Shaanxi Chemical Industry’s Boiler No. 1: Upgrade with a New Core to Meet New Challenges

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Shaanxi Chemical Industry’s Boiler No. 1: Upgrade of Its Control System to Meet New Challenges Author/Source: Shaanxi Chemical Industry Date: April 19, 2022 Clicks: 32 On April 8, taking advantage of the shutdown for maintenance of Boiler No. 1, Shaanxi Chemical Industry began upgrading its DCS control system for this boiler, in order to enhance the reliability and stability of the DCS system and ensure the safe operation of the facility as well as continuous production over long periods of time. As of April 18, the upgrade and renovation of the DCS control system for Boiler No. 1 have been largely completed. The DCS for Boiler No. 1 uses the automated control system from HollySys Company; it was put into use in 2010 and has played a vital role in plant monitoring, safe production, and process stability. Over time, the equipment gradually ages, causing the system to operate slowly and lagging, which affects the stable operation of the device as well as its ability to achieve high performance; it is therefore urgent to upgrade and optimize the system. The company has included this maintenance project as a key task in the plant’s major overhauls, aiming to improve the plant’s intrinsic safety level and promote sustainable production. This maintenance campaign involved a comprehensive upgrade and renewal of 16 system cabinets, operation stations, etc.; over 5,000 components were inspected and diagnosed using network DP techniques. The CPUs and power modules in I/O cabinet No. 10 and its expansion cabinets, I/O cabinet No. 11 and its expansion cabinets, I/O cabinet No. 12 and its expansion cabinets, as well as the DEH cabinet, were replaced with those from the K-CUT01 and K-PW11 series. The control wires and network cables are as dense as a spider’s web, intricately intertwined; the logical relationships between these wires are complex, making construction difficult. The company attaches great importance to the maintenance work on Boiler No. 1, and has specifically invited 3 technical personnel from HaliTech to assist the Electrical and Instrumentation Plant in carrying out the system upgrade for Boiler No. 1. The technical staff carefully trace the origin and destination of each control cable, number them, take photos for documentation, and firmly attach the pre-made labels indicating \"board number + channel number\" to the cables. Multiple people are involved in the verification process, and proper labeling and recording are carried out for the cables being disconnected. Cable reset is carried out by following the various markings on the wires, from top to bottom and from left to right; the wires are organized and fixed in an orderly manner to meet the requirements of being straight and aligned, ensuring that the cables connected to the terminals are securely fastened. After power is supplied to the system cabinet, check the status indicators of the cards; configure and name these cards hardware-wise to enable DCS control of on-site fluid transfer operations. The technical staff also carried out thorough system debugging and circuit verification, adjusting each circuit associated with the various components to ensure zero errors and no potential issues, thus enabling the system to start up successfully on the first attempt.