weather conditions with the help
of auxiliary energy, such as electric heating.

The solar water heating system with PLC as the control core and the solar hot water monitoring system
with PC and configuration software as the monitoring system enhance the automatic technology level
and control performance of the solar water heating system.

System Design

Solar water heating system consists of solar collectors, various kinds of manual valves, solenoid valves,
circulation pumps, heat storage water tanks, electric heating water tanks, water temperature and water
level sensors, inverters and control systems.

LK-based solar water heating control system can monitor, control and interlock the process parameters,
electrical parameters and equipment operating status, provide alarm signals and report printing. A series
of communication chains between the main station and remote station are used to complete data
acquisition, data communication, sequence control, time control, loop regulation and upper level
monitoring and management that are necessary for the whole process.

The whole system consists of a central control room, a field PLC control main station and 4 remote I / O
stations. The field PLC control stations are composed by a programmable logic controller (PLC) system
and detection instrumentations, to provide distributed control for the whole plant. The data
communication between the central control room and the PLC control room is achieved by high-speed,

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real-time industrial Ethernet whose speed is 100Mbps.

图1 太阳能热水控制系统图
激光打印机 Laser Printer

操作员站 Operator Station

喷墨打印机 Inkjet Printer

操作员站 Operator Station

工程师站 Engineer Station

UPS 电源 UPS Power Supply

工业以太网交换机 Industrial Ethernet Switch

1000Mbps 环形工业以太网 1000Mbps ring Industrial Ethernet

中央控制室 Central Control Room

PLC 控制主站冗余系统配置 Redundancy system configuration of PLC control

master station

冗余 PROFIBUS-DP 现场总线 Redundancy PROFIBUS-DP Field bus

远程 I/O 站 Remote I/O station

外环集热器远程站 Outer ring heat collector remote station

内环集热器远程站 Inner ring heat collector remote station

中环及空气集热器远程站 Middle ring and air heat collector remote station

空调水箱远程站 Remote station of water tank of air conditioner

图1 太阳能热水控制系统图 Figure 1. Solar Water Heating Control System

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Diagram

System Configuration

 Central Control Room

 The central control room is equipped with two monitoring operation stations which are hot
standby for each other, two engineer stations, a failure printer, a chart printer, a UPS power
supply and a network cabinet;

 As redundancy devices, the two monitoring operation stations may focus on monitoring or
configuration function respectively and serve as the hot standby for each other when a failure
occurs, thus realizing a flexible operation method. When necessary, computers in other
location of the plant can also connect the monitoring operation stations through the LAN to
monitor the production and operation status of the processes in the field in real-time.

 Field Control Level (PLC Control Station)

 The field control station is equipped with a control cabinet and a UPS power supply. The
control cabinet contains a LK Series PLC, a 24VDC power supply, a fiber optical Ethernet
switch, over-voltage protection devices, miniature circuit breakers, terminal blocks, small
relays, cables for installation and connection
and accessories, etc.

 The system at field control level receives

dispatch of the production and management
level, but its operation does not depend on it:
If monitoring computer fails or is not in use,
or the communication network fails, the field
control station will continue to work and the entire process will not be affected.

 Local Control Level

Switch the "Local/Remote" knob on the local control box to the "Local" position, and then achieve local
manual control through the "Start/Stop" button on the box.

Control Strategy

 Heat Collecting Cycle

The maximum temperatures of the collector are Tn1, Tn2, Tn3, Tn4, Tn5, and the maximum temperature
of the water tank of the air conditioner is TA:

 When Tn1-TA ≥ 6 , pumps Pn1 and Pn6 will start; When Tn1-TA ≤ 2 , pumps Pn1 and Pn6
will stop.

 When Tn2-TA ≥ 6 , pumps Pn2 and Pn6 will start; When Tn2-TA ≤ 2 , pumps Pn2 and Pn6
will stop.

 When Tn6 ≥ 80 and Tn6-Tn3 ≥ 10 , the blower runs and pump Pn3 starts; When Tn6-Tn3 ≤
5 , the blower and pump Pn3 stop, when Tn3-TA ≥ 6 , pumps Pn3 and Pn6 will start; When
Tn3-TA ≤ 2 , pumps Pn3 and Pn6 will stop.

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 When Tn4-TA ≥ 6 , pumps Pn4 and Pn6 will start; When Tn4-TA ≤ 2 , pumps Pn4 and Pn6
will stop.

 When Tn5-TA ≥ 6 , pumps Pn5 and Pn6 will

start; When Tn5-TA ≤ 2 , pumps Pn5 and
Pn6 will stop.

 Fluid Complement of Antifreeze Fluid Tank

 When F1 (F2, F3, F4, F5) ≤ 0.2MP, start the

fluid complement pump Pbn.

 When F1 (F2, F3, F4, F5) ≥ 0.2MP, stop the

complement pump Pbn.

防冻—40 度能正常工作 Anti-freezing—be capable of working at 40;

承压-0.6Mpa 的工作压力 Pressure-bearing-0.6Mpa working pressure;
分体安装-集热器安装在楼顶、窗台、墙壁 Separating installation-the collector is installed on
热水器水箱-安装在室内，打开水龙头就出热水防雪， top floor, windowsill and wall;
防冰雹冲击，安装在屋顶可以代替瓦 Water tank of water heater-is installed indoor. Hot
water is supplied by turning on the rap. It is
anti-hailstone and can substitute tiles if installed on
the roof.

