The continuous upgrading of technology is something that every industry and enterprise needs to do at all times, and the petrochemical industry is no exception. The petrochemical industry has never given up the development and pursuit of new technologies, which has promoted the continuous development of petrochemical automation technology. The continuous innovation of automation technology has also promoted the development and transformation of the petrochemical industry. In this paper, Huang Buyu, a senior expert in the field of petrochemical automation, gave a detailed review of the six development trends of petrochemical automation technology in recent years, which is a reference for enterprise development.
In recent years, a series of “world-class†scale refining and chemical integration projects in China's petrochemical industry have been completed and put into operation, such as Shanghai Secco Ethylene Project, Guangdong Huizhou Ethylene Project, Yangba Integrated Ethylene Project, and Maoming Petrochemical Ethylene Project (expansion). ), Hainan Shihua Refining Project, Qingdao Refining Project, Fujian Refining and Chemical Integration Project, Dushanzi Refining and Chemical Integration Project, Huizhou Refining Project, Tianjin Refining and Chemical Integration Project, Zhenhai Ethylene Project, etc. As a senior expert in the field of petrochemical automation that has witnessed the development of China's petrochemical industry for more than 40 years, Huang Buyu has reviewed in detail the development trends of petrochemical automation technology in recent years.
Trend 1: The level of integrated automation systems continues to improve
World-scale factories need integrated automated systems. For the current large-scale refining and chemical integration enterprises, in order to cope with global competition, the construction of enterprise information system is highly valued, which requires the DCS system to break the situation that only a single device control forms an "information island" through the system. Integration enables true plant-wide centralized control, operation and management. At the same time, the newly-built large-scale petrochemical enterprises have large-scale production facilities and simultaneous construction. The control system has a scale of tens of thousands of points, involving distributed control systems/fieldbus control systems (DCS/FCS) and safety instrumented systems (SIS). Fire and Gas Detection System (FGS), Compressor Control System (CCS), Rotating Equipment Monitoring System (MMS), Equipment Package Control System (PECS), Analytical Data Acquisition System (ADAS), Tank Area Data Acquisition System (TDAS), Storage automation system (MAS), equipment management system (AMS), operational data management system (ODS), advanced control (APC), real-time optimization (RT-OPT), operational training simulation system (OTS) and other automated control systems To achieve integration between the entire plant control system, higher requirements are imposed on the level of integration of the automation system. The Tianjin Refining and Chemical Integration Project, which has just been put into commercial operation, includes 10 sets of refinery units, 9 sets of chemical units, public works and auxiliary facilities, and off-site projects. The scale of automation system integration is about 143,900 points for DCS I/O and 44,300 points for SIS I/O. With the in-depth application of computer network technology in the automation system, the era of automatic control system only as an "information island" has passed, and the large-scale and integrated automation system is an inevitable trend of historical development!
Trend 2: MAV becomes a new model
The MAV strategy, which implements the integration strategy of the entire plant instrumentation and control system in the mode of the main automation vendor (Main Automation Vendor), is an emerging automation system construction model in the petrochemical industry in recent years. The ultimate goal of adopting the MAV model is to provide owners with an automated system that is cost-effective, has a long life cycle, and has a low overall cost. In this model, MAV is the partner of the overall planning and design unit of the project, providing users with overall solutions and network structure; hardware/software configuration; engineering management and operation procedures; functional design specification standards; engineering design, configuration, generation, debugging Third-party system integration, debugging; operation and maintenance support services and other services. Practice has proved that this model has many advantages, including on the one hand, it is conducive to the overall coordination of engineering, on the other hand, it is conducive to the standardization of various interfaces and man-machine interfaces, thereby realizing the synchronization of multiple production devices and public engineering integrated automation systems; Develop functional design specifications to ensure the standardization of integrated automation systems; help to manage multiple EPCs at home and abroad; ensure high quality and high level of integrated automation system engineering; facilitate centralized operation management, resource optimization, and reduce life cycle costs. It can cope with the challenges and needs of the construction and operation of modern large-scale petrochemical projects.
