1、Italy-Comi-centrifuge-control意大利离心机控制原理此PPT适用于对离心机有一定基础知识的人员使用，要想懂控制原理首要条件是懂结构和动作过程，否则应参考相关资料对离心机结构和部件做详细了解。E&M Team概述目录 操作步骤 控制E&M Team 报警步骤E&M TeamMain step main1.Inerting 2.Start main motor3.Loading4.Centrifugation5.discharge操作步骤步骤E&M Teamlnerting1.Phase start Active 后参数自动设置2.Check 开阀purge valve
2、YV1451 and vent valve YV1720Delay 1Min.O2 calibration YV1247=1移动探头 YV1245=1 吹气O2 19%,reached YV1247=0 YV1245=0 Message:PAL PALL FAL Alarms Bypassing3.激活PID控制(Pressure Flow regulating)4.O2 检测 浓度QI1240PAL(18mbar)PALL(10mbar)message6.Timing 30s7.End message(centrifuge ready变成绿色)8.永久钝化阶段（工作过程的钝化，重点是保压&监
3、控）操作步骤步骤E&M TeamLoading/feeding（进料）1.Speed=setpoint 30rpm2.Cake detector=on3.Open liquid valve YV6200=14.Open valve YV5102/5103=15.Cake detector=ready6.Counting time 30m(if empty of the reactor)7.Cake detector=reached8.Close valve YV5102/5103=09.Cake detector=back10.Blowing11.Draining12.Reloading13.
4、Washing操作步骤步骤E&M Team操作步骤Discharge SFCdischarge1.Speed=Set point +/-30rpm2.Discharge SFC=start3.Confirm（Enable）4.Discharge Pipe inertisation5.Discharge bypass 180S6.Open valve YV6000A=17.Knife forward=start（speed=15mm/s）8.Stand-by9.Knife=reached GH0263=1,hold10.Speed adjust（可选）11.Timing（18mm/s)2.12A
5、LM_002_02PAHH PI0021VERY HIGH PRESSURE INSIDE THE CENTRIFUGE 机体内部压力高高报(90mbar)2.23ALM_003_02VA VI0080VIBRATION TRANSMITTER FAULT 振动变送器故障2.14ALM_004_02GL GA0262KNIFE OUT OF POSITION 没有下料/清洗时：刮刀不在起点位置2.15ALM_005_02GL YS0265HCR OUT OF POSITION 余料反吹装置位置错误：1、没有反吹时不在起点位置；2、反吹阀开启后还在初始位置2.16ALM_006_02ZA ZI0
6、018CAKE DETECTOR SIGNAL FAULT 滤饼探头信号故障2.17ALM_007_02XA101HYDRAULIC UNIT THERMAL PROTECTION 油泵过载2.18ALM_008_02ZS ZA0081CENTRIFUGE UNBALANCE 离心机严重不平衡（“老鼠尾巴”动作）2.19ALM_009_02FAL FA0166LOW OIL FLOW TO FRONT BEARING 润滑油流量低（前轴承）2.110ALM_010_02FAL FA0165LOW OIL FLOW TO REAR BEARING 润滑油流量低（后轴承）2.111ALM_011_
7、02GL YS 6000SOLIDS DISCHARGE VALVE OPEN 关阀命令输出后，固体下料阀仍然开或没关到位2.112ALM_012_02GH YS 6000SOLIDS DISCHARGE VALVE CLOSED 固体下料阀关2.213ALM_013_02GL YS 6200LIQUID DISCHARGE VALVE OPEN 液体下料阀开2.114ALM_014_02GH YS 6200LIQUID DISCHARGE VALVE CLOSED 液体下料阀关2.215ALM_015_02XA04KNIFE MOTOR FREQUENCY CONVERTER FAULT 刮