 The Circulation between the Air Conditioner Tank

 When TA ≥ 70 and TA-TB ≥ 5 , P1 starts; when the TA-TB ≤ 2 or TA ≤ 65 , P1 stops.

 When TB ≥ 60 , the solenoid valves fb6 and fb7 open and P3 starts; when TB ≤ 55 , the
solenoid valves fb6 and fb7 close and P3 stops.

 When TB-TA ≥ 5 , P1 starts, When TB-TA ≤ 2 , P1 stops. ( When water tank A heats the
domestic water tank, after the temperature drops, the water tank B transfers heat to the water
tank A)

 Water level control of air conditioner water tank

 When LA (LB) ≤ 75%, the solenoid valve fb1 opens; when LA (LB) ≥ 100%, fb1 close.

 Alarm Conditions

 When Tn1 or Tn2 or Tn3 or Tn4 or Tn5 ≥ 100 , send alarm signals;

 When the pressure of heat collecting cycle pipe F1 (F2, F3, F4, F5) ≤ 0.2MP, send alarm
signals;

 When TA> 95 or TB> 95 , send alarm signals;

 When the controllable equipment is damaged or there is any failure at analog quantity test
points, send alarm signals.

 Control of Standby Pump

All water pumps in the system are equipped with standby pumps, and it is required that the main pump

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and the standby pump switch their role at fixed period, ,which can be set (The default is one time a day).
When the pump in use is damaged, the system shall be capable of switching to the standby pump and
send alarm signals.

 Other Control Instructions

 The water tank of the air conditioner is installed in

the north building, and its temperature value and
liquid level are shared by four buildings. Data must
be transferred to the field control cabinets in east,
west, south buildings via wireless transmission, so
as to allow the solar heat collector to heat the water
tank of the air conditioner.

 Ps5, fbs1 and fbs2 are controlled manually and automatically on the field control cabinet in
south building , after data exchange, signal output are controlled at the field control cabinet in
north building (due to the water pump cycle, the control work must be put in north building, and
the current design will not consider how to control, but position for interface and low-voltage
electrical apparatus shall be reserved in the cabinet of north building)

 Pe3, fbe1, fbe2 are controlled manually and automatically on the field control cabinet in east
building, after data exchange, signal output are controlled at the field control cabinet in north
building (due to the water pump cycle, the control work must be put in north building, the
current design will not consider how to control, but position for interface and low-voltage
electrical apparatus shall be reserved in the cabinet of north building)

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Environmental Protection

China's environmental industry develops gradually with the development of environmental protection
cause, as the state is increasing support for the environmental protection cause and the effective
supervision of the market, the environmental protection industry will truly become a vital growth point of
national economy.

Waste Incineration Generation

In today's world, environmental pollution has become a global problem, garbage is a product of human
life, with economic development and growing
modernization of the material consumption, municipal
solid waste (MSW) is increasing year by year. In 2000,
municipal solid waste in China amounted to 0.15 billion
tons / year; MSW featured by large amount and wide
distribution, caused serious social problems in cities and
towns. The waste pollutes water, soil, and air and transmits disease, affecting the human living
environment, meanwhile the waste occupies vast land, affecting the city's environmental quality and
sustainable development.

MSW Incineration power generation technology uses incinerators to incinerate combustible materials in
domestic waste, eliminating a large number of harmful substances in waste by high temperature
incineration to achieve the purpose of waste decontamination and reduction, at the same time uses the
recovered heat for heat supply, power supply to achieve the purpose of waste recycling. At current, this
technology is gradually popularized and applied in china.

Desulphurization Control System of Power Plant

The main flue-gas desulphurization processes in coal-fired power plant:

flue gas desulphurization methods in coal-fired power plant include:
wet method, semi-dry method, dry method, renewable process and
joint de-SO2 / NOX desulphurization process.

 Limestone /Lime - gypsum Wet Process (Lst W/LW- FGD)

Currently, wet flue gas desulphurization is the most efficient FGD

technology for desulphurization with fast reaction speed of desulphurization; Desulphurization
absorption reaction and product formation were carried out at low temperature; and desulphurization
efficiency is high, suitable for flue gas desulphurization of high, medium and low-sulfur coal .However,
this technology has the problems as more complex equipments and universal serious corrosion, high
operation and maintenance cost as well as secondary pollution.

 Spray Drying Process (SDA - FGD)

Spray drying method (SDA) is a major semi-dry technology and a relatively new FGD technology, which
developed in United States and Europe during the early 70s-mid 70s. Currently, the total capacity of the
commercial application of spray drying has reached 15WGe, and its market footprint is only behind the

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wet method, ranking 2 in the market.

 Limestone Injection into the Furnace and Activation of Calcium oxide (LIFAC) LIFAC is a
dry desulphurization process specially designed by Tampella Power Company in Finland in
early eighties.

 Circulating Fluidized bed Desulphurization (CFB - FGD)

Circulating fluidized bed desulphurization process is a new dry desulphurization process developed by
Lurgi Company in Germany. Based on the principle of fluidized bed desulphurization bed, this process
extends the contact time between desulphurization agent and flue gas by several recycling of
desulphurization agent (lime powder), greatly improving desulphurizing agent utilization. In addition to
many advantages of dry desulphurization, it also has a special advantage: If calcium sulfur ratio is very
low, the desulphurization efficiency can reach over 93% of the wet method process.

