Abstract: This paper introduces the structure of our plant's TPS system. Using the TPS system as a platform, the paper describes the development of gas control programs and operation control panels using the TPS system's functional program modules, tools, and Control Language (CL). Keywords: TPS; gasifier control; program development and application 1 Introduction With the rapid development of China's social economy, DCS, a leader in the field of automation control, has also been rapidly promoted. In our plant's "8.13" project, three sets of foreign DCS systems were adopted in the automatic control instrumentation section. The gasification and synthesis unit DCS uses Honeywell's TPS system, and the urea unit DCS uses Rosemount's RS3. DCS is an abbreviation for Distributed Control System, commonly known as a distributed control system in China. It incorporates the application results of 4C technology, integrating continuous control, batch control, sequential logic control, and data acquisition functions. In the engineering design of our plant's gasification system, the design institute adopted the following scheme for the gasifier control section: a PLC is connected to the TPS system, and the PLC performs the automatic control of the gasifier. Our factory has mature experience in using PLCs in gasifiers; our eight old gasifiers are controlled by PLCs. However, we believe that using a PLC under a TPS system is a redundant investment and adds a fault point to the control process. Therefore, we suggested removing the PLC and having the TPS directly control the gasifiers. After discussion, this part of the design work was completed by our factory. 2. Composition of our factory's TPS system: TPS is an abbreviation for Total Plant Solution. It is an automation system that unifies the entire factory's business information system and production process control system on a single platform. The TPS system mainly consists of GUS (Global System for User Operations), HPM (High-Performance Process Management Station), NIM (Network Interface), HM (Historical Module), AM, printers, and communication networks PCN, LCN, UCN, etc. Taking our factory's TPS system as an example, the system configuration diagram is shown above. Our factory's TPS is divided into three parts: the gasification system, the synthesis system, and the scheduling system. There are a total of 9 GUS operator stations, 4 Remote operator stations, 2 sets of redundant network interface modules (NIM), 1 historical module (HM), 3 sets of redundant high-performance controllers (HPM), 2 printers, 1 pair of redundant LCN communication cables and UCN cables, LCN communication from gas production to synthesis is connected through 1 pair of redundant optical cables, and communication of the dispatch system is connected to the synthesis PCN network through 1 pair of redundant optical cables. 3. Generation of the control scheme for the gasifier control system: The idea of ​​the control scheme is as follows: (1) Build a PM point to load, start and monitor the operation of the CL program. At the same time, it can provide 127 flag registers, 80 real number registers, 4 time registers and 16 string registers for the CL program to use; (2) Build a CL program to complete the judgment and control of all logical relationships in the gasifier control; (3) Build 2 Logic Points. Since the CL program cannot directly control the DO output, it is necessary to build 2 Logic Points to control the DO output; (4) Build a gasifier program control panel on the monitoring diagram. It is mainly used to monitor the operation status of the gasifier and display the time of each cycle. The operator can use it to perform various operations on the gasifier. The overall program control flowchart of the gasifier is shown below: 4. Gasifier Process Control Requirements: Our plant's gasifier is a cyclic intermittent gas production process, divided into five stages: blasting, purging, top-blowing gas production, bottom-blowing gas production, and secondary top-blowing. During operation, the gasifier is also divided into inertia and gas production modes. The following is the valve action sequence table provided by the process. Safety Requirements: When restarting the gasifier after a shutdown of more than 10 minutes, the chimney valves in the secondary top-blowing and purging stages of the first cycle must not be energized. Subsequent cycles will resume normal operation. 5. Control Program Development: CL (Control Language) is a built-in control engineering language in TPS, which can be used to develop continuous, sequential control, and calculation applications. It can access all parameters and functions of HPM/APM. CL is indeed a very good control language, especially when developing complex sequential control programs, as it simplifies the process significantly compared to control programs composed of standardized modules within TPS. Its installation, startup, and monitoring are executed by the PM point. 