Abstract: In the project of the standby primary exhaust fan of Jinan Iron and Steel Group's No. 3 steelmaking plant, we used the existing QUANTUM automation control platform to realize cross-network segment control of the standby fan, enabling the standby fan to provide real-time backup for 3 online fans on different network segments.
Keywords: network segment, control, fan, online
Using Quantum automation panel to controlling backup fan
In different networks
ZHANG Xitao
(NO.3 Steel-making plant of Jigang Ltd. Co., Jinan 250101, China )
Abstract: When we build our backup fan in NO.3 Steel-making plant of Jigang Ltd. Co., we use Quantum automation panel to control the backup fan in different network.It comes true when the online fan has some trouble, the backup fan will immediately working.
Key word: network, control, fan, online
1. Introduction
As a core piece of equipment in converter steelmaking, the safe, efficient, and stable operation of the primary exhaust fan is crucial to the smooth operation of the entire steelmaking system. Simultaneously, as a key device for steelmaking gas recovery, the primary exhaust fan also impacts the environmental protection, energy recovery, and negative energy steelmaking processes of the entire steelmaking process. Therefore, ensuring the stable and efficient operation of the primary exhaust fan is a primary concern for any steel plant. Jinan Iron and Steel Group's Third Steelmaking Plant currently has three 120-ton converters, each with three corresponding primary exhaust fans. In practical application, frequent malfunctions of the primary exhaust fans have affected normal converter production. To completely resolve this production problem, the Third Steelmaking Plant decided to install a new backup primary exhaust fan as a backup for the other three fans. The three converters at Jinan Iron and Steel Group's Third Steelmaking Plant were put into operation in two phases. Due to project constraints, the industrial Ethernet used in the two phases was not on the same network segment. Since the new backup fan must be available for all fans, it was necessary to implement cross-network segment communication via PLC.
2. Introduction to the QUANTUM Automatic Control Platform
2.1 Hardware Platform Introduction
The Quantum system is a dedicated computer system with digital quantity processing capabilities. Quantum features a modular, scalable architecture for real-time control of industrial and manufacturing processes. It includes Quantum series CPUs, I/O modules, I/O interfaces, communication modules, power supplies, and a backplane. The CPU is a high-performance programmable controller based on 486, 586, and Pentium processors, compatible with Unity Pro software. Some features implemented in the CPU include:
● Superior scan time and I/O throughput.
● Ability to handle timed interrupts and I/O-based interrupts.
● Can handle both quick tasks and main tasks.
● Memory can be expanded via a PCMCIA memory expansion card.
● The CPU has multiple built-in communication interfaces.
● The high-end models feature a user-friendly diagnostic and operational LCD display on the front panel.
The Quantum system offers a variety of options for open, standards-based network and fieldbus connectivity. Supported networks include Modbus Plus, Modbus, TCP/IP, SY/MAX Ethernet modules, remote I/O modules, hot standby modules (Concept/ProWORX), and more. Combinations of these networks ensure a simple, high-performance communication architecture that tightly meets the integration requirements of computer and controller connections.
TCP/IP Ethernet is the communication method used in our wind turbine system. Achieving cross-network segment system communication is a key focus of this electrical system upgrade. The Quantum automatic control platform provided us with powerful Ethernet templates, the NOE771XX series. This series is compatible with software such as Unity Pro, Concept, and ProWORX, and features standard web pages, Modbus TCP packets, I/O scanning services, FDR clients, and SNMP management capabilities.
2.2 Software Platform
Schneider Electric's Concept software platform is a PLC configuration programming software based on the Schneider Electric Quantum hardware platform. It is a mature software platform with practical and powerful functions.
Concept conforms to the international standard IEC 1131-3, providing a unified configuration environment. The guiding principle for Concept's development was that all system configuration programs and all editors should have the same look and feel. Most configuration steps, especially program creation, are designed independently of the PLC being programmed. The entire program is divided into sections corresponding to the logical structure, and the Concept configuration tool allows objects (such as function blocks, steps, and transitions) to be easily selected, placed, or moved graphically. During object placement, feasibility testing already occurs in the SFC (Sequential Function Chart/Sequential Language) editor because most connections between objects are automatically generated during placement. In the FBD (Function Block Diagram/Function Block Language) and LD (Ladder Diagram) editors, feasibility testing occurs when blocks are connected. Unapproved connections, such as those between different data types, are removed during configuration. Feasibility testing also occurs during placement in the LL984 editor (Ladder Logic 984). In the IL editor (instruction list) and ST editor (structured text), unapproved instructions can be identified by colored outlines. After the program runs successfully for the first time, it can be optimized in graphical mode by moving connecting blocks and text to improve display.