Waste Incineration Power Generation

In recent years, the traditional treatment on municipal solid

waste has focused on land filling, but more and more large
and medium cities have treated the municipal solid waste
by burning in recent decade. Municipal solid waste
(MSW) treatment by incineration has been a new trend of
historical development, because the traditional land filling
has been increasingly lagged from municipal solid waste
treatment demands. The waste incineration treatment has
been the common method and means employed in many advanced countries and regions in the world,
especially widely used in developed countries such as EU, US, Japan. Now, the municipal solid waste
(MSW) incineration treatment has been gradually expanded and used in China.

The waste incineration power plant automatic control system, based on Hollysys LK series
programmable logic controller (PLC), and characterized by powerful functions, stable performance,
flexible communication, is fully able to meet the control requirements of the waste incineration power
plant, improve productivity and ensure the system running stably.

Process & Control

The waste incineration power plant mainly consists of waste reception system, incineration system,
waste heat boiler, combustion air system, turbine generation system, flue gas purification system, slag
and leaking water treatment system, steam and condensed water system, scrap metal collection,
automatic control and meter system.

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Figure 1: Process Flow of Waste Incineration Power Plant

抽气供热 Exhaust and heat supply

垃圾 Waste
蒸汽 Steam
汽轮机 Turbine
蒸汽 Steam
发电机 Generator
发电 Power generation
煤 Coal
焚烧炉和锅炉 Incineration furnace and boiler
烟气 Flue gas
汽轮机 Turbine
多液体碱雾发生器 Multi-fluid alkaline spray generator
布袋除尘 Bag filter
排放 Exhaust
飞灰 Fly ash
渣 Bottom ash
综合利用 Comprehensive utilization
综合利用 Comprehensive utilization

 Waste Reception System

The waste transported outside plant is weighed and stored. The control system is to mainly identify the
vehicle and record waste weight, and transmit the information to the central control room of main house.

 Incineration System

The waste and mixed fuel is poured into the incineration furnace for burning, which enable hazard
substance to decompose under high temperature, and transmit heat to the waste heat boiler. The main
functions of control system are as below:

 Control the waste quantity in the incineration furnace when the feeder is running.

 Control the rotary speed of incineration furnace body in the incineration system and charging
motor.

 Fully control operating frequency of primary fan, secondary fans and induced draft fan in a
combined mode.

 Control flue gas temperature in the combustion chamber without dioxin generation.

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 Waste Heat Boiler

The waste heat furnace system is to generate the steam via the heat of the incineration boiler and drive
the turbine unit to generate the power. The main functions of control system are as below:

 Automatically adjust the opening of water supply valve by PID modules to achieve automatic
control of water supply of boiler.

 Monitor boiler temperature and pressure.

 Flue Gas Purification System

In order to meet prevailing environmental protection emission standards, every boiler is provided with a
flue gas purification system, so as to remove ash, acid gas and heavy metal in the flue gas. The main
functions of control system are as below:

 Start up the bag-type dust remover upon the flue gas temperature between 130 and 190 and
protect the bag by starting up bypass valve through PLC program upon over range.

 Control spray alkali liquid in the anti acid spray tower to ensure the flue gas PH value.

System Configuration

The automatic control system for waste

incineration consists of one central control
room, three site PLC control stations and
one high speed, safe and industrial Ethernet.
The central control room includes 3 operator
stations (one is also used as the engineer
station). Through industrial Ethernet with
optical fiber as the transmission medium,
monitor and control all site PLC control
stations. 3 site control stations refer to
incineration furnace and auxiliary machine
control station, turbine and auxiliary machine
control station and flue gas treatment control
station. 图 2 系统网络结构图

打印机 Printer
操作员站 Operator station
打印机 Printer
操作员站 Operator station
工程师站 Engineer station
UPS 电源 UPS
LK 冗余系统 LK redundancy system
LK 冗余系统 LK redundancy system
LK 冗余系统 LK redundancy system

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冗余 PROFIBUS-DP 总线 redundancy PROFIBUS-DP bus

冗余 PROFIBUS-DP 总线 redundancy PROFIBUS-DP bus
冗余 PROFIBUS-DP 总线 redundancy PROFIBUS-DP bus
焚烧炉及辅机控制站 Incineration furnace and auxiliary control station
汽轮机及辅机控制站 Turbine and auxiliary control station
烟气处理控制站 Flue gas treatment control station
图 2 系统网络结构图 Figure2 System Network Structure
The above site control stations are responsible for monitoring relevant process electric equipments and
related meters in respective structures and surroundings, and transmitting demanded information to the
central control room in the office building.

System Characteristics
 Distributed Control System

The waste incineration is based and power generation is supplemented in the waste incineration power
plant. The independence of the whole control system is notably higher than normal thermal power
generation units. The better flexibility of the distributed system ensures realistic operability and flexible
management of the waste incineration power generation.

 Open System and Flexible Communication Capability

The waste elements vary largely; therefore, modern waste incineration power plant has more variables
and information exchanges and transmissions than normal thermal power generation units. The
advanced high speed control network is employed for mutual operation of coordination and management
system of the whole control system to provide powerful transmission network support; while LK PLC
adopts the most general industrial protocol, ensuing connection between control system and other
management and monitoring system.

 Cost Performance Solution

Compared with the thermal power generation, the waste incineration power generation costs greatly;
therefore, it’s very important to control the cost. LK large PLC control system has a high cost
performance, also reserves fine expansion, openness and reliability, largely reducing equipment
maintenance cost and system management cost.

