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1761-L20AWA-5A
1761-L20AWA-5A
1761-L20AWA-5A
Tereos France 是法制糖业的一家企业,拥有九家制糖厂,五家酿酒厂和四家包装厂,每年从甜菜中生产出 150 万吨糖以及 500,000 立方米酒精和生物乙醇。
每年,位于阿拉斯(在加来海峡省地区)附近的 Tereos Boiry Sainte Rictrude 制糖厂为农工领域的制造商(饮料、巧克力、果酱、饼干和制品制造商)生产 250,000 吨白糖。这种糖只能在一个很短的时间段内生产,从每年的 9 月中旬开始至 12 月结束。这段时间被称为“制糖期”。在这个时间段内,甜菜会被收割运输到制糖厂进行加工。
在制糖期的每一天,Boiry 加工 20,000 吨甜菜,生产出 2,800 吨糖,消耗 15 兆瓦的电!这家制糖厂通过两台锅炉为汽轮发电机供应蒸汽,自己发电。工厂只在启动阶段和非制糖期才会接入家电网 (EDF)。
挑战
这两台锅炉是制糖厂的命脉,每小时分别可以生产高达 140 和 120 吨蒸汽。其中 85% 的蒸汽用于发电,剩余 15% 的蒸汽用于制糖的各个环节。2009 年,控制这两台锅炉的分布式控制系统有些过时了,Tereos 决定换掉这个系统。
Tereos 的目标:升级和优化这两台锅炉的控制,并将这两台锅炉集成到整个工厂的单一控制和命令系统中。这家公司联系了许多供应商,在审查这些供应商给出的建议后,选择将锅炉命令移植到 Rockwell Automation PlantPAx 系统。
该公司于 2009 年 3 月作出了这个决定,而 9 月制糖期就要开始了。这对 Rockwell Automation 来说是一个相当大的挑战,因为工厂若没有锅炉是无法运营的。此外,锅炉控制需要非常具体的专业知识:极复杂的调控算法、燃烧器的调整以及用于预期负载需量的极其复杂的计算。
帮助确保限度地降低这次移植的风险,并且在截止时间之前完成移植 — 这需要各种各样的专业技能。这正是 Rockwell Automation 解决方案大显身手之处。其锅炉管理方面的专业知识和风险管理方面的丰富经验在这种情况下是不可或缺的。Rockwell Automation 解决方案团队对既有系统进行了回顾性分析,并制定了一个移植解决方案,该方案能够使锅炉在风险的情况下实现运营。
该解决方案以 PlantPAx 过程自动化系统为中心,基于三个冗余的 Allen-Bradley® ControlLogix® 可编程自动化控制器并完全集成到工厂的整个系统中。Rockwell Automation 的锅炉管理专家调整了燃烧控制和命令所需的设置和连续自动化过程。
2009 年 8 月底,就在制糖期开始之前,该工厂进行了长达一周的“空运行”,在此期间,这家制糖厂的团队和 Rockwell Automation 团队进行了调整,并检测了负载。系统的后调整只能在生产启动阶段进行,因此,没有任何出错的余地。
制糖期天一帆风顺,供电能力和预期的一样大幅提高。Boiry 制糖厂电力 - 自动化经理 Michel Hennebique 确认说:“在 Rockwell Automation 管下的启动阶段和试运行进展得很顺利,所有调整工作都在这两天里完成了。整个制糖期间没有出现任何故障。”
Tereos 现在完成了两个制糖期,从 Rockwell Automation 解决方案带来的改进中获益颇丰。负责 PlantPAx 系统的 Rockwell Automation 解决方案团队已经证明了该系统取代传统分布式控制系统解决方案的能力以及它作为这种解决方案的竞争优势。
“锅炉控制得到改善,特别是在控重新加热方面;锅炉产出现在达到 96%。锅炉运行也比之前更加可靠。使用 Rockwell Automation 解决方案,可将两个锅炉相互连接,并且功率匹配现在由 PlantPAx 系统自动执行。所有这些改变都归功于 Rockwell Automation 团队在整个项目中提供的技能和可靠的支持。”Boiry 电力和自动化经理说道。
锅炉控制和命令系统现在与其工厂设备完全集成在一起,使整个生产点的追溯操作可以统一管理:报、操作员操作和流程历史。“们利用这次移植,与 Rockwell Automation 一起对们的督工作站进行了工程学方面的审查,Plant PAx 系统变得更具用户友好性,们的操作员特别喜欢这一点。”Boiry 自动化团队补充道。
利用 Rockwell Automation 的解决方案,Boiry Sainte Rictrude 制糖厂的大多数制造工艺(渗出、提纯、结晶)现在都实现了自动化。自 2012 年以来,两个车间(洗涤和筛选)也将由 Rockwell Automation 控制。这家制糖厂被视为 Tereos 集团的基准工厂。
但是 Hennebique 并不打算就此停下脚步。已经制定了实施具体 Rockwell Automation 软件的计划,以在能耗方面实现节约,并且还制定了计划来使用 FactoryTalk AssetCentre — 可追溯性软件,对制糖厂运营流程中实施的所有更改进行控。
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20BP535U0ANNNNC0 PowerFlex 700 535 A 300 kW. AC Drive
100-K09KW400 IEC Contactor
190E-AND2-DB25C 1.6 - 2.5 A 190E Eco Starter with CB
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190S-AND1-CB25C-TE 190S Compact Comb Starter w/CB
1497A-A7-M18-3-N MACHINE TOOL TRANSFORMER
2100PE-WLGJT40/1 LVMCC
