In recent years, a series of "world-class" refining and chemical integration projects have been completed and put into operation in China's petrochemical industry, such as the Shanghai SECCO Ethylene Project, Guangdong Huizhou Ethylene Project, Yangba Integrated Ethylene Project, and Maoming Petrochemical Ethylene Project (Extension ), Hainan Shihua Refining Project, Qingdao Refinery Project, Fujian Refining & Chemical Integration Project, Dushanzi Refining & Chemical Integration Project, Huizhou Refinery Project, Tianjin Refining & Chemical Integration Project, Zhenhai Ethylene Project, etc. As a senior expert who has witnessed the development of the petrochemical industry in China's petrochemical industry for more than 40 years, Huang Buyu gave us a detailed review of several major trends in petrochemical automation technology in recent years.
Trend 1: The level of integrated automation system continues to increase
World-scale plants need integrated automation systems. For the current large-scale integrated refining and chemical companies, in order to cope with global competition and attach great importance to the construction of enterprise informatization systems, this requires the DCS system to break the situation in which it was only a single device control to form an “information isolated island†through the system. Integration enables true plant-wide centralized control, operation and management. At the same time, the current large-scale petrochemical enterprises have large-scale and synchronous production facilities, and the control system scales up to several tens of thousands of points, involving distributed control systems/fieldbus control systems (DCS/FCS), safety instrumented systems (SIS), Fire and Gas Detection System (FGS), Compressor Control System (CCS), Rotating Equipment Monitoring System (MMS), Equipment Package Control System (PECS), Analytical Data Acquisition System (ADAS), Tank Area Data Acquisition System (TDAS), MAS, AMS, ODS, Advanced Control (APC), RT-OPT, OTS, and other automated control systems In order to achieve integration between the control systems of the whole plant, higher requirements are placed on the integration level of the automation system. The Tianjin Refining and Chemical Integration Project that has just been put into commercial operation includes 10 sets of refinery equipment, 9 sets of chemical equipment, public works and auxiliary facilities, and off-site engineering. The scale of automation system integration reached about 143,900 points for DCS I/O and about 44,300 points for SIS I/O. With the in-depth application of computer network technology in automation systems, the era of automatic control systems only as "information isolated islands" has passed, and large-scale, integrated automation systems are the inevitable trend of historical development!
Trend 2: MAV becomes a new model
The MAV strategy, which is the implementation of the integration strategy of the whole plant instrumentation and control system in the mode of the main automation vendor (Main Automation Vendor), is an emerging model of automation system construction in the petrochemical industry in recent years. The ultimate goal of using the MAV model is to provide owners with an automated system that is cost-effective, has a long life cycle, and has a low overall cost. In this model, MAV serves as the partner of the project's overall planning and design unit, providing the user with the overall plan, network structure, hardware/software configuration, project management and operating procedures, functional design specification standards, engineering design, configuration, generation, and debugging. Third-party system integration, debugging, operation and maintenance support services and other services. Practice has proved that this model has a variety of advantages, including on the one hand conducive to the overall coordination of the project, on the other hand conducive to the standardization of various interfaces, man-machine interface, thereby achieving multiple production devices, public engineering integrated automation system synchronization; Formulate functional design specifications to ensure the standardization of integrated automation systems; help to manage multiple EPCs at home and abroad; ensure high quality and high level of integrated automation system engineering; facilitate centralized operations management, optimize resources, and reduce life cycle costs. It can meet the challenges and demands of the construction and operation of modern large-scale petrochemical projects.
Of course, for large-scale petrochemical projects, MAV's choice is crucial. It is a multiple test of suppliers' products, engineering, services, and overall coordination capabilities. For now, the petrochemical industry MAV is still abroad. Well-known companies, such as Emerson, Honeywell, Siemens, Yokogawa, ABB, etc., have already started this attempt for domestic automation companies, but they still need engineering experience to become truly competitive MAVs. There is still a long way to go for the accumulation.
Trend 3: Network Architecture Information Security Issues
The current modern petrochemical companies generally adopt the ERP/MES/PCS three-tier network structure in the network architecture. The integrated network structure urges us to consider from the perspective of hardware, software, and maintenance from the beginning of planning. With the continuous extension of digital technologies such as smart HART technology, fieldbus technology and wireless technology to control systems and field instruments, information on data bus processing will continue to increase, and the safe transmission and rational use of information will be an important aspect of automatic control systems. test. At the same time, a large number of computer and network technologies are gradually used to replace the hardware and software devices inherent in automatic control systems. How to ensure the safety and reliability of the DCS system will be an important issue faced by engineering companies and manufacturers! At present, the issue of network security in petrochemical companies has attracted extensive attention from industry experts, researching security functions and strategies such as network hardware, software, engineering and maintenance, and responding to risks. Faced with the information security problems that accompany the application of new network technologies, everyone is actively exploring solutions, strengthening management, and constantly improving.
Trend 4: The application of fieldbus technology is moving forward
With the continuous development of fieldbus technology and products, and the continuous enrichment of application experience, fieldbus technology is also continuously being developed in the process industry and manufacturing industry. In the field of petrochemicals, a series of major projects such as the CNOOC Huizhou Ethylene Project and the Fujian Refining and Chemical Integration Project have successfully used field bus technologies such as FF and Profibus since the start of the Shanghai Secco Ethylene Project that began operation in 2005. Fieldbus technology continues to advance with the implementation of these large projects. From the point of view of effectiveness, it can be said that fieldbus technology is feasible in large-scale petrochemical projects and can achieve predictive maintenance and remote maintenance. However, there are still changes in the concept of users, and the technical level of on-site maintenance personnel is required to be higher. And the technology itself needs to be further improved, making the application of fieldbus technology slow in the petrochemical industry.
Trend 5: The application of industrial Ethernet faces new issues
Industrial Ethernet systems are the lifeblood of large-scale digital and automated systems. They are advancing new options and new technologies that drive information automation, and can promote and enhance the levels of life management, energy management, and safety management. The openness and standardization of industrial Ethernet provide users with cost savings in network construction. However, as pointed out in “Trend 3â€, the application of industrial Ethernet technology poses new challenges to network security in the life cycle, prompting us to Continuously researching the new issues of the overall network architecture and security strategy, including the ability to protect against harsh electromagnetic interference (EMI) environment and fault-free communication; redundant industrial Ethernet reliability, availability, maintainability, and security. Currently, the application security of industrial Ethernet at the process industry control layer still deserves special attention. It is necessary to ensure the security of information transmission through technologies such as firewalls and anti-virus software.
Trend 6: Future Growth of Automation Technology
The establishment of low-emission, low-energy, and low-pollution new economic development models based on low-carbon energy systems, low-carbon technology systems, and low-carbon industrial structures has promoted the development of automation technologies. China's carbon dioxide emissions and industrial energy consumption are generally high. Among them, the average energy consumption of crude oil processing, ethylene processing, and large-scale synthetic ammonia is higher than the international advanced level. In order to achieve a 40% to 45% reduction in per unit GDP of carbon dioxide emissions by 2020 compared to 2005, it is necessary to explore a low-carbon economic development path that suits China's national conditions. The petrochemical industry is one of the important industries. The development of a new economy will undoubtedly promote the development of automation technology.
Comprehensive utilization of wind energy, nuclear energy and solar energy, and automation technologies such as municipal, building, and environmental protection will become the growth points in the future automation market.
Finally, Huang Buyu concluded that: “The petrochemical industry has never given up the development and pursuit of new technologies, which has promoted the continuous development of petrochemical automation technology. On the other hand, continuous innovation in automation technology has also promoted the development and transformation of the petrochemical industry. ."
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