8、刀变频器报警2.216ALM_016_02PAL PA0095LOW NITROGEN PRESSURE TO THE BEARING SEAL delay 5min 唇封压力低报500mbar)2.2 报警 AlarmsShutdownE&M TeamSHUTDOWN ALARMSNr.Ident.TagDescriptionAction1ALM_001_03XA01BASKET ROTATION MOTOR FREQUENCY CONVERTER FAULT 主马达变频器报警3.12ALM_002_03XA04KNIFE MOTOR FREQUENCY CONVERTER FAULT 刮刀
9、变频器报警（已改为Warning）3.33ALM_003_03PAL PA0095LOW NITROGEN PRESSURE TO THE BEARING SEAL 唇封压力低报（已经延时10分钟）3.14ALM_004_03TAHH TA0163FRONT BEARING VERY HIGH TEMPERATURE 前轴承温度高高报(90/110C)3.15ALM_005_03TAHH TA0164REAR BEARING VERY HIGH TEMPERATURE 后轴承温度高高报(90/110C)3.16ALM_006_03TA TA0163FRONT BEARING TEMPERATU
10、RE SIGNAL FAULT 前轴承温度信号故障(90/110C)3.17ALM_007_03TA TA0164REAR BEARING TEMPERATURE SIGNAL FAULT 后轴承温度信号故障(90/110C)3.18ALM_008_03SA SA0161BASKET SPEED SIGNAL FAULT 速度传感器信号故障3.19ALM_009_03PA PI0021CENTRIFUGE PRESSURE SIGNAL FAULT 压力传感器信号故障3.110ALM_010_03QA QI1240OXIGEN SIGNAL FAULT 氧气探头信号故障3.212ALM_011
11、_03XA102POWER FAILURE 电源故障(+delay 3s)3.1 报警 Alarms Safety Interlock speed=0E&M TeamSAFETY INTERLOCK ALARMSNr.Ident.TagDescriptionAction1ALM_001_04GL GA0090FRONT CASING OPEN 钝化或转动时：大盖打开了4.12ALM_002_04GL GA0091GL GA0092FRONT CASING LOCKING RING OPEN 钝化或转动时：锁环打开了4.13ALM_003_04SAH SI0161OVERCOMING OF TH
12、E BASKET MAXIMUM SPEED 主电机超速4.24ALM_004_04SALL SI0161ZERO BASKET SPEED SURVEYING NOT ACTIVE OR FAULT 零速未检测到4.25ALM_005_04HS01EMERGENCY STOP 急停4.36ALM_006_04TAH TA0160BASKET ROTATION MOTOR HIGH TEMPERATURE 主马达温度过高4.17ALM_007_04TAH TA0260KNIFE MOTOR HIGH TEMPERATURE 刮刀马达温度过高4.18ALM_008_04K1MA K1MBBASK
13、ET MOTOR MAIN CONTACTORS FAILURE 主马达接触器故障4.19ALM_009_04K2MA K2MBKNIFE MOTOR CONTACTORS FAILURE 刮刀马达接触器故障4.110ALM_010_04K3MA K3MBHYDRAULIC MOTOR CONTACTORS FAILURE 油泵马达接触器故障4.1 11ALM_011_04PALL PI0021VERY LOW PRESSURE INSIDE THE CENTRIFUGE 压力低低报(10mbar)4.4 12ALM_012_04QAHH QI1240VERY HIGH OXYGEN PERC
14、ENTAGE INSIDE THE CENTRIFUGE 氧气高高报（6%）4.413ALM_013_04XA104PRESSURE CONTROL THRESHOLDS SLEEPING FAILURE 钝化后休息时间过长（12H无动作）4.414ALM_014_04QAQI1240OXYGEN ANALYSER FAULT 氧气变送器故障4.4 报警 Alarms reset 复位条件复位条件1.Message2.Warning only speed=safety speed（150rpm）3.Shutdown only speed=04.Safety Interlock only spe
