Plant Conference 2010 LNG 플랜트액화공정 Stimulation을통한 OTS 기반구축 고등기술연구원플랜트엔지니어링센터김형진 2010. 12. 17
연구배경 LNG 플랜트 test-bed 건설및운영시발생가능한위험과비용을감소시킬목적으로 가상 LNG 플랜트로 contol logic 이나 start-up, emergency shut-down 등운전특성을사전에점검하고 사전점검결과를공정설계 modeling 에 feedback 하여공정을개선하기위해 LNG 플랜트동적공정시뮬레이터와제어시스템연계필요 목표 : 시뮬레이터 DCS 연계인터페이스구축 시뮬레이터 DCS 연계인터페이스설계 -OPS Server 데이터통신아키텍처설계 - 제어로직프로그래밍준비 - HMI, OPC Client 설계 시뮬레이터 DCS 연계인터페이스구현 - OPC Server 데이터통신프로그래밍 - 제어로직프로그래밍 - HMI, OPC Client 프로그래밍 시뮬레이터 DCS 연계테스트 -OPC Server 데이터통신테스트 - 제어로직연계테스트 - HMI, OPC Client 구현기능테스트
연구대상공정 C3MR Liquefaction Process -Propane(C3) - Mixed Refrigerant (MR) - Natural Gas (NG) Compressor speed Choke valve opening LNG -160 1bar 30kg/h NG 10 70bar 33kg/h C3 37 16.4bar 112kg/h MR 37 61bar 60.74kg/h Compressor speed NG -32.7 69bar 33kg/h MR out -35 3.8bar 60.74kg/h Choke valve opening MR in -32.9 60bar 50.25kg/h MR composition -N2 - Methane - Ethane -Propane
C3MR 액화공정도 프로판사이클생략 ( 쿨러 5 개로대체 ) F1 F2 F3 Feed Gas 36 o C 10 o C 69bar E-3 E-4 70 bar 12 kg / h MR8 MR5 MR6 MR7 MR9 45 o C MR4 62 bar E-25 E-26 E-24 V-4 MR3 V-2 V-3 MR2 E-23 E-21 E-19 F4 Mixer MR13 F5 E-5 E-11 E-6 E-9 E-10 MR10 MR14 E-12 E-13 MR12 Natural Gas Mixed Refrigerant MR1 42 o C 1 bar 20 kg / h V-1 MR11 1. bar Flare gas LNG Product 165 o C 10kg / h
시스템개요
시스템개념도
시스템구성도 Measure d Variable Data Control Variabl e Data Link OPC DA server to OPC DA server - tag number (device address) - control I/O data Contro l Logic OPC Client (HMI, Reporting, consume data, OPC interface) Simulator OPC DA Server (publish data) OPC interface OPC DA Server (publish data) 개발순서 1. 사전준비조건제어시스템에 control logic 을심어놓는다. 2. OPC protocol의 bridging 기법으로 STEP7 simulator의 OPC DA server와제어시스템의 OPC DA server 연계 3. 제어시스템의 OPC DA server와 OPC client 연계 Control System Soft Controller 개발도구 -ifix 5.0 unlimited I/O, 개발자용 - controller Siemens SIMATIC S7-314 control logic embedding programming with STEP7 language 제어시스템 PC S7-300 with CPU 314C-2DP I/O link item properties - Machine name - Server name - Access path - Item ID - Data type
시스템구성 시뮬레이터 - HMI - 제어시스템연계 시뮬레이터와제어시스템간의 I/O data feedback 을통한제어로직사전점검 5 HMI (ifix) 1 PC 2 Control Logic Loading Program (STEP7) 6 Simulator (INDISS) OPC protocol OPC client Process Database ifix I/O driver for Siemens S7-300 - I/O data feedback - control logic check-out 3 PC Adapter USB OPC server INPUT: control logic check-out result OUTPUT: simulation model I/O data INPUT: simulation model I/O data OUTPUT: memory control logic check-out result 4 PLC (Siemens S7-300 with CPU 314C-2DP)
시스템개발프로세스 DCS hardware I/O driver OPC protocol HMI s process database
OPC Data 통신 OPC Server & Client 내부구조 Conceptual OPC Client Anatomy Protocol API Application Communication Module Conceptual OPC Server Anatomy Translation/Mapping Module OPC Communication Module OPC interface OPC Communication Module Translation/Mapping Module Native Communications Module Protocol API
Control Logic Programming
HMI 구현 시뮬레이터제어시스템연계인터페이스구현 대상 : 상용급 LNG 플랜트액화공정 (Refrigeration + Liquefaction) HMI I/O list 추출 NO. Unit Name INDISS PDF name HMI ifix name Ty pe 1 1. Feed gas/hp propane cooler 15_MC01.TubeInletFluidStream.Temperature Temp_311stream 15_MC01_propanecooler_in_temp double 2 15_MC01.TubeOutletFluidStream.Temperature Temp_501stream 15_MC01_propanecooler_out_temp double 3 15_MC01.TubeInletFluidStream.MassFlow Flow_311stream 15_MC01_propanecooler_in_flow double 4 2. Feed Gas/MP Propane Cooler 15_MC02.TubeOutletFluidStream.Temperature Temp_502stream 15_MC02_propanecooler_out_temp double 5 3. Scrub Column 15_MD01.In03Stream.Pressure Press_502stream 15_MD01_column_in_press double HMI 계층구조설계 :3levels, 27 screens Level1 Level2 Level3 LNG Refrigeration / Liquefaction Process Overview MR Circuit MCHE - MR Circuit MR Liquid Expander LP MR Compressor MP MR Compressor HP MR Compressor HP MR Separator Propane Circuit MR Propane Coolers Propane Suction Drums Propane Compressor Propane Accumulator Scrub Column Feed Gas / Propane Coolers Scrub Column & OVHDS Condenser Scrub Column Reflux Drum and Pumps Defrost Gas Heater MCHE and Endflash Drum MCHE - LNG Circuit LNG Liquid Expander End Flash Drum LNG Product Pumps HP Fuel Gas Train Facilities End Flash Gas Compressor End Flash Gas Coolers Fuel Gas Train Facilities
HMI 구현 C3MR 액화공정 Human Machine Interface (HMI) 구현사례 LNG Refrigeration / Liquefaction Process Overview MR Circuit Propane Circuit Scrub Column MCHE and Endflash Drum HP Fuel Gas Train Facilities Trending Alarms Alarm Summary Heat & Mass Balance menu Liquefaction - Scrub Column Liquefaction - MCHE and Endflash Drum Liquefaction - HP Fuel Gas Train Facilities
Simulator HMI PLC 연계구현 Simulator (INDISS + OPC server) HMI (ifix + OPC client + PLC I/O driver) PLC (S7 314) control mode - auto: simulator - manual: PLC control logic - Simulator, PLC s real-time PV, SP, OP data feedback - Simulator, PLC s control logic check
결론 결론 가상 LNG 플랜트로사전테스트를통한위험과비용감소를위한 LNG 플랜트동적공정시뮬레이터와제어시스템연계를위한아키텍처설계완료 시뮬레이터제어시스템연계인터페이스설계및구현 - 시뮬레이터 OPC Server I/O data 통신모듈설계및구현 - LNG 플랜트 C3MR 액화공정 control logic programming - 연계인터페이스사용자 HMI 설계및구현 시뮬레이터제어시스템연계테스트 - 운전원훈련시스템 (OTS) 기반구축