Of course, for large petrochemical projects, the choice of MAV is crucial. It is a multiple test for suppliers in terms of products, engineering, services and overall coordination capabilities. For the time being, the MAV in the petrochemical industry is still abroad. Well-known companies, such as Emerson, Honeywell, Siemens, Yokogawa, ABB, etc., have begun to try this aspect for domestic automation companies, but to become a truly competitive MAV, engineering experience is still needed. There is still a way to go before the accumulation.
Trend 3: Network Architecture Information Security Issues
The current modern petrochemical enterprises usually adopt the ERP/MES/PCS three-layer network structure in the network architecture. The integrated network structure prompts us to consider everything from hardware, software and maintenance from the beginning of the planning. With the continuous extension of digital technologies such as intelligent HART technology, fieldbus technology and wireless technology to control systems and field instruments, the information processed by the data bus will continue to increase, and the safe transmission and rational use of information will be an important part of the automatic control system. test. At the same time, a large number of computer and network technologies are used to gradually replace the hardware and software equipment inherent in the automatic control system. How to ensure the safety and reliability of DCS system will be an important issue faced by engineering companies and manufacturers! At present, the network security problems of petrochemical enterprises have attracted extensive attention from experts in the industry, and research on security functions and strategies such as network hardware, software, engineering and maintenance, and dealing with risks. Faced with the information security problems that accompany the application of new network technologies, everyone is actively exploring solutions, strengthening management, and constantly improving.
Trend 4: The application of fieldbus technology is moving forward
With the continuous development of fieldbus technology, products and application experience, the application of fieldbus technology in the process industry and manufacturing industry is also constantly expanding. In the petrochemical industry, since the beginning of the Shanghai Secco ethylene project, which was put into operation in 2005, a series of major projects such as CNOOC Huizhou Ethylene Project and Fujian Refining and Chemical Integration Project have successfully and extensively used fieldbus technologies such as FF and Profibus. Fieldbus technology continues to advance with the implementation of these large projects. From the perspective of the effect, it can be said that the fieldbus technology is feasible in large-scale petrochemical projects, and predictive maintenance and remote maintenance can be realized. However, there are still changes including the concept of users and high technical requirements for on-site maintenance personnel. As well as the technology itself needs to be further improved, the application of fieldbus technology in the petrochemical industry is relatively slow.
Trend 5: Industrial Ethernet applications face new challenges
Industrial Ethernet system is the lifeblood of large-scale digital and automation systems. Promoting new choices and new technologies driven by information technology will promote and enhance the level of life management, energy management and safety management. The openness and standardization of industrial Ethernet save users cost in network construction, but as also mentioned in Trend 3, the application of industrial Ethernet technology poses new challenges to network security in the life cycle, prompting us to Continuous research on the overall architecture of the network and new security policy issues, including EMI environmental protection capabilities, fault-free communication capabilities; redundant industrial Ethernet network reliability, availability, maintainability, security and so on. The application security of industrial Ethernet in the process industry control layer still deserves special attention. It is necessary to ensure the security of information transmission through technologies such as firewalls and anti-virus software.
Trend 6: The future growth point of automation technology
The establishment of a new economic development model with low emissions, low energy consumption and low pollution based on low-carbon energy systems, low-carbon technology systems and low-carbon industrial structures has promoted the development of automation technology. China's carbon dioxide emissions and industrial energy consumption are generally high. Among them, the average energy consumption of crude oil processing, ethylene processing and large-scale synthetic ammonia is higher than the international leading level. In order to achieve a 40% to 45% reduction in CO2 emissions per unit of GDP by 2020, it is necessary to explore a low-carbon economic development path that suits China's national conditions. The petrochemical industry is one of the important industries. The development of a new economy will undoubtedly promote the development of automation technology.
Wind power, nuclear energy, solar energy comprehensive utilization, municipal, building, environmental protection and other automation technologies will become the growth point of the future automation market.