Desulphurization System

Now, main desulphurization processes are widely applied, such as

limestone/gypsum wet desulphurization, spray drying desulphurization,
circulating fluidized bed flue gas desulphurization, sea water
desulphurization and electronic beam desulphurization. The technical route
of the thermal power plant desulphurization prepared in China has priority
on limestone/gypsum wet desulphurization process. In this process, the
wet flue gas desulphurization is a key technology, especially for larger than 200MW units. The
investigation by coal research organization of international energy agency shows that wet
desulphurization device accounts for 85% of total installed capacity, in which the limestone/gypsum

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method is up to 36.7%. It’s the basic process for the flue gas desulphurization of large thermal power
plants and characterized by high efficiency (higher than 95%), mature
technology and reliable equipment running.

The control proposal of the limestone/gypsum wet flue gas

desulphurization process system fully brings the technical strength of
Hollysys LK series PLC into full play, such as high performance, high
reliability, easy use and maintenance, and largely reduces the
physical strength of operators. Reliability and continuity of the system
running fully realize the function of large-scaled control systems and has strong advantages in cost and
opening.

Desulphurization Automatic Control System

According to process requirements, the desulphurization process system consists of three subsystems,
1# furnace system, 2# furnace system and public system.. 1# furnace system has the same
configuration with 2# furnace system. They are respectively responsible for the flue gas desulphurization
of 1# and 2# boilers, which is divided into flue subsystem and absorption tower subsystem by functions.
The public system refers to functional equipment commonly used by 1# and 2# boilers, including
limestone slurry system, gypsum dehydration system, gypsum storage system, waste water treatment
system and electrical system.

According to desulphurization process

flow, the whole control system is also
divided into three subsystems. On the
consideration of actual control
requirements and reliability requirements
of the whole system, three subsystems
employ LK210 redundancy-function
CPU of LK series as the main controller
to form the control system and
communication network of the
redundancy structure. Three
subsystems respectively control 1# and
2# furnace systems and public system.
图1 脱硫自动化控制系统图
The controlled object involves valves,
frequency converters, motors and temperature control equipment. The monitoring center computer is
connected with three subsystems by redundancy ring industrial optical fiber Ethernet with
communication rate as 100Mbps and communication medium as optical fiber. Two operator station
computer configurations belong to Redundancy system and communicate with site I/O substation by
Redundancy PROFIBUS-DP site bus network to form a whole organic system.

打印机 Printer
操作员站 Operator station
打印机 Printer
操作员站 Operator station

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工程师站 Engineer station

UPS 电源 UPS
LK 冗余系统 LK redundancy system
冗余 PROFIBUS-DP 总线 redundancy PROFIBUS-DP bus
冗余 PROFIBUS-DP 总线 redundancy PROFIBUS-DP bus
冗余 PROFIBUS-DP 总线 redundancy PROFIBUS-DP bus
1#炉系统 1# furnace system
2#炉系统 2# furnace system
3#炉系统 3# furnace system
图1 脱硫自动化控制系统图 Figure 1: Automatic Control System of
Desulphurization

 Monitoring Center

Being arranged in the central control room, the monitoring center consists of monitoring computer,
Ethernet switch, printer, uninterrupted power supply (UPS), etc.. Among three monitoring computers,
one is used as engineer station and other two are used as redundancy operator station for standby heat
equipement for each other. When one operator station is in failure, the other one may take the place with
switch time less than 300ms. Hollysys FacView monitoring module software is installed on the operator
station to manage monitoring and operation of the whole plant, instantly dispose, control, operate and
manage collected data. Other computers arranged in other places of the plant may be conveniently
connected with each other by local area network if necessary.

 System Sub-control Station

Three system sub control stations include 1# and 2# furnace system and public system sub control
stations, which are composed of Redundancy power module, Redundancy LK210 CPU module,
communication module, backboard and I/O module supporting Redundancy PROFIBUS-DP, being
installed in the PLC control cabinet. PLC control cabinet also covers air switch, connection terminal,
relay, grounding terminal and wires and other accessories.

The system sub control station is the control core of the whole system and fully complete such functions
as logic computation, mathematical computation, data collection, equipment control, system
communication connection and so on. Redundant-designed configuration includes power supply
redundancy, CPU redundancy and communication network redundancy. Any failure will not cause
system shutdown and it will meet stable and continuous operation requirements of the system to
maximum extent.

 I/O Substation

According to different system equipment locations and process sections, every system sub control
station also includes several I/O substations. The site I/O substation may be distributed in different areas
by powerful PROFIBUS-DP site bus network of Hollysys LK large-scaled PLC. I/O substation mainly
includes I/O control cabinet, communication interface module, analog input module, analog output
module, digital input module and output module. I/O substation is not responsible for data processing
and logic computation, but site data collection and signal interface. It transmits the data collected to

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respective system sub control stations by PROFIBUS-DP site bus network and responsible for receiving
equipment demands from the system sub control stations and carrying out equipment operation.

