Application of KingView software in hot coal furnace monitoring system

This article mainly introduces the application of KingView software in the thermal coal furnace monitoring system. The combined use of KingView software and the host computer successfully replaced the touch screen in the original control system, showing great advantages in cost performance. Especially in the newly added thermal coal furnace system, it can be directly configured on the original host computer.

1. Heat transfer furnace control system and network structure

The control system uses PLC and host computer to realize the automatic control function of the heat transfer furnace. PLC and host computer communicate using OMRON's Controller LINK method to form a network structure of the same level. The host computer uses the heat transfer furnace configuration software to configure the human-machine interface, which has beautiful pictures and strong interactivity. The control system uses two host computers to realize dual-machine hot standby, one is the host and the other is the slave. The master and slave use TCP/IP protocol to form a local area network, and the slave obtains data from the host in a timely manner for data refresh. In normal operation, only the host can issue operation instructions, and the slave only has a display function; when a fault occurs during the operation of the host, the system will automatically switch the slave to the host to replace the original host to issue operation instructions. When any PLC fails to communicate with the host, a corresponding alarm text prompt will appear in the alarm screen of the host. When the faulty host is repaired and returns to normal, the system will automatically switch the master and slave back to their original state. When the system is running, there will be a login user name, operation authority, and local status indication in the upper left corner of the interface.

In KingView 6.5, the supported graphic objects are greatly enriched, including real-time reports, historical reports and alarm windows, which can reproduce the scene realistically. The IE terminal can also print reports and download report data. Reliable security technology makes data more secure, and authenticates the users who operate the Web to ensure the security of operation. Users can also edit and publish the website homepage information and icons. Data storage function is crucial for any industrial system. With the popularization and improvement of industrial automation, the requirements for the storage and access of important data in industrial sites are getting higher and higher. General configuration software has the shortcomings of slow storage speed for large batches of data, easy data loss, short storage time, large storage space, and slow access speed. For large-scale and high-demand systems, solving the storage and access of historical data is an urgent problem. KingView 6.5 conforms to this development trend and provides a high-speed historical database to support the storage and query of ms-level high-speed historical data. Using the latest data compression and search technology, the database compression ratio is less than 20%, which greatly saves disk space and greatly improves the query speed. The data within a month is queried at hourly intervals and completed within 100ms. The post-insertion and merging of historical database data can be fully realized. The historical data fragments stored in special devices can be completely inserted into the historical database through the KingView driver; the KingView historical data fragments on the remote site can also be merged into the historical data server, which truly solves the problem of data loss.

2. KingView Software Instructions

1. Heat medium furnace ignition operation screen

There are two types of furnace lighting: automatic furnace lighting and system test (manual furnace lighting).
(1) Automatic furnace lighting
Follow the steps below to perform the automatic furnace lighting process:
(a) Switch the upper computer human-machine interface to the "combustion process" interface (as shown in Figure 1);

Figure 1 Combustion process interface

Figure 2 Heat medium system flow chart

(b) Reset - press the reset button A3 on the control cabinet panel.
(c) Start - press the start button A1 on the control cabinet panel.

During the automatic furnace lighting process, the "Automatic furnace lighting process" sub-screen is displayed on the right side of the screen. As the automatic furnace lighting sequence is executed, the various indicators light up and go out in sequence. After the automatic furnace lighting is successfully completed, the "Automatic furnace lighting process" sub-screen disappears, and load adjustment can be performed. In this screen, the administrator can modify the furnace lighting parameters. Use the mouse to move the cursor to the ignition parameter oil valve or air valve opening, enter the correct ignition valve opening, and press the "Confirm" key. The other 4 variables: oil volume PV, air volume PV, oil pressure PV, and oil pressure MV are only used as indicator variables.

(2) System test (manual furnace ignition)

Only users with the administrator level or above can log in to perform system test (manual furnace ignition) operation. Switch the upper computer human-machine interface to the "system test" screen. Press "Enter system test" to enter the test state. At this time, the air valve and oil valve are already at the ignition opening (not adjustable). If you do not want to perform system test at this time, you can press the "Exit system test" button to exit this state.