20DC170A0ENNANANK PowerFlex 700S 170 A 90 kW AC Drive
21T-316972-A02 Kit LiquiFlo Combined Power Board
1233X-BNB-3-4LGR-6GP-38-90-415-TB6 NEMA Pump Panel,Extra space,Cype
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9399-HDWAREREFPT HARDWARE INTERFACE CONFIG. USER GUIDE (PORTUGUESE)
103S-ATDJ3-CB40C-KN 2.5 - 4 A MCS Starter & Circuit Breaker
1494V-00-A 1494V Circuit Breaker Kit
100-C23ZQ400 23 A 100-C contactor
1492-HM2RB272 BLOCK,TERMINAL 600V MAX
103S-ATEJ3-CC10C-KN-TE 6.3 - 10 A MCS Starter & Circuit Breaker
20AC060M3AYNANC0 PowerFlex 70 60 A 30 kW AC Drive
9356-PRO2500U8R UPGRADE: OUT-SUPT: RSSQL PROF.5000 TO 70000 TAG
150-B180JBD-3-6P-GU6-SCR-UL 150 Motor Controller
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194C-C10-8271 IEC CNTRL SW VOLTMETER 0-RS-ST-TR 45 10A
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28 CARBOLOY VNMG-432E 48 CARBIDE INSERTS 570
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20BD040A3NYNANB0 PowerFlex 700 40 A 30 Hp AC Drive
1756-N2XT ControlLogix XT Slot Filler
1492-JD3-BL IEC 2-Ckt Feed-Through Blk 2.5mm
1492-CAB050E69 Digital Cable Wiring System
20BB070A3ANNAND1 PowerFlex 700 70 A 25 Hp AC Drive
100-VAWG18-R26 Wire
20BC043A3AYNADA0 PowerFlex 700 43 A 22 kW AC Drive
140M-D8E-C16-TE PROTECTOR,MOTOR 1600 AMP MAX
190E-KNNZJ2-CC10S 6.3 - 10 A 190E Eco Starter with CB
1485R-P3R5-F5 DeviceNet Physical Media
150-B35NCDE 150 Motor Controller
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20LE800N3ENNJNA0EA PowerFlex 700L 800 A 870 Hp AC Drive
20AD5P0A3AYYADC1 PowerFlex 70 5 A 3 Hp AC Drive
190S-FND3-F5C-A20-KY-TE 32 - 45 A 190S Compact Comb Starter w/CB
1609-PBAT Replacement Battery UPS Accessory
1497B-A1-M17-0-N CONTROL POWER TRANSFORMER
20BD248A3AYNAND1 PowerFlex 700 248 A 200 Hp AC Drive
190S-CNDJ1-DC16C-KY 10 - 16 A 190S Compact Comb Starter w/CB
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100-C12SKJ10 CONTACTOR NON-REVERSING 600V MAX 12A MAX
100-C16UEJ01 IEC 16 A 100-C contactor
21M-64LR4160-A0 Carrier Liquiflo 1.0 AC Drive
20AC2P1A3AYNNNC1 PowerFlex 70 2.1 A 0.75 kW AC Drive
141A-NFAFR5 Fuse Conversion Kit
9301-2SE3300PTR SUPT REINSTATEMENT CONTRACT FOR 93012SE3300PT RSVIEW32 RUNTIME 1500 SOFTWARE (PORTUGUESE)
2711P-T7C15B2 PV PLUS 700, TOUCH, CNET, AC PS, EXT MEM INCL RS232, ETHERNET, USB
All Machine Parts Inc Maxi Torque Rite Air Pressure 90 PSI Do Not Exceed 120 PSI
20DD8P0A3NYNACGNE PowerFlex 700S 8 A 5 Hp AC Drive
9301-2SE3400FRU3 RSVIEW32 RUNTIME 150-32K UPGRADE IN-SUPT (FR)
ALLEN-BRADLEY 77131-107-02 Lamp Base Real Part
20G11FD065AA0NNNNN PowerFlex 755 AC Drive