System Control Function

According to design requirements for system process and actual situation of production equipment, the
control function and the control strategy of this process include:

操作员窗口 Operator window

1#图形画面 1# figure menu
选择 Select
刷新 Refresh
缩放 Zoom
顺控打开 Sequence control on
顺控关闭 Sequence control off
顺控打开 Sequence control on
顺控关闭 Sequence control off
混合器 Mixer
混合器 Mixer
顺控启动 Sequence control start
顺控停止 Sequence control stop
1# 旋转给料阀 1# spiral feeding valve
2# 旋转给料阀 2# spiral feeding valve
工艺水 Process water
石灰石浆池 Limestone slurry pond
石灰石浆液制备 Limestone slurry preparation
系统总编 System overview
烟道系统 Flue system
升压风机 Boost fan
气汽换热器 Air and steam exchanger
石灰石浆液 Limestone slurry liquid
净化空气 Purified air
吸收器接口 1 Absorber interface 1
吸收器接口 2 Absorber interface 2
氧化空气 Oxidation air
工艺水 Process water

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事故浆池 Emergency slurry pond

旋流站 Spiral flow station
真实皮带机 Vacuum belt conveyer
废水系统 Waste water system
石膏贮存 Gypsum storage
回主画面 Back to main menu

 Data Acquisition

Data acquisition system is able to collect and process all signals related to desulphurization system and
equipment status signals, so as to provide the operator with related running information timely and
achieve safe and economic running. It may timely make alarm upon any abnormal working condition
occurred to the desulphurization device and improve equipment utilization ratio.

 Analog Quantity Control

According to process requirements of flue gas

desulphurization, the analogy quantity control function
includes boost fan inlet pressure control, absorption
tower PH value and tower outlet SO2 density control,
absorption tower liquid level control, gypsum slurry
discharge quantity control and limestone slurry density
control.

 Sequence Control

The sequence control system may enable the operator to monitor and control all motors and valves of
the desulphurization system in the control room and provide the equipment with interlock and protection.
The sequence control system is able to accomplish high-intelligence control of numerous equipments.
Based on relevant functional principles, the equipments are classified into groups which including
functional groups and sub-functional groups. Operate start and shutdown of the equipment according to
logic sequence.

操作员窗口 Operator window

1#图形画面 1# figure menu
选择 Select
刷新 Refresh
缩放 Zoom
吸收塔接口 1 Absorption tower interface 1
第二级除雾器 2nd layer spray remover
除雾器下冲洗层 Spray remover lower flush layer
除雾器上冲洗层 Spray remover upper flush layer
第一级除雾器 1st spray remover
除雾器下冲洗层 Spray remover lower flush layer
吸收塔喷淋层 Absorption tower spray layer
吸收塔喷淋层 Absorption tower spray layer
吸收塔喷淋层 Absorption tower spray layer

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顺控打开 Sequence control on

顺控关闭 Sequence control off
压力 Pressure
流量 Flow
工艺水 Process water
事故浆池 Emergency slurry pond
工艺水 Process water
系统总编 System overview
烟道系统 Flue system
升压风机 Boost fan
气汽换热器 Air and steam exchanger
石灰石浆液 Limestone slurry liquid
净化空气 Purified air
吸收器接口 1 Absorber interface 1
吸收器接口 2 Absorber interface 2
氧化空气 Oxidation air
工艺水 Process water
事故浆池 Emergency slurry pond
旋流站 Spiral flow station
真实皮带机 Vacuum belt conveyer
废水系统 Waste water system
石膏贮存 Gypsum storage
回主画面 Back main menu

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User List

No. Project User Remark

New Energy

Baoying Xiexin Environmental Protection

Baoying Xiexin Biomass Power Straw power
1 Biology Thermal Power Straw Direct
Generation Co., Ltd. generation
Burning Technology Reform Project

Lianyungang Xiexin Biomass Power

Lianyungang Xiexin Biomass Straw power
2 Generation Straw Direct Burning
Power Generation Co., Ltd. generation
Technology Reform Project

Shenyang Huayitong Control

3 Bio Energy (straw diesel oil) Project Bio energy
System Co., Ltd.

2*6MW Waste Incineration Power

Jiexiu Guotai Green Energy Co., Waste power
4 Generation Project Desulphurization
Ltd. generation
Control System

Beijing DQY Biogas Power Generation Biogas power

5 Beijing DQY Eco-Fam
Control System generation

Beijing Yuandong Four

Gas Power Generation Unit Combined Dimensional System Gas power
6
Control System Engineering Technology Co., generation
Ltd.

Himin Sun-Moon Mansion North Building Himin Solar Energy Group Co.,
7 Solar energy
Control System Ltd.

Himin Sun-Moon Mansion East, West Himin Solar Energy Group Co.,
8 Solar energy
and South Building Control System Ltd

Daya Bay Nuclear Power

9 DCS/PLC Basic Training System Operations and Management Nuclear power
Company

Electric Power

Shanxi Shangrun Zhongyi

2*12MW Power Project 1#Air Cooling
1 Mechanical and Electrical Air cooling unit
Unit PLC Monitoring System
Equipment Co., Ltd.

Semi Coke Exhaust Gas Power

Fugu Country Hongyuan Semi
2 Generation Project 2*15mw Direct Air Air cooling unit
Coke Electric Co., Ltd.
Cooling System

Tongxiang Puyang Xiexin

1×15MW Flue Gas Desulphurization
3 Environmental Protection Desulphurization
Project PLC System
Thermal Power Co., Ltd.

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 LK Series PLC Industry Solutions

No. Project User Remark

Boiler Desulphurization Project of Zibo Zibo Shunlong Industrial

4 Desulphurization
Thermal Power Co., Ltd. Automation Equipment Co., Ltd.

t Glue Gas Desulphurization Project of Jinan XBT Automation Meter

5 Desulphurization
Shandong Licun Thermal Power Plan Co., Ltd.

Shenyang Tonghe Electric

Shenyang Guohui Desulphurization and
6 Automation Engineering Co., Desulphurization
Dedusting System
Ltd.