There are three types of parking: active parking, fault parking and emergency parking. These three situations are indicated in the "Combustion System" screen and the "System Test" screen.

(a) Active parking

Active stop means stopping the operation of the heat medium furnace manually. Just press the "Stop" button in front of the control cabinet. The PLC automatically executes the post-processing procedure, including: closing the oil inlet valve and opening the oil return valve; fully opening the air valve for strong wind purge; opening the steam purge valve to purge the oil pipeline behind the oil inlet valve; and closing the steam purge valve and the atomizing steam valve at the same time.

(b) Fault parking

Fault stop is due to a fault, and the heat transfer furnace interlock stop is executed. At the same time, the alarm interlock point is displayed on the alarm screen on the touch screen. The PLC automatically executes the post-processing program.

(c) Emergency Stop

If the heat medium furnace stops due to an emergency, you need to press the "Emergency Stop" button in front of the control cabinet. The PLC will not only automatically execute the post-processing program, but also stop the fan, oil pump, and heat medium pump.

2. Heat transfer furnace load adjustment screen

The heat medium furnace load regulation includes five regulation loops: combustion air regulation loop, oil quantity regulation loop, flue gas residual oxygen regulation loop, and heat medium main pipe outlet temperature regulation loop. For ease of operation, these regulation loops are placed in one screen "load regulation" (see Figure 3).

Figure 3 Load regulation implementation interface

(1) Air volume and oil volume control circuit

Manual adjustment: After the PLC is powered on, the adjustment loop is automatically locked in the manual state. If you want to switch from other control states to manual adjustment, just click the "Manual" key with the mouse. At this time, the "Manual" key turns gray, and other control mode keys return to their original green state, indicating that the state can be switched next time, and "Manual" is displayed in the status display area. When manually adjusting, just enter the required MV value from the "MV:" data area (when the mouse clicks the MV data area, a numeric keyboard will automatically pop up on the screen), and press the "Confirm" key.

Automatic adjustment: Press the "Automatic" key, the adjustment mode will switch from other control modes to the "Automatic" state, the "Automatic" key will turn gray, and the "Manual" key will turn green, indicating that the next switchable state will be "Manual". The adjustment loop will automatically adjust the valve opening according to the set value to keep the measured value consistent with the set value. There are two ways to give the SP value: one is to directly give the SP value manually, you can enter the required SP value in the "SP:" digital input area through the numeric keyboard, or directly drag the SP indicator in the bar indicator bar to set it, that is, internal setting; the other is when the "Automatic" and "Fixed Burning" control modes are selected in the heat medium main pipe outlet temperature adjustment loop, the SP value of the air volume and oil volume is calculated by the heat medium main pipe outlet temperature loop and given externally, and does not need to be set by the operator.

(2) Heat medium main outlet temperature control circuit

In this regulation loop screen, there are two control modes: "Automatic" and "Fixed Burning".

"Automatic" control mode: Press the "Automatic" key in the heat medium temperature control loop on the load adjustment screen. The oil and air volume control loops are displayed in the automatic state, and the oxygen volume is set to the corrected state by default. The SP values ​​of the oil and air volume are given outside the heat medium outlet temperature control loop, and the "Automatic (External)" state is displayed. The heat medium furnace control system is put into full automatic operation without the need for operator settings. At this time, the operator only needs to enter the required set value in the SP data area of ​​the heat medium temperature control loop.

"Fixed Burn" control mode: press the "Fixed Burn" key in the heat medium temperature control loop on the load adjustment screen. The oil volume control loop is displayed as automatic, the air volume control loop is displayed as automatic (external), and the oxygen volume is set to the corrected state by default. The set value of the oil volume is entered by the operator in the digital input area of ​​"Set Value SP:" through the numeric keyboard. The set value of the air volume is given externally by the proportional calculation of the fuel flow control loop, and no manual input is required.

(3) Flue gas residual oxygen regulation circuit

This circuit has two states: "correction" and "no correction". When the heat medium main pipe outlet temperature control circuit is put into "automatic" or "fixed burning" control mode, this circuit automatically enters "correction" control to perform residual oxygen correction. Press the "no correction" button to remove the residual oxygen correction. (4) Other functions of the screen

PID parameter modification: Login with administrator level or above has the authority to modify PID parameters. "Real-time trend": Display the real-time curve of PV, SP and MV values ​​of the corresponding loop. Note: After the parameters are modified, press the "input" key of the corresponding loop to write the PID parameters into the loop parameter area before they can take effect.

