The Pilz PSS 4000 automation system is characterized by the ability to consistently distribute control functions in peripheral equipment according to the mechatronics scheme. Therefore, as far as the control function is concerned, it does not matter where the corresponding program segment is executed. Basically, this is the basic principle for the highly automated operation and monitoring of the 2,500 km natural gas pipeline between China and Myanmar. In the 14 compressed gas transmission stations along the line, the automation system ensures safe process control and functional safety in accordance with SIL 3 levels. But its advantages do not stop there: PSS 4000 also performs multiple tasks related to automation and safety simultaneously in the same system.
Overview of compressed gas transmission stations
This natural gas pipeline extends from the west coast of Myanmar to Kunming City, Yunnan Province, China. It can meet part of China's huge energy demand and reduce dependence on maritime transportation. The pipeline is jointly operated by the state-owned CNPC and Myanmar Oil and Gas Company. This magnificent project was launched in 2009; the natural gas pipeline has been in operation since July 2013. The pipeline transports about 30 billion cubic meters of natural gas from west to east each year; meanwhile, the planned crude oil pipeline is under construction.
Reliable and safe operation over 2,500 kilometersThe 14 compressed gas transmission stations along the pipeline ensure the smooth and trouble-free transmission of natural gas. Each automated process is connected according to a defined safety level, and the purpose is to reduce and reduce the risk of harm to people and the environment and damage to equipment as much as possible. In order to transport natural gas reliably and safely over long distances, certain pipeline pressures and related minimum temperatures must be maintained. If the pressure drops, the temperature also drops. Due to the characteristics of natural gas, the risk of icing is correspondingly increased-with consequent negative effects on airflow and pipeline systems.
Guopeng Technology Co., Ltd. is headquartered in Beijing, China. As a member of this joint engineering partner, I am responsible for the use of electric heating systems to prevent freezing and maintain continuous airflow. Use multiple sensors to monitor the temperature and flow rate in the pipe network: when the value is lower than the defined minimum value, the heating system is activated. The defined maximum value ensures that the heating system is stopped again at an appropriate time. In accordance with the requirements of the pipeline operator, this security measure will operate automatically under absolutely reliable conditions. But what type of safety equipment is suitable for reliably monitoring the execution of the switching signal? Failure to perform effective detection when the temperature and airflow values ​​exceed or fall below the defined values ​​may cause an explosion in extreme cases, cause harmful effects on people and the environment, and cause long-term interruption of natural gas supply. Indirect costs will rapidly increase to millions.
Such requirements are designed to achieve Safety Integrity Level (SIL) 3. Zhu Yiming (Zhu Yi Ming) is an engineer from Guopeng Technology Co., Ltd., responsible for the development and reliable operation of the heating system. He recalled an experience in Germany in the early years: "At that time, I was caught by an excellent safety solution on a large hydraulic press. Shocked; that is the Pilz solution," Zhu Yiming said. Therefore, he contacted Pilz Beijing branch. The natural gas pipeline is essentially a complex production equipment that must meet extremely diverse control and safety requirements. The PSS 4000 automation system is very suitable for this project because the system has been successfully used in a large number of mechanical engineering applications.
The automation system of this complete safety automation supplier can realize the optimal interaction between software and hardware components, network equipment and real-time Ethernet SafetyNET p. The outstanding feature of this system is extremely diverse functions and combination options, which are completely different from classic automation solutions. Whether it is a stand-alone machine or an interconnected device, the PSS 4000 automation system can consistently distribute control functions, making project implementation more flexible and simple. At the same time, a "classic" automation structure with a centralized PLC control system can also be constructed.
PSS 4000: Safety monitoring of PID controllerRegarding the safe monitoring of natural gas temperature and flow, there is a mandatory requirement: the selected solution should be able to use a safe PID controller. Although there are a large number of automation systems on the market that can monitor non-safety-related PID controllers, there are very few PLC control systems that can implement safe process control. The PSS 4000 automation system combines reliable safety and automation in the same system: PID controllers are implemented through specific software function blocks on the PAS4000 software platform.
The PSSuniversal PLC control system belongs to the PSS 4000 automation system, communicates with higher-level equipment control systems via Modbus/TCP, and is used in all 14 compressor stations. It can safely monitor airflow, temperature, pressure, and emergency stop buttons. It can also monitor and control automatic functions such as alarms or signal lights. "For us, the key is that the PSS 4000 integrates automation and safety functions in the same system. All functions can be realized using intuitive software, and the ultra-high cost performance is unparalleled," said Zhu Yiming. With the help of various editors programmed or configured according to EN/IEC 61131-3, any changes and adjustments can be easily implemented through the software. "In this project, Pilz not only provided advanced technology, but was also an equal partner in developing the best project solutions, as well as security experts, consultants and rear support in the programming and debugging process," Zhu Yiming concluded.
Judging from its application in the classical engineering field, the application of the PSS 4000 modular automation system in pipeline engineering (such as the Myanmar-China natural gas pipeline engineering) is still somewhat special. However, the rich solutions that can be implemented using this system, the logical structure of the system, the ease of implementation, and the equally important good experience in daily use all prove the huge advantages of the system: at present, another natural gas pipeline project (China and Uzbekistan) is in the planning stage.
Rich applicationsSince the PSS 4000 automation system was launched on the market, a large number of rich and diverse applications have been implemented. In addition to classic mechanical engineering applications, it also includes large projects such as cable cars, dock cranes, mining, adventure parks, chemical industries, bridge and gate system automation, costly and complex stage technology, and even pipelines. In many cases, features such as simple installation, flexible programming with various editors, and creation of hardware-independent software are crucial. In many applications, the focus is on the potential expansion capability of the device, that is, very high flexibility.
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