15、ed=0 复位方法复位方法1.DCS 按钮按钮 (报警条件消除后可以复位，硬件联锁点报警后复位不了，需报警条件消除后可以复位，硬件联锁点报警后复位不了，需E&I）2.刮刀硬件联锁故障复位刮刀硬件联锁故障复位 (E&I Only)主电机降至主电机降至150rpm，刮刀接触器会断开，变频器断电，报警会一直，刮刀接触器会断开，变频器断电，报警会一直Hold住。住。E&I可以短接安全可以短接安全PLC A61 I15-24V线标线标2（PLC复位复位DO点，也就是安全点，也就是安全PLC复位输入点）复位输入点）3.断电断电(E&I Only)注意：注意：DP终端电阻终端电阻没电可能会引起回路上的其他离
16、心机通信故障！没电可能会引起回路上的其他离心机通信故障！4.安全安全PLC复位复位如爆破片破裂（详见下页）如爆破片破裂（详见下页）E&M Team 报警Alarm for E&I 安全安全PLC故障复位故障复位步骤步骤1.停电2.接线（新PLC装储存卡），所有I/O线连接完成3.短接OA0-I19 接线端子4.上电5.Diag 灯闪烁10S 后 拆除OA0-I19短接线6.断电7.上电E&M Team 报警控制原理 P&ID图E&M Team离心机控制控制原理 P&ID图E&M Team离心机控制控制系统 动力电源动力电源 POWER CABINET 380V供电 主电机和刮刀带变频器 控制部
17、分控制部分1.DCS2.PLC Siemens S7-3003.SAFETY PLC4.LOCAL PANEL5.控制电源由UPS 220V供电E&M Team离心机控制控制E&M TeamRing open开锁环分两步：1.试开盖2.Open YV1720 PI0021=0 开盖Delay 7S Opened 条件条件/联锁联锁1.Speed=0(SI0161)，running=0 （EU0160A灯灰色）2.Pressure=0(PI0021PALL 10mbar3.O2 QI1240min.（80%SP）eg.18*80%=14.4 N3/H计时清零条件1.P PI0021QAH 3%o
18、r3.N2 FI1451设定值（18）的80%时 YV1451PID切换为压力控制参数3.Vent valve YV1720 按压力控制Inerted1.PID控制切换2.Purge valve YV1451 和 Vent valve YV1720 按压力控制3.永久钝化监测离心机控制控制E&M TeamInerting-永久钝化 参数监控参数监控1.P：PAL PALL PAH PAHH2.O2：QAH（3%）QAHH（6%）3.N2 流量流量不用不用监控，保压良好的话监控，保压良好的话FI1451=0 控制控制1.PID控制的切换控制的切换Normal PID SP=30mbar增大增大N
19、2流量流量PID if PAL=1 增大排气阀开度增大排气阀开度PID if PAH=1YV1720排气阀开排气阀开度限定，大：度限定，大：60-100%，小：，小：40-100%2.Bypass Valve的控制：的控制：YV1710=1最多最多170s if PAHH=13.辅助控制阀的控制：辅助控制阀的控制：YV1700=1 if PAHH=1离心机控制控制E&M TeamBypass pressure monitoring 180s 允许允许bypass的可能（之一即可）的可能（之一即可）1.Cycle start or2.Inerting or3.Discharge solid va
20、lve YV6000 open or4.HCR YV0265A open or5.Vent bypass valve YV1710 open or6.PAHH PI0021 190S之内只能请求Bypass 1次离心机控制控制E&M TeamPressure control Pressure parameters设定值1.Purge pressure 40mbar2.Working pressure 30mbar3.Discharge pressure 20mbar4.Decrement pressure 3mbar 对N2阀YV1451的压力控制设定值SP：将自动减少（即30-3=27mba
21、r)。5.Increment pressure 3mbar 对排气阀YV1720的压力控制设定值SP：将自动增加（即30+3=33mbar)。此举将设定点错开，避免两个阀同时动作频繁，增加压力控制系统的稳定性。6.PAL 18mbar7.PALL 10mbar8.PAH 60mbar9.PAHH 90mbar离心机控制控制E&M TeamPressure control 回顾PID图，注意：正常控制时，辅助阀YV1700是关闭的，N2的排放不是走捷径，而是要通过母液下料管，再通过接收罐T01的气相管与排气控制阀YV1720连接，进行压力调节。Pressure 控制1.Working press
22、ure Normal PID2.PAL（18mbar)PID switch to more flow of YV14513.PALL(3%)YV1451=fixed opening YV1720按压力控制7.QAHH 6%interlocked8.Discharge alarms bypass 180S9.HCR aux.valve YV1700=1,bypass valve YV1710=1，YV6000=0防止破袋,HCR valve YV1400 and YV1710脉冲开启10.Stop YV1451=0,YV1720=1 open 离心机控制控制E&M TeamLip seal YV