1492-ACAB006BB69 Analog Cable Wiring System
Allen Bradley 1771-IBD B Rev E04 Input Module 10-30 VDC Series B PLC AB 1771IBD
1485P-K1E4-R5 DevicePort - DeviceBox - T-ports
D1771-6.5.27 DIRECT COMMUNICATION MODULE(1771-DCM)USER'S MNL
20AD034A0NYYANG0 PowerFlex 70 34 A 25 Hp AC Drive
MPL-B660F-MJ22AA MOTOR,SERVO,48.0NM,3000RPM,MULTI,460V
1233X-BNBD-A2E-38 NEMA Pump Panel,Extra space,Cype
23B-D017D104NN-P6-S4-S7 23B AC Packaged Drive
1494C-DNX30-A3-B1 30A Cable Operated Disconnect Kit
1734-IB4 24V DC 4 CHANNEL SINK INPUT MODULE (PRICED PER PIECE, SOLD IN LOTS OF 10)
1492-EBLDC3 End Barrier
21M-64LW4160-M1003 McQuay Liquiflo 1.0 643 A AC Drive
100-C90B200 IEC 90 A 100-C contactor
ALLEN BRADLEY W33 FNFP W33
Allen-Bradley PanelView 1200 Operator Interface 2711TC1MC
1492-PD31123 Pwr Blk Power Distribution 3-Pole 380 A
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9302-TIDS SUPT RENEWAL CONTRACT FOR 9302TID CONTROLVIEW FOR DOS TEXAS INSTRUMENTS DRIVER SOFTWARE
103S-EWD3-DB63CC-KY 4 - 6.3 A MCS Starter & Circuit Breaker
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1585D-M4TBJM-30 M12 TO RJ45 PATCHCORD
20BC015A0AYYAND0 PowerFlex 700 15.4 A 7.5 kW AC Drive
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ALLEN BRADLEY 1769-ADN NSFP 1769ADN
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190E-AND2-CB25R-KN-S10 1.6 - 2.5 A 190E Eco Starter with CB
30 Amp Gould Shawmut Fuse Terminal Block 60358J
109-C23ADXXX-3E Non-Reversing Starter
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1494C-DJ611-A4-B-D 100A Cable Operated Disconnect Kit
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ALLEN BRADLEY AB Cat 771-OD16 A Isolated 120V AC Output Module 0d16 120vac
21BD096HJANNANC0NNNN-ND-B0-C1- PowerFlex 700 Packaged Drive AC configu
140A-C-UXD Undervoltage Release Module
21AD022D3AYNAND0NNNN-HD-B0-C1-J2-J4-L1-L2-P2-S1-S18 PowerFlex 70 Packaged Drive
150-B240NCDB-8B 150 Motor Controller
1336-TR-SP6A KIT,THERMISTOR,IG,1336STG,FRAME G
20BD014A0AYNAED0 PowerFlex 700 14 A 10 Hp AC Drive
ALLEN-BRADLEY SLC 500 1746-IB8 A INPUT MODULE QUANTITY
152B-F85FBD-47-1F Controller w/Fusible Disc & IC
1492-MS6X12VU31-40 Wiring System 6mm x 12mm 80 Mkrs/Crd
100-K12ZT200M IEC 12 A Contactor
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ALLEN BRADLEY 1794-IV16 SER A FLEX I/O 24V INPUT MODULE CARD 63468
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103T-ATD3-QB10C-E1B Combination Starter
1000TR-CT110R TRANE 110A STARTER ASSY
9305-RSVADFVCFRE RSVIEW32 ACTIVE DISPLAY FLOAT. VIEW CLNT (FRENCH)
103S-ETD3-DB63C-KN-SP-TE 4 - 6.3 A MCS Starter & Circuit Breaker