Gaoqing Thermal Power Jinan XBT Automation Meter

7 Desulphurization
Desulphurization Project Co., Ltd.

Ningxia Chuangtong Chemical Water Ningxia Chuangtong Automatic Chemical water

8
Automatic Control System Project Control Engineering Project treatment

Automatic Control Project of Shanxi

9 Shanxi Nanyao Group Cogeneration
Nanyao Group Industrial Park

Hulunbeier Antai Thermal Power

Automatic Control System of Donghai
10 Co., Ltd. Cogeneration
Laerfa Power Plant

Shengli Oil Field Power Machinery Plant Dongying Shida Dongqing Gas power
11
Gas Power Generation Project Petroleum Technology Co., Ltd. generation

Metallurgy

Inner Mongolia Keqiyinduo Metal Smelt China Enfi Engineering Plumbum

1
Control System Technology Co., Ltd. smelting

Jiangxi Jinde Plumbum Smelting Control Plumbum

2 Jiangxi Jinde Aluminum Co., Ltd.
System smelting

Luoyang Yongning Plumbum Smelting Luoyang Yongning Golden & Plumbum

3
Control System Plumbum Co., Ltd. smelting

Chenzhou Yuteng Chemical Plumbum Chenzhou Yuteng Chemical Co., Plumbum

4
Smelting Control System Ltd. smelting

105t Plumbum Smelting DCS Control Qinghai Xiyu Non-Ferrous Metal Plumbum
5
System Co., LTd. smelting

Uzhumuchin Biqi 105t/a Zinc Smelting China Enfi Engineering

6 Zinc smelting
Control System Technology Co., Ltd.

10m3 Shaft Furnace Control System of Steel/Shaft

7 Jinyuan Furnace Material Co.,
Jinyuan Furnace Material Co., Ltd. furnace
Ltd.

Natural Gas

Zibo Yongshengda Automatic Gas Station control

1 Zibo Yongshengda Gas Co., Ltd.
Control System system

208
 LK Series PLC Industry Solutions

No. Project User Remark

Cixi Fumao Pipeline Gas SCADA Cixi Fumao Pipeline Gas Co.,
2 SCADA system
Control System Ltd.

Tongxiang Phase III Natural Gas Project

3 Tongxiang Gas Corporation SCADA system
PLC Control System

Atmospheric Improvement Project

4 Zhumadian Qixian Subproject SCADA Henan Yunan Gas Co., Ltd. SCADA system
System

Zhengzhou Gas Immediate Pressure Zhengzhou Weier Automation Station control

5
Station Control System System Co., Ltd. system

Petrifaction and Chemical

Zhongyuan Oil Field Acid Water Control Zhongyuan Oil Field Supply
1 Petrifaction
System Center

Dongying Runda Petroleum

Hebei Dagang Oil Field Combined
2 Technology Development Co., Petrifaction
Automatic Control System
Ltd.

Hangzhou aroma Chemical

3 Reactor Device Control System Reactor
Company

Electrolytic Zinc Project of Lingbao Lingbao Jinyuan Chenguang

4 Electrolytic zinc
Jinyuan Chenguang Chemical Co., Ltd. Chemical Co., Ltd.

Henan Shunda Chemical Coal

Henan Shunda Chemical Co.,
5 Transportation and Coke Feeding Coking
Ltd.
Control System

Tangshan Changwang Chemical

6 CO2 Recycling Device Control System CO2 recycling
Co., Ltd.

Jineng Carbon Production Line Control Jineng Carbon Industry Carbon

7
System Corporation production line

30000t/y Neoprene Project Cooling Shanna Synthetic Rubber Co.,

8 Neoprene
Station PLC Control System Ltd.

Shanxi Shengxiongyuan Chemical Xi’an Heli Electronic Technology

9 Drying system
Drying System Co., Ltd.

Rail Traffic

Beijing No.10 Subway SCADA System Beijing Subway Operation Co.,

1 Rail traffic
Substation Automation System Ltd.

Shenzhen No.1 Subway Extension Line Shenzhen Subway Operation

2 Rail traffic
SCADA System Co., Ltd.

Wuhan Monorail SCADA System

3 Wuhai Subway Group Rail traffic
Substation Automation System

209
 LK Series PLC Industry Solutions

No. Project User Remark

Dalian Modern Rail Traffic Co.,

4 Dalian Monorail SCADA Project Rail traffic
Ltd.

Tianjin Rapid Rail Zhongshenmen West

Tianjin Urban Investment and
5 Section Engineering Substation Rail traffic
Development Co., Ltd.
Automation System

Tianjin Traffic Hub Engineering Tianjin Urban Investment and

6 Rail traffic
Substation Monitoring System Project Development Co., Ltd.

Shanghai Subway Project on Trial of

Beijing Yanxing Huaye Control
7 Beijing Yanxing Huaye Control Rail traffic
Technology Co., Ltd.
Technology Co., Ltd.