23、1420 open条件1.Alarm=02.Inerting purge valve open or3.Speed 0 Alarm 唇封压力低报PA00951.1150*1.05 rpm)5.P PALL(10mbar)6.O2 QAHH(6%)7.Centrifuge motor high temperature（110C)8.Very high vibrations(18mm/s)9.Frequency converter fault(外电瞬时波动，就有报警，所以会塌料）离心机控制控制E&M TeamOil Pump Start 条件1.Safety interlock=02.Motor=
24、on or3.Speed 0 Stop 步骤1.Motor off2.Speed=03.Timing 60s离心机控制控制E&M TeamSolid valve Open 启动条件启动条件1.Safe interlock=0,shutdown alarm=0 2.Close valve DB101.DBX1.4=03.DB101.DBX1.3=1PALL=0Speed30rpm，running=1(SI0161)先Discharge pipe inertisation=OK (钝化过程由DCS控制）Discharge/CIP active=1点击YV6000D=on同时output:Bypas
25、s request DB101.DBX0.3=1 set 3sBypass short=1（PLC to DCS DB100.DBX35.5=1)Discharge bypass 180s=active DB101.DBX1.3=1（自动）即YV6000自动开启4.再次开阀：DCS 画面按钮 YV6000 延时190s之后 离心机控制控制E&M TeamSolid valve Close启动条件1.DB101.DBX1.3=0YV6000D on=0 orBypass short=0（PLC to DCS DB100.DBX35.5=0 延时180S)orDischarge/CIP activ
26、e=02.DB101.DBX1.4=1离心机控制控制E&M Teamknife联锁跳停的联锁跳停的条件要条件要全部满足（见下页）全部满足（见下页）进刀进刀 条件条件1.Alarm-interlock=02.刀不在终位刀不在终位 I0.5=0(GA0263灰色)3.Discharge/CIP=active（前提Discharge pipe inertisation=OK）4.YV6000=open (注注：DCS的的interlock条件条件)5.DB101.DBX0.6=16.or 下料时：刀下料时：刀离开了离开了初位，点击退刀，初位，点击退刀，这时刮刀也会前进这时刮刀也会前进 退刀退刀 条件
27、条件1.Alarm-interlock=02.刀刀不在初位不在初位 I0.4=0(GA0262灰色)3.Discharge/CIP=active&YV6000=open&DB101.DBX0.7=1 or4.Critical alarm=1(关键报警时自动退回）关键报警时自动退回）离心机控制控制E&M TeamKnife control硬件硬件跳停跳停/联锁联锁1.Safety emergency2.Locking ring open3.Frame open4.P PALL5.O2 QAHH6.motor high temperature7.Frequency converter fault(
28、导致主马达safety speed)离心机控制控制E&M TeamCake thickness 滤饼厚度检测滤饼厚度检测1.厚度设定2.激活检测功能 气缸动作，带动检测杆转到探测位置（向靠近滤布方向）+同时带动检测部分（包括行程反馈，厚度到位检测的接近开关）移动到需要检测的位置3.滤饼厚度检测杆的定位 检测杆的位置检测是通过检测气缸的行程来实现，在气缸表面绑定一个长度相当的滑线电阻电位器，电位器的阻值与气缸行程一一对应，气缸行程与检测杆的位置一一对应，检测杆的位置与滤饼最大厚度一一对应，所以只要检测到电位器的电阻值就能知道滤饼厚度检测点的位置。4.厚度到达不断的进料使滤饼厚度增加，慢慢增长到滤饼厚度检测点的位置，就会碰到检测杆，给检测杆一个作用力，该作用力使检测杆另一端上的固定接近开关离开感应板（当然要克服感应板背后的弹簧拉力），一旦（距离）变化触发接近开关状态改变，表示滤饼厚度已经到达。5.执行后续相关动作离心机控制控制E&M TeamCake detector 滤饼厚度设定值接受条件1.激活Cake detector2.Cake thickness=not reached 3.设定值min(46)SPMax.(145mm)离心机控制总结 Thank You!E&M Team