140A-C-UXC Undervoltage Release Module
20F11ND040AA0NNNNN PowerFlex 753 AC Drive
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190S-BNZJ2-CC10C-KN 190S Compact Comb Starter w/CB
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8 ALLEN-BRADLEY 1794-IB16 FLEX-I/O 24VDC SINK INPUT MODULES TERMINALS
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ALLEN BRADLEY 1791-16BC 179116BC
190E-AND2-CB16B-KY 1 - 1.6 A 190E Eco Starter with CB
100-C85KF10 85 A 100-C contactor
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20BD4A0AYYANB0 PowerFlex 700 3.4 A 2 Hp AC Drive
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1738-ADN18 ArmorPoint Adaptor
20DD8P0A3EYNACAUE PowerFlex 700S 8 A 5 Hp AC Drive
109-CDKD0-E1D-2-MC IEC Enclosed Non-Reversing Starter
190S-DND2-DC25C-KN-R10-V 18 - 25 A 190S Compact Comb Starter w/CB
191S-CND3-CB10C-R-S20 191S Rev. Compact Starter w/CB
1492-JD3RB512 IEC 2-Ckt Feed-Through Blk,Resistor,4mm
107S-DJ3-DC10C-KY-SP-TE 6.3 - 10 A Reversing Starter & Breaker
1492-CABLE014X Digital Cable Wiring System
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190S-AND2-CB63D-TE 4 - 6.3 A 190S Compact Comb Starter w/CB
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1420-V2A-485 PowerMonitor 500 Serial Power Meter
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6189V-35HDD 3.5" HARD DISK DRIVE STANDARD
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20BC037A3NYNANA0 PowerFlex 700 37 A 18.5 kW AC Drive
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9358-PBPCNT03ENE RSBATCH NT FOR PROCESLGIX PC BASED PHASES 03 UNITS
190E-KPND2-CC16B-TE 10 - 16 A 190E Eco Starter with CB
F1785-L20C15SERD FIRMWARE UPGRADE FOR 1785-L20C15 PLC5 PROCESSOR MO
140M-N8P-E12-PD-XF MOTOR CIRCUIT PROTECTOR
103S-AWD2-CB10S-KY-SP-TE 0.63 - 1 A MCS Starter & Circuit Breaker
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1492-EBJ16 Terminal Block End Barrier
100-NX202TM IEC CONTACTOR
1492-PLOTPLTA Plotter Plate
140M-F8E-C32-DX 140M Circuit Breaker
2090-CPBM4DF-16AF09 MP-Series 9 m Length Pwr and Brake Cable
20BD180A3ANNACN0 PowerFlex 700 180 A 150 Hp AC Drive
CLICK PLC 16PT 24VDC INPUT MODULE SINKING OR SOURCING INPUTS C0-16ND3
140M-Q8P-D60-CX 140M Circuit Breaker
156-B30CA1 30 A Contactor
21G1ABD485AN0NNNNN-ND-L3-P3 PowerFlex 755 Packaged Drive
1492-MS6X12H41-50 Wiring System 6mm x 12mm 80 Mkrs/Crd
103T-AWD3-RB63D-C2A-F11-KN-V Combination Starter
9358-BHIST02ENE RSBIZWARE BATCHHISTORIAN - 1 BATCH SERVER
194R-D32-1753 DIN Fuse 32 A Rotary Disconnect Switch
1492-F8BL TERMINAL BLOCK 300V MAX
1492-SP3B070 SUPP. PROTECTOR MINI CIRCUIT BREAKER