Shenzhen Rail Traffic No. 4 Line Phase Beijing Hollysys System

8 Rail traffic
II Project Main Control System Engineering Co., Ltd.

Shenzhen Subway No.2 Line

Beijing Hollysys System
9 Construction Integrated Monitoring Rail traffic
Engineering Co., Ltd.
System

Heat Supply

Coal Transportation and Slag Removal Yangquan Heat Power Heat source
1
PLC System Company plant

Taiyuan Heat City West Heat Source

Heat source
2 Coal Transportation and Slag Removal Taiyuan Heat Power Company
plant
PLC System

Nanhai Xiqiao Textile Base Heat Supply Nanhai Changhai Power Heat net
3
Integrated Monitoring System Generation Co., Ltd. monitoring

Shenyang Urban Heat Supply Co., Ltd. Shenyang Urban Heat Supply Heat net
4
PLC Heat Exchange Monitoring System Co., Ltd. monitoring

Qinhuangdao Shuanglong
Agricultural Base Heat Supply Heat net
5 Mechanical and Electrical Co.,
Monitoring Project monitoring
Ltd.

Zibo Huantai Chunyuan Heat Exchange Zibo Henghe Automatic Heat exchange
6
Station Automatic Control System Equipment Co., Ltd. station

Shenxi Lixian Power Plant Automatic Shenxi Ziguan Automatic Heat exchange
7
Control System System Engineering Co., Ltd. station

Water Industry

Shenxi Tianzhen Yuanjie Wastewater

Shenxi Tianzhen Yuanjie Wastewater
1 Treatment Plant Automatic Control
Wastewater Treatment Co., Ltd. treatment
Meter System

Tianjin Jizhuangzi Wastewater Wastewater

2 Tianjin Chuangye Environmental
Treatment Plant Deodorization Project

210
 LK Series PLC Industry Solutions

No. Project User Remark

Electric Control System Protect R&D Center treatment

Dahusan Wastewater Treatment Plant Dahusan Wastewater Treatment Wastewater

3
Automatic Control System Co., Ltd. treatment

Langfang Wen’an Wastewater Wastewater

Hebei Construction Group
4 Treatment Plant Automatic Control and treatment
Erection Engineering Co., Ltd.
Meter System

Liujiaxia Chemical Fertilizer Wastewater Wastewater

5 Gansu Liuhua (Group) Co., Ltd.
Treatment Control System treatment

Lanzhou LX-MEMETC Water Treatment Lanzhou LX-MEMETC Water Wastewater

6
PLC System Treatment Technology Co., Ltd. treatment

Jinan High-Tech Holding Lianghe Wastewater

Jinan High-Tech Holding Group
7 Section Wastewater Treatment Station treatment
Co, Ltd.
Automatic Control System

Shanxi Daxian Wastewater Treatment Daxian Wastewater Treatment Wastewater

8
Plant Automatic Control Meter System Plant treatment

Jiangxi Leping Industrial Park Wastewater

9 Leping Wastewater Treatment Project
Wastewater Treatment treatment

Xingtai Qilihe Wastewater Treatment Wastewater

Xingtai Road and Bridge
10 Engineering Automatic Control Meter treatment
Construction Corporation
System

Xianning Yong’an Wastewater Wuhan Tianchuang Wastewater

11 Treatment Plant Project Automatic Environmental Protection Co., treatment
Control Meter System Ltd.

Taiwen Wastewater Treatment Plant Wastewater

Longquan Water (Taian) Co.,
12 Construction Engineering Automatic treatment
Ltd.
Control System

Daqing Zhaoyuan Urban Drainage and Wastewater

Ziguang Environmental
13 Wastewater Treatment Automatic treatment
Protection Co., Ltd.
Control System

Harbin Tianda Water Treatment Reform Harbin Tianda Control Wastewater

14
Project Engineering Co., Ltd. treatment

Jilin Liuhe Wastewater Treatment Plant Jilin Liuhe Wastewater Wastewater

15
Automatic Control and Meter System Treatment Plant treatment

Tongfang Arms Department No.208

Reclaimed water
16 Middle School Automatic Control System Tsinghua Tongfang Co., Ltd.
treatment
Project

Shandong Jinan Property Management Shandong Jinan Property Reclaimed water

17
Vocational College Reclaimed Water Management Vocational College treatment

211
 LK Series PLC Industry Solutions

No. Project User Remark

Treatment Project

Jinan Reclaimed Water Reclaimed water

Jinan Reclaimed Water Recycling
18 Recycling Engineering treatment
Engineering Automatic Control System
Construction Leading Center

Cixi 15 Pump stations SCADA Control Cixi Water Supply and Drainage Urban pump
19
System Company station

Cixi Pump Station Automatic Control Cixi Water Supply and Drainage Urban pump
20
System of 4 Towns Company station

Shanghai Qingke Environmental Urban pump

21 Cixi Town Waste Pump Station Project
Engineering Co., Ltd. station

Ordos Kangbashi No. 1 Pure Water

22 Ordos Huitong Water Co., Ltd. Pure water
Plant Automatic Control Meter System

Qingdao Jihongtan Water Plant

Qingdao Yinhuang Jiqing Water
23 Automatic Control System Reform Pure water
Co., Ltd.
Engineering Contract

Liuhua Group Water Supply Purification

24 Gansu Liuhua (Group) Co., Ltd. Pure water
Project

Jiaxiang Urban Running Water Quality

25 Jiaxiang County Water Bureau Pure water
Improvement Automatic Control System

Tianjin Dagang District Gangxi Water Tianjin Zhenjin Engineering

26 Pure water
Distribution Project Group Co., Ltd.

Jihongtan Reservoir No. 2 Water Plant

Qingdao Yinhuang Jiqing Water
27 Phase I Project Automatic Control Pure water
Co., Ltd.
System Engineering

Water Resources and Hydropower

Shenzhen Dongshen Electronics

1 Hubei Xintankou Pump Station Project Pump station
Co., Ltd.

Tianjin Luanhe River Diversion Project Beijing Jianghe Tonghui Water

2 ErwangZhang Management Section Resource and Hydropower Pump station
Pumping Station Reform subproject Equipment Co, Ltd.

