1. Project Name: China Coal Group Shanxi Jinyang Energy Co., Ltd. Coal Preparation Plant Renovation and Expansion Project Control System

2. Country / region: Shanxi Province, China

3. Industry: Coal

4. Number of I/O signals

5. CPU model: CPU401-0501

Parameters: redundant CPU, high-performance CPU, built-in 2 * RS232 (standard MODBUS), 1 * Ethernet port (standard MODBUS/TCP), program space: 32M.

6. Technical Description:

The PLC control system realizes real-time control of the density, pressure, button acquisition and field device at coal preparation field. PLC stations of raw coal system, main washing system, concentration system, filter press system, and other auxiliary production systems constitute the workshop equipment layer network; This layer adopts the MOST widely used PROFIBUS bus technology in the world nowadays. It adopts state-of-the-art NA-400 series control system of Atekon Technology Co., Ltd. and Industrial Ethernet as the hardware platform for the automation system of the coal washing plant.

The network topology diagram of the PLC cabinet of the washing control system is shown in the following figure.

The plant-wide centralized control (including closed-loop) system is equipped with the following PLC stations:

(1) PLC station of raw coal heavy-medium sorting control system: It locates in the power distribution room of the plant main building including the PLC cabinet of the No.0 DP main station and the PLC cabinets of the No.1 and No.2 DP substations, which mainly monitors the raw coal grading screen, the heavy-medium shallow tank, the de-mediating screen, the magnetic separator, the block refined coal centrifuge, the combined medium pump, the dilute medium pump and the belt machine, scraper machine and other equipment in the plant main building and detects relevant signals. It also regulates and controls the shunting and automatic water replenishment of 5 shunt boxes and 13 automatic regulating valves;

(2) PLC station of sludge heavy medium system: It locates in the power distribution room of the plant main building including the PLC cabinet of the No. 3 DP substation, which mainly controls the sorting equipment for the slack coal below 13mm;

(3) PLC station of Hydrocyclone separation system: It locates in the power distribution room of the plant main building including the PLC cabinet of the No. 4 DP substation, which mainly controls the sorting equipment for the slack coal below 0.5mm;

(4) PLC station of raw coal preparation system: It locates in the power distribution room of the raw coal workshop including the PLC cabinets of the No. 5 and No. 6 DP substations, which mainly monitors 13 coal feeders, belt conveyors, scraper machine, sewage pumps, iron removers of tape transport machine, grading screens and other equipment and detects relevant signals;

(5) PLC station of concentration and tailing coal filter press system: It locates in the power distribution room of the filter press workshop, mainly monitoring the tail coal filter press system and related pumps, belts and scrapers;

(6) PLC station of inferior coal and gangue storage and transportation system: It locates in the power distribution room at the top of inferior coal warehouse, including the PLC cabinet of the No. 7 DP substation, which mainly controls and detects equipment such as belts.

(7) PLC station of slack coal and block coal storage and transportation system: It locates in the power distribution room at the top of slack coal warehouse, including the PLC cabinet of the No. 8 DP substation, which mainly controls and detects equipment such as belts.

(8) PLC station of air compressor room: It locates in the power distribution room of the air compressor room, including the PLC cabinets of the No. 9 and No. 10 DP substations, which mainly controls the low-pressure fan and detects the axle temperature.

The above-mentioned PLC master station, the computer monitoring management station of the upper monitoring system, and the data acquisition station all communicate through Ethernet or optical fiber, forming a control layer network. The field layer uses a PROFI-BUS bus. The bus system consists of transmission technology, communication technology protocols, common guides and dedicated guides. Since PROFIBUS has a unified communication protocol and has developed different common application guides and dedicated application guides based on it, PROFIBUS can be widely used in the field device layer of each process section of the coal washing plant.

The redundant CPU401-0501 of NA400 series high-performance programmable logic controller produced by Atekon Technology was selected as the centralized controller of the whole plant. The system used a large number of E3 and frequency converters with Devicenet communication interfaces, so CMM401-0106 communication module of NA400 series of Atekon Technology was selected for networking control. The protection for rope pulling, deviation, stall and blockage of various types of belts in the system is collected through the Dupline bus, and CMM401-0411 serial port communication module of NA400 series of Atekon Technology was selected to communicate with its master station, and the on-site protection signals are collected in real time, which greatly improves the reliability of the system and the safety of production.