EIP Solution for Data Acquisition System of Oil Refinery

 

 

Data Acquisition System
Large-scale refineries produce fuel and chemical raw materials and the production involves a complete processing technology. Most of the production equipment adopts Distributed Control System (DCS) and features a high level of automation. And the engineering data of each device is sent to Computer Integrated Manufacturing System (CIMS) of the factory. Nevertheless, the utilities meter data (like water, electricity, gas and heat), tank data, as well as in-and-out-factory records are independent and still collected by statistical staff. This can not meet the requirements of modern management. In order to obtain accurate information of the factory and make good use of the information, manage the production efficiently, optimize resources distribution and improve the economic benefits of the enterprise, it is necessary to build "The Utilities Meter Data Acquisition System of Refinery" to gather decentralized data at metering center, balance materials and then deliver data to the CIMS of the factory via optical fiber.

 

System Principle
The system is composed of Up-PC software and Down-PC software. Both of them are programmed by C language and assembly language. It is simple to use, operates on a real-time basis and needs few human guidance. All the software adopts modular design. Each module is responsible for one function and follows top-to-bottom software development principle.

 

 

The Functions of Up-PC
1) Main Configuration
Chassis: IPC-810E/6113LP4/7271AT
Motherboard: FSC-1814V2NA
Accessories: Core 2 Duo E4600(2.4GHz)/1GB/80G


2) Functions
The Up-PC employs Industrial PC and is equipped with printer and big screen monitor. The main function of the Up-PC system software is to transmit data between Up-PC and Down-PC through communication network, and dealing with the data acquired by Down-PC, including saving data to database, displaying flow chart, trend diagram, bar chart, data table and printing all kinds of reports.

 

The Functions of Down-PC
One of the main tasks of Down-PC is to directly face the intelligent meter of each tank, collect production data and save it in a certain format; the other task is to keep monitoring communication line if there is a data transmission request from Up-PC, and transmit the data quickly and accurately to Up-PC. Down-PC must guarantee the accuracy, integrity and real-time nature of the data. In the second task, Down-PC should be capable of identifying ineffective calls (i.e. cross-talk in telephone, main computer call incomplete or line fault). Down-PC, as a “black box” module in this system, stays between Up-PC and production equipment. The key characteristic of Down-PC is to run continuously without crashing. Once it starts up, it needn´t any human guidance. Hence, to guarantee its normal uninterrupted operation, the hardware of Down-PC must feature exceptional reliability, and the software must feature extreme reliability and security. Even in the worst cases like power failure or program error, Down-PC should possess self-diagnostic feature and self-recovering function.

 

Down-PC software includes: system initialization setup module; bottom communication service module; top communication service module; data acquisition module; system malfunction self-diagnostic and self-recovering module.

 

EVOC embedded microcomputer MEC-1003 is used as Down-PC. Two RS-232 serial ports obtain the data of flow meter. LAN ports transfer data to Up- PC. MEC-1003 has the characteristics of miniaturization, modularization, combination and strict standardization, and can work as black box and withstand extreme environments. MEC-1003 adopts DC power supply with supply voltage ranging from 8V to 32V. It can be powered by battery in case of power failure.

 

System Evaluation
The system collects and manages the utilities meter data of the oil refinery, thus achieving material balance and improving management level for the whole refinery.

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