Finally, Huang Buyu concluded: "The petrochemical industry has never given up the development and pursuit of new technologies, which has promoted the continuous development of petrochemical automation technology. On the other hand, the continuous innovation of automation technology has also promoted the development and transformation of the petrochemical industry. ."
In recent years, a series of “world-class†scale refining and chemical integration projects in China's petrochemical industry have been completed and put into operation, such as Shanghai Secco Ethylene Project, Guangdong Huizhou Ethylene Project, Yangba Integrated Ethylene Project, and Maoming Petrochemical Ethylene Project (expansion). ), Hainan Shihua Refining Project, Qingdao Refining Project, Fujian Refining and Chemical Integration Project, Dushanzi Refining and Chemical Integration Project, Huizhou Refining Project, Tianjin Refining and Chemical Integration Project, Zhenhai Ethylene Project, etc. As a senior expert in the field of petrochemical automation that has witnessed the development of China's petrochemical industry for more than 40 years, Huang Buyu has reviewed in detail the development trends of petrochemical automation technology in recent years.
Trend 1: The level of integrated automation systems continues to improve
World-scale factories need integrated automated systems. For the current large-scale refining and chemical integration enterprises, in order to cope with global competition, the construction of enterprise information system is highly valued, which requires the DCS system to break the situation that only a single device control forms an "information island" through the system. Integration enables true plant-wide centralized control, operation and management. At the same time, the newly-built large-scale petrochemical enterprises have large-scale production facilities and simultaneous construction. The control system has a scale of tens of thousands of points, involving distributed control systems/fieldbus control systems (DCS/FCS) and safety instrumented systems (SIS). Fire and Gas Detection System (FGS), Compressor Control System (CCS), Rotating Equipment Monitoring System (MMS), Equipment Package Control System (PECS), Analytical Data Acquisition System (ADAS), Tank Area Data Acquisition System (TDAS), Storage automation system (MAS), equipment management system (AMS), operational data management system (ODS), advanced control (APC), real-time optimization (RT-OPT), operational training simulation system (OTS) and other automated control systems To achieve integration between the entire plant control system, higher requirements are imposed on the level of integration of the automation system. The Tianjin Refining and Chemical Integration Project, which has just been put into commercial operation, includes 10 sets of refinery units, 9 sets of chemical units, public works and auxiliary facilities, and off-site projects. The scale of automation system integration is about 143,900 points for DCS I/O and 44,300 points for SIS I/O. With the in-depth application of computer network technology in the automation system, the era of automatic control system only as an "information island" has passed, and the large-scale and integrated automation system is an inevitable trend of historical development!
Trend 2: MAV becomes a new model
The MAV strategy, which implements the integration strategy of the entire plant instrumentation and control system in the mode of the main automation vendor (Main Automation Vendor), is an emerging automation system construction model in the petrochemical industry in recent years. The ultimate goal of adopting the MAV model is to provide owners with an automated system that is cost-effective, has a long life cycle, and has a low overall cost. In this model, MAV is the partner of the overall planning and design unit of the project, providing users with overall solutions and network structure; hardware/software configuration; engineering management and operation procedures; functional design specification standards; engineering design, configuration, generation, debugging Third-party system integration, debugging; operation and maintenance support services and other services. Practice has proved that this model has many advantages, including on the one hand, it is conducive to the overall coordination of engineering, on the other hand, it is conducive to the standardization of various interfaces and man-machine interfaces, thereby realizing the synchronization of multiple production devices and public engineering integrated automation systems; Develop functional design specifications to ensure the standardization of integrated automation systems; help to manage multiple EPCs at home and abroad; ensure high quality and high level of integrated automation system engineering; facilitate centralized operation management, resource optimization, and reduce life cycle costs. It can cope with the challenges and needs of the construction and operation of modern large-scale petrochemical projects.