Hubei Zhongxiang Zhengjiawan Pump Wuhan Lianhua Electric Co.,

3 Pump station
Station Monitoring System Ltd.

Tianjin Luanhe River Diversion Project

ErwangZhang Management Section
Tianjin Tengyue Water Source
4 Substation Comprehensive Assurance Hydropower
Center
and Automatic Control Reform
Subproject

5 Jilin Yangpao Hydropower Station Baoding Zhongli Electric Hydropower

212
 LK Series PLC Industry Solutions

No. Project User Remark

Monitoring System Technology Development Co.,
Ltd.

Baoding Zhongli Electric

Jilin Shangshi Hydropower Station
6 Technology Development Co., Hydropower
Monitoring System
Ltd.

Yunnan Kunming Tunnel Lighting Kunming Jinxianghai

7 Water resource
Control System Technology Co., Ltd.

Constructional Material

Chongqing Wuxian Yuxi Cement PLC

Control System (whole plant control Chongqing Wuxian Yuxi Cement
1 5 6 Cement
system, 2*10 t/y raw material and 10 t/y Co., Ltd.
cement)

Xinye Xinhang Cement PLC Control

2 Xinye Xinhang Cement Co., Ltd. Cement
System (106t/y powder)

Quartz Crucible Production Line Control Saint-Gobain Quartz (Jinzhou) Quartz

3
System Co., Ltd. production line

Jinjiang Titanium Dioxide Powder Phase

Henan Billions Chemicals Co., Titanium dioxide
4 IV Project Acidolysis chemical sequence
Ltd. powder
control system

Zibo Botong Petrifaction Technology Zibo Botong Petrifaction

Asphalt
5 Development Co., Ltd. Asphalt Induction Technology Development Co.,
induction agent
Agent project Ltd.

Machinery Equipment

Changchun Dima Automatic

1 Auto test system Auto test
Control Equipment Co., Ltd.

BYD Auto Parts Welding Automatic Auto parts

2 Xi’an BYD Auto Co., Ltd.
Control Project welding

Harbin Ruiye Industrial Control Hydraulic

3 Hydraulic Test Platform Project
Co., Ltd. machine

Penghua Equipment Production Line Shandong Xinjufeng Technical Packing

4
Control System Packing Co., Ltd. machine

Road
Auxiliary control system of road Jilin Heima Information
5 construction
construction machine Engineering Co., Ltd.
machine

Shenyang Fan Group Automatic

Beijin Group Compressor Auxiliary
6 Control System Engineering Compressor
Centrifugal Control System
Company

7 Zhejiang Jinhua New Material Limited Shenyang Fan Group Automatic Compressor

213
 LK Series PLC Industry Solutions

No. Project User Remark

Reciprocating Compressor Control Control System Engineering
System Company

Beijing Gongda Zhiyuan

Coal feeder
8 Coal Feeder Auxiliary Control System Technology Development Co.,
machinery
Ltd.

GCL Wind Energy Equipment Paddle

9 Paddle Machinery Control System
(Funing) Co., Ltd. machinery

Yancheng YUEDA KIA Auto Painting Changzhou Gongxing Gear Painting

10
Production Line Manufacturer Co., Ltd. equipment

Shipbuilding
11 Xiamen Shipbuilding Control System Shanghai Xiaowen
equipment

Jilin Heima Information Weighing

12 Beicheng Iron Alloy Weighing System
Engineering Co., Ltd. equipment

Beicheng Jinsheng Nickel Weighing Weighing

13 Jinlin Jiding Trading Co., Ltd.
Control System equipment

Paper

1 Paper Machine Driving System Sinkiang Xinya Paper Group Paper

Changchun Yitai Pulp Paper

ZXC directional double spiral crowed
2 Technology Development Co., Paper Making
syrup machine Control Project
Ltd.

Others

Building
Panjin Kaiyang Building Automatic Liaoning Liaohe Taili Petroleum
1 Automatic
Control System Technology Co., Ltd.
Control System

Xiexin Wind Power (Jiangsu)

2 Fan Blade Production Line Production line
Co., Ltd.

Beijing Gaoge Zhisheng

Henan Zhongyuan Roll Plant Automatic
3 Technology Production line
Powder Production Line
Co., Ltd.

Jiaoda University Laboratory Cooling Xi’an Tangdi Automatic

4 Cooling system
System Technology Co., Ltd.

Reservoir Ice Storage Cooling Control Weifang Wanbang Automatic

5 Cooling system
System Equipment Co., Ltd.

Zhejiang Laiyi Biological Technology

Hangzhou Hollysys Automation Biological
6 Limited NPQ Technical Reform Project
Co., Ltd. engineering
Control System

7 Zhejiang Sanxin Technology Limited Zhejiang Sanxin Technology Torsional

214
 LK Series PLC Industry Solutions

No. Project User Remark

Laboratory Project Torsion Vibration Co., Ltd. vibration test
Test System system

215