3. Oil pressure and oil temperature adjustment circuit screen

These two regulating loops are placed in the "Load Regulation" screen. Both the oil pressure and oil temperature regulating loops adopt single-loop control mode, with only two control modes: "manual" and "automatic". In the "automatic" state, the operator enters the set value in the "SP" data area. The control mode and the modification of each parameter are the same as above.

4. Other functions

(1) Heat transfer furnace parameter setting screen (screen display omitted)

Select "Parameter Settings" from the main screen to enter the system parameter settings screen. This screen is for alarm parameter settings, and can only be modified by logging in at the administrator level or above.

(2) Alarm screen

Check the alarm records in the alarm screen. There are two alarm tables in the alarm screen: current alarm and historical alarm.

(a) Current alarm: Displays the current alarm point, with the latest alarm point at the top of the table. When the system has an alarm point, the control cabinet alarm sounds. The alarm and interlock sounds are different so that operators can distinguish them. After the system alarms, the operator first presses the mute button on the screen to mute it, and then finds the cause and troubleshoots it.

(b) Historical alarms: This table records all alarm points that have occurred, with the latest alarm point at the top of the table. The red font in the table is the record when the alarm occurred. The black font is the record when the alarm point disappeared.

Figure 4 Alarm list

(3) Historical trend screen

All the main operating parameters of the system are displayed in Figures 5 and 6, which are convenient for operators to observe and record, and to query the recorded data at previous times.

Figure 5 Historical trend chart

Figure 6 Historical data report

(4) Report screen

(a) Real-time report screen

In the host computer control system, the system records the important parameters of each heat medium furnace system and peripheral system in real-time reports. Operators can print real-time reports at any time according to different time points to grasp the system operation parameters at any time.

(b) Daily Report

Every hour, the system will store all the measured values ​​in the control system in the report. Starting from zero o'clock on each working day, a file will be stored every day to record the 24-hour operation data of the day. When the operator is ready to query the report file of the corresponding system, he will first "refresh the list". At this time, the list box will call out the record file stored in the system. The file is a combination of the name and date of the corresponding system, and the suffix is ​​".rtl". When the report file of a certain day to be queried is selected, the list box column will appear with the selected file. At this time, click the "report query button", and the required report will be displayed in the report control of the screen. In the daily report screen, the daily report can be deleted, printed, printed preview, and page setting functions can be used to realize the comprehensive processing of the report.

Note: "Delete Report" function key, only users with administrator privilege level or above can delete the daily operation record report.

(5) Other functions

The control system logs in on the main screen. The administrator and system administrator login is valid for 30 minutes, and the operator login is unlimited. The unlocking switch and ignition parameters of all interlocking points of the system are set in the "Start and Stop Screen". Only those who log in with the administrator authority level or above can modify the unlocking and ignition parameters. After the system is unlocked, there will be a corresponding Chinese prompt in the header of the screen.

Conclusion

The combined use of KingView software and the host computer successfully replaced the touch screen in the original control system, showing great advantages in cost performance. Especially in the newly added heat transfer furnace system, it can be directly configured on the original host computer.

In terms of performance, the KingView software has the setting of permission functions. The heat transfer furnace control system has three login user levels: operator, administrator, and system administrator. The operator only has the operation permission; the administrator has a series of advanced permissions such as operation, parameter modification, system testing, and unlocking; in addition to the above functions, the system administrator also has the function of modifying the operator and administrator login. However, due to its own limitations, the KingView software can also modify the data in the slave screen, but the modified data cannot be downloaded to the PLC, and the data in the host screen remains unchanged at this time, resulting in the data of the master and slave machines not matching. Therefore, it is forbidden to modify the data in the slave screen. When the local area network between the master and slave machines fails, the two host machines will be in the host state at the same time. As a user of the KingView software, while experiencing its super functions, I also realized the limitations of domestic software. I hope that the development of the KingView software will pay more attention to the stability of system applications.