Of course, for large petrochemical projects, the choice of MAV is crucial. It is a multiple test for suppliers in terms of products, engineering, services and overall coordination capabilities. For the time being, the MAV in the petrochemical industry is still abroad. Well-known companies, such as Emerson, Honeywell, Siemens, Yokogawa, ABB, etc., have begun to try this aspect for domestic automation companies, but to become a truly competitive MAV, engineering experience is still needed. There is still a way to go before the accumulation.
Trend 3: Network Architecture Information Security Issues
The current modern petrochemical enterprises usually adopt the ERP/MES/PCS three-layer network structure in the network architecture. The integrated network structure prompts us to consider everything from hardware, software and maintenance from the beginning of the planning. With the continuous extension of digital technologies such as intelligent HART technology, fieldbus technology and wireless technology to control systems and field instruments, the information processed by the data bus will continue to increase, and the safe transmission and rational use of information will be an important part of the automatic control system. test. At the same time, a large number of computer and network technologies are used to gradually replace the hardware and software equipment inherent in the automatic control system. How to ensure the safety and reliability of DCS system will be an important issue faced by engineering companies and manufacturers! At present, the network security problems of petrochemical enterprises have attracted extensive attention from experts in the industry, and research on security functions and strategies such as network hardware, software, engineering and maintenance, and dealing with risks. Faced with the information security problems that accompany the application of new network technologies, everyone is actively exploring solutions, strengthening management, and constantly improving.
Trend 4: The application of fieldbus technology is moving forward
With the continuous development of fieldbus technology, products and application experience, the application of fieldbus technology in the process industry and manufacturing industry is also constantly expanding. In the petrochemical industry, since the beginning of the Shanghai Secco ethylene project, which was put into operation in 2005, a series of major projects such as CNOOC Huizhou Ethylene Project and Fujian Refining and Chemical Integration Project have successfully and extensively used fieldbus technologies such as FF and Profibus. Fieldbus technology continues to advance with the implementation of these large projects. From the perspective of the effect, it can be said that the fieldbus technology is feasible in large-scale petrochemical projects, and predictive maintenance and remote maintenance can be realized. However, there are still changes including the concept of users and high technical requirements for on-site maintenance personnel. As well as the technology itself needs to be further improved, the application of fieldbus technology in the petrochemical industry is relatively slow.
Trend 5: Industrial Ethernet applications face new challenges
Industrial Ethernet system is the lifeblood of large-scale digital and automation systems. Promoting new choices and new technologies driven by information technology will promote and enhance the level of life management, energy management and safety management. The openness and standardization of industrial Ethernet save users cost in network construction, but as also mentioned in Trend 3, the application of industrial Ethernet technology poses new challenges to network security in the life cycle, prompting us to Continuous research on the overall architecture of the network and new security policy issues, including EMI environmental protection capabilities, fault-free communication capabilities; redundant industrial Ethernet network reliability, availability, maintainability, security and so on. The application security of industrial Ethernet in the process industry control layer still deserves special attention. It is necessary to ensure the security of information transmission through technologies such as firewalls and anti-virus software.
Trend 6: The future growth point of automation technology
The establishment of a new economic development model with low emissions, low energy consumption and low pollution based on low-carbon energy systems, low-carbon technology systems and low-carbon industrial structures has promoted the development of automation technology. China's carbon dioxide emissions and industrial energy consumption are generally high. Among them, the average energy consumption of crude oil processing, ethylene processing and large-scale synthetic ammonia is higher than the international leading level. In order to achieve a 40% to 45% reduction in CO2 emissions per unit of GDP by 2020, it is necessary to explore a low-carbon economic development path that suits China's national conditions. The petrochemical industry is one of the important industries. The development of a new economy will undoubtedly promote the development of automation technology.
Wind power, nuclear energy, solar energy comprehensive utilization, municipal, building, environmental protection and other automation technologies will become the growth point of the future automation market.
Finally, Huang Buyu concluded: "The petrochemical industry has never given up the development and pursuit of new technologies, which has promoted the continuous development of petrochemical automation technology. On the other hand, the continuous innovation of automation technology has also promoted the development and transformation of the petrochemical industry. ."
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