1794-IRT8K Flex 8 Point Distributed I/O Comb Module
140U-J2X3 Frame
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348-NX-512 ball screw Axis 53488400101 Ballscrew
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100-0KF200 40 A 100-C contactor
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2098-DSD-030X-DN DRIVE, 15A/30A, ULTRA3000 W/DEVICENET/INDEX
1761-L20AWA-5A
1761-L20AWA-5A
Tereos France 是法制糖业的一家企业,拥有九家制糖厂,五家酿酒厂和四家包装厂,每年从甜菜中生产出 150 万吨糖以及 500,000 立方米酒精和生物乙醇。
每年,位于阿拉斯(在加来海峡省地区)附近的 Tereos Boiry Sainte Rictrude 制糖厂为农工领域的制造商(饮料、巧克力、果酱、饼干和制品制造商)生产 250,000 吨白糖。这种糖只能在一个很短的时间段内生产,从每年的 9 月中旬开始至 12 月结束。这段时间被称为“制糖期”。在这个时间段内,甜菜会被收割运输到制糖厂进行加工。
在制糖期的每一天,Boiry 加工 20,000 吨甜菜,生产出 2,800 吨糖,消耗 15 兆瓦的电!这家制糖厂通过两台锅炉为汽轮发电机供应蒸汽,自己发电。工厂只在启动阶段和非制糖期才会接入家电网 (EDF)。
挑战
这两台锅炉是制糖厂的命脉,每小时分别可以生产高达 140 和 120 吨蒸汽。其中 85% 的蒸汽用于发电,剩余 15% 的蒸汽用于制糖的各个环节。2009 年,控制这两台锅炉的分布式控制系统有些过时了,Tereos 决定换掉这个系统。
Tereos 的目标:升级和优化这两台锅炉的控制,并将这两台锅炉集成到整个工厂的单一控制和命令系统中。这家公司联系了许多供应商,在审查这些供应商给出的建议后,选择将锅炉命令移植到 Rockwell Automation PlantPAx 系统。
该公司于 2009 年 3 月作出了这个决定,而 9 月制糖期就要开始了。这对 Rockwell Automation 来说是一个相当大的挑战,因为工厂若没有锅炉是无法运营的。此外,锅炉控制需要非常具体的专业知识:极复杂的调控算法、燃烧器的调整以及用于预期负载需量的极其复杂的计算。
帮助确保限度地降低这次移植的风险,并且在截止时间之前完成移植 — 这需要各种各样的专业技能。这正是 Rockwell Automation 解决方案大显身手之处。其锅炉管理方面的专业知识和风险管理方面的丰富经验在这种情况下是不可或缺的。Rockwell Automation 解决方案团队对既有系统进行了回顾性分析,并制定了一个移植解决方案,该方案能够使锅炉在风险的情况下实现运营。
该解决方案以 PlantPAx 过程自动化系统为中心,基于三个冗余的 Allen-Bradley® ControlLogix® 可编程自动化控制器并完全集成到工厂的整个系统中。Rockwell Automation 的锅炉管理专家调整了燃烧控制和命令所需的设置和连续自动化过程。
2009 年 8 月底,就在制糖期开始之前,该工厂进行了长达一周的“空运行”,在此期间,这家制糖厂的团队和 Rockwell Automation 团队进行了调整,并检测了负载。系统的后调整只能在生产启动阶段进行,因此,没有任何出错的余地。
制糖期天一帆风顺,供电能力和预期的一样大幅提高。Boiry 制糖厂电力 - 自动化经理 Michel Hennebique 确认说:“在 Rockwell Automation 管下的启动阶段和试运行进展得很顺利,所有调整工作都在这两天里完成了。整个制糖期间没有出现任何故障。”
Tereos 现在完成了两个制糖期,从 Rockwell Automation 解决方案带来的改进中获益颇丰。负责 PlantPAx 系统的 Rockwell Automation 解决方案团队已经证明了该系统取代传统分布式控制系统解决方案的能力以及它作为这种解决方案的竞争优势。
“锅炉控制得到改善,特别是在控重新加热方面;锅炉产出现在达到 96%。锅炉运行也比之前更加可靠。使用 Rockwell Automation 解决方案,可将两个锅炉相互连接,并且功率匹配现在由 PlantPAx 系统自动执行。所有这些改变都归功于 Rockwell Automation 团队在整个项目中提供的技能和可靠的支持。”Boiry 电力和自动化经理说道。
锅炉控制和命令系统现在与其工厂设备完全集成在一起,使整个生产点的追溯操作可以统一管理:报、操作员操作和流程历史。“们利用这次移植,与 Rockwell Automation 一起对们的督工作站进行了工程学方面的审查,Plant PAx 系统变得更具用户友好性,们的操作员特别喜欢这一点。”Boiry 自动化团队补充道。
利用 Rockwell Automation 的解决方案,Boiry Sainte Rictrude 制糖厂的大多数制造工艺(渗出、提纯、结晶)现在都实现了自动化。自 2012 年以来,两个车间(洗涤和筛选)也将由 Rockwell Automation 控制。这家制糖厂被视为 Tereos 集团的基准工厂。
但是 Hennebique 并不打算就此停下脚步。已经制定了实施具体 Rockwell Automation 软件的计划,以在能耗方面实现节约,并且还制定了计划来使用 FactoryTalk AssetCentre — 可追溯性软件,对制糖厂运营流程中实施的所有更改进行控。
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