3. Implementation of cross-network segment control using the QUANTUAM platform
3.1 Analysis of the actual situation
Fiber optic redundant ring network for converter No. 3 (172.17.48.XX) |
Fiber optic redundant ring network for converter No. 1 (172.16.57.XX) |
Fiber optic redundant ring network for converter No. 2 (172.17.48.XX) |
Secondary switching equipment (gateway) |
Figure 1: Actual ring network topology
The automated control of the primary exhaust fans of the three converters is implemented by the Quantum platform. As shown in Figure 1, the primary exhaust fans of the three converters belong to three different fiber optic redundant ring networks, with network segments of 172.16.57.XX and 172.17.48.XX respectively.
The newly installed standby fan control PLC needs to exchange data with other control PLCs (oxygen lance system, vaporization system, etc.) on the 172.16.57.XX and 172.17.48.XX networks. This means that a communication register in the standby fan must be read and written by PLCs on two different network segments, and also read and write the registers of various related PLCs in different network segments.
3.2 Utilizing the QUANTUM automatic control platform to achieve
3.2.1 Setting up the hardware environment
In typical Quantum hardware configurations, a single system master station uses only one NOE network module for industrial Ethernet communication. However, our requirements are unique. Therefore, we adopted the approach of dual network cards across network segments in computers, placing two NOE network modules within a single Quantum master station. The resulting topology is shown in Figure 2.
Fiber optic redundant ring network for converter No. 3 (172.17.48) |
Fiber optic redundant ring network for converter No. 1 (172.16.57) |
Fiber optic redundant ring network for converter No. 2 (172.17.48) |
Secondary switching equipment (gateway) |
Figure 2: Ideal ring network topology
Configure the Concept hardware configuration table as shown in Figure 2 below:
Figure 3: PLC NOE Module Configuration Table
For the two NOE network modules configured in the table, configure different network addresses respectively, as shown in Figure 4, to realize cross-network segment hardware linking of PLC.
Figure 4: NOE Module IP Configuration
In this way, we have completed the PLC-level cross-network segment connection in terms of hardware. After actual testing, the network is smooth and the data exchange is normal.
3.2.2 Software Programming Implementation
PLC for interlocking the No. 1 converter and blower |
PLC for interlocking the blower of converter No. 2 |
Backup fan start register 400001 |
PLC related to the No. 3 converter and blower |
After the hardware implementation, we need to implement the normal exchange of data flow between the two network segments in the software programming. The key registers in the standby fan, such as the fan start and stop, need to be connected with the main control PLC in different network segments, as shown in Figure 5.
Figure 5: Key Data Communication Methods
This would require the standby fan to establish channels with each main control PLC on each network segment, meaning the standby fan needs three times the number of channels as the online fan. Each main control PLC would need to establish channels with both the standby and online fans simultaneously, requiring modifications to the programs of each system – an impractical solution without disrupting normal production. Therefore, we configured the standby fan to establish data exchange channels only with the online fans. When the standby fan is in operation, it uses the original fan's channels to communicate with other main control PLCs, as shown in Figure 6. This significantly reduces the impact of the modification on the main control PLCs and also lowers the associated risks.
Figure 6: Data Channel Implementation
After practical application testing, this method has been proven to stably and reliably provide backup fans for online fans on different network segments, and has ensured the continuity of converter production.
4. Conclusion
Through this upgrade, the standby primary exhaust fan of Jinan Iron and Steel Group's No. 3 steelmaking plant was successfully put into operation, laying a solid foundation for the plant's stable and high production. How to utilize the existing automated control platform more flexibly and efficiently to maximize its effectiveness has become our main research topic for the next step.
About the author:
Zhang Xitao (March 1976~): Male, engineer, engaged in the research and application of automation and industrial Ethernet at the No. 3 Steelmaking Plant of Jinan Iron and Steel Group.
Contact information:
Address: Electrical Automation Workshop, No. 3 Steelmaking Plant, Jinan Iron and Steel Group, Jinan City, Shandong Province
Postal code: 250101
Email: [email protected]
Telephone: 0531-88847025/88847105
Mobile phone: 13864105869