5.1 Control Program Flowchart: Based on the timing diagram and requirements provided by the process, we divide the CL control program into the following parts: R_MAN; S_MAN; R_A_G_1; R_A_G; R_G_I_1; R_G_I; STOP. The flowchart is as follows: 5.2 Writing the control program and the function of each program segment: SEQUENCE 200A (HPM;POINT PM200A) EXTERNAL $NM02N13 PHASE GAS_13 STEP R_MAN IF FL(19)=OFF THEN (SET FL(11)=ON;SET FL(21),FL(22),FL(23)=OFF; &SET FL(1),FL(2), FL(3),FL(4), FL(5),FL(6), FL(7),FL(8), FL(9),FL(10),=OFF; &SET NN(20), NN(77), NN(71), NN(73), NN(75), NN(55), NN(56), NN(57), NN(58), NN(59)=0) R-MAN program segment: mainly completes the task of putting the gas furnace into a safe state, and at the same time resets and clears the digital register. SETP S_MAN IF FL(18)=ON AND FL(19)=ON AND FL(20)=OFF THEN GOTO STEP R_A_I_1 IF FL(18)=ON AND FL(19)=ON AND FL(20)=ON THEN GOTO STEP R_A_G_1 IF FL(18)=OFF THEN GOTO STEP STOP IF FL(18)=ON AND FL(19)=OFF AND FL(20)=ON THEN GOTO STEP S_MAN IF FL(18)=ON AND FL(19)=OFF AND FL(20)=OFF THEN GOTO STEP S_MAN S-MAN program segment: based on the actual operation of the operator, judges and moves the program pointer to the required program segment. Manual operation of each solenoid valve can also be performed on this section. STEP R_A_G_1 SET TIME(1)=$NM02N13.DATE SET FL(31),FL(32)=OFF SET FL(33)=0N R_A_G_1 program segment: read and assign relevant data when the gas is automatically generated STEP R_A_G SET NN(1)=NN(11) SET NN(2)=NN(1)+NN(12) SET NN(3)=NN(2)+NN(13) ……… GOTO STEP R_A_G R_A_G program segment: assign and calculate relevant digital registers when the gas is automatically generated, complete the action control of all valves in each stage of automatic gas generation and various operations such as delay and stepping of the gas furnace. STEP R_A_I_1 SET TIME（3）=$NM02N13.DATE SET FL（11）,FL（12） FL（13）,FL（14） FL（15）,FL（31） FL（32）=OFF SET FL（33）=0N R_A_I_1 program segment: Read and assign relevant data when the gas is automatically inert STEP R_A_I SET NN（21）=NN（27） SET NN（22）=NN（27）+NN（28） SET NN（23）=NN（22）+NN（29） ……… GOTO STEP R_A_I R_A_I program segment: Assign and calculate relevant digital registers when the gas is automatically inert, and complete the action control of all valves in each stage of automatic inertization and various operations such as delay and stepping of the gas furnace. STEP STOP IF FL（18）=ON AND FL（19）=ON AND FL（20）=ON THEN GOTO STEP R_A_G_1 IF FL（18）=ON AND FL（19）=ON AND FL（20）=OFF THEN GOTO STEP R_A_I_1 IF FL（18）=ON AND FL（19）=OFF AND FL（20）=ON THEN GOTO STEP R_MAN IF FL(18)=ON AND FL(19)=OFF AND FL(20)=OFF THEN GOTO STEP R_MAN SET FL(11)=ON SET FL(1),FL(2) FL(3),FL(4) FL(5),FL(6) FL(7),FL(8) FL(9),FL(10)=OFF SET FL(12),FL(13) FL(14),FL(15) FL(21),FL(22) FL(23)=OFF IF NN(7)>=NN(8) THEN SET NN(7)=NN(7) ELSE SET NN(7)=NN(7)+1 GOTO STEP STOP END 200A STOP program segment: When the gasifier is shut down, each solenoid valve is controlled to a safe position according to the process requirements. 6 Gasifier program control panel design: Operators need a human-machine interface for operating the gasifier. The gasifier program control panel is designed to fulfill this requirement. The gasifier program control panel contains two programs: gasifier gas production program and gasifier inertia production program. The control panel is mainly used to complete the gasifier start/stop, automatic/manual, gas production/inertia production, step, delay, full top blowing, manual recovery, air queuing, and modification of control time for each stage. On the gasifier program control panel, operators can also see the gasifier's operating status and the running time for each stage. For safety reasons, a dialog box will pop up on the control panel during important operations, requiring operator confirmation before execution. 7. Summary: Since the new gasifier in our plant was put into operation in May 2002, the gasifier control program has been running smoothly. This shows that: ① When using the TPS system for logic control, we do not need to use a PLC, thus reducing our investment costs. ② From a safety perspective, because the core components of the TPS—High-Performance Process Manager (HPM), Network Interface Module (NIM), Communication Network (LCN), and UCN—all adopt a redundant structure, the failure rate is significantly lower than that of a PLC. ③ Reducing control and communication links makes the entire control system simpler. ④ Making operation and data display easier.