Integrated Application of Honeywell Experion C300 and HC900 Hybrid Controller in Pulping Industry
Time:
Dec 30,2023
[Abstract]: This paper introduces the structure, characteristics and Experion of Honeywell hybrid controller in pulping process control.®The integrated application of PKS system platform has the characteristics of visibility, easy diagnosis, easy debugging and high safety compared with the traditional relay safety protection system, which provides a reference for the application of HC900 in other industries.
【 abstract】 ：This article describe the Honeywell hybrid controller, including structure, character and the application in pulp process control integrated with Experion® PKS system. Comparison to traditional relay safety protection system, this system possess visible, diagnosable, easy commission, high safety etc. advantages. And this application provides an example for other areas.
Key words: HC900 Experion®Process Knowledge System Hybrid Controller PCDI
[Keywords]: HC900 Experion®PKS Hybrid controller Peer Control Data Interface
1. Overview
The new project of Shandong Asia Pacific Senbo Pulp and Paper Co., Ltd., a subsidiary of Singapore Golden Eagle Group, is currently the largest single-line pulping and alkali recovery plant in the world. The process control of the plant uses Honeywell's latest generation of DCS system Experion.®The process knowledge system PKS310, which uses Experion as a platform to integrate process control and safety systems into a single and unified whole. The whole system has applied a large number of redundant C300 controllers, Profibus, Hart bus and Honeywell's patented fault-tolerant Ethernet technology. Although the total IO quantity is large, the system still retains enough expansion space. What is more unique is that according to different control requirements, the system also integrates the application of Honeywell HC900 hybrid controller, which is currently the largest project of Honeywell process control system in the domestic pulp and paper industry.
The new project of Shandong Asia Pacific Senbo Pulp and Paper Co., Ltd., a subsidiary of Singapore Golden Eagle Group, is currently the largest single-line pulping and alkali recovery plant in the world. The process control of the plant uses Honeywell's latest generation of DCS system Experion.®The process knowledge system PKS310, which uses Experion as a platform to integrate process control and safety systems into a single and unified whole. The whole system has applied a large number of redundant C300 controllers, Profibus, Hart bus and Honeywell's patented fault-tolerant Ethernet technology. Although the total IO quantity is large, the system still retains enough expansion space. What is more unique is that according to different control requirements, the system also integrates the application of Honeywell HC900 hybrid controller, which is currently the largest project of Honeywell process control system in the domestic pulp and paper industry.
2. Introduction of HC900 Hybrid Controller
The Honeywell HC900 hybrid controller is an advanced loop and logic hybrid control unit with a modular design to meet the control and data management needs of a variety of process equipment. This hybrid design provides users with a very ideal solution for process control. At the same time, due to the use of open Ethernet connection and Modbus TCP protocol, a variety of third-party HMI/SCADA software can be used to achieve network access.
This article mainly introduces the C70R redundant controller structure used in the project.
The Honeywell HC900 hybrid controller is an advanced loop and logic hybrid control unit with a modular design to meet the control and data management needs of a variety of process equipment. This hybrid design provides users with a very ideal solution for process control. At the same time, due to the use of open Ethernet connection and Modbus TCP protocol, a variety of third-party HMI/SCADA software can be used to achieve network access.
This article mainly introduces the C70R redundant controller structure used in the project.
2.1 HC900 hardware structure is introduced
2.1.1 C70R Redundant Controller
The CPU of the HC900 controller includes C30, C50, C70 for non-redundant and C70R for redundancy.
The fully redundant HC900 controller consists of two master-slave C70R controller modules, two independent power supply modules, a redundant controller switching module and a separate rack without local I/O. A key switch on the redundant controller switching module (RSM) can also manually change the operation mode of the master-slave C70R controller to switch the working state and mode.
The HC900 hybrid controller provides open Ethernet communication and can be connected to a real-time database via the PKS's SCADA. The C70R provides redundant Ethernet ports for point-to-point real-time communication with the C300 controller and remote IO real-time communication. The C70R module uses a dual scan mode to handle fast digital scans and regular analog input scans. The function modules performed during the regular scan are synchronized with the analog input measurements, and the maximum refresh rate is 500ms. Non-redundant controller, the fast scan function block has a maximum update rate of 27ms. For redundant controllers, the maximum update rate is 53ms.
The HC900 C70R controller module uses flash memory cards to save the configuration program and battery-backed RAM memory to store dynamic data so that data can be fully recovered in the event of a power outage.
After the HC900 controller is powered on, the first available C70R controller module is the main controller, and the main controller refreshes the backup controller in real time. In the event of a failure, the information required for control synchronization can be consistent.
The master controller changes to the backup slave controller under the following conditions:
Main controller failure
Manual switching of the key switch located on the RSM redundant switching module
Command from host communication
The C70R CPU host communication uses a redundant network. All network ports on the master controller remain active. The network port on the slave controller is not available for external communication, and the Honeywell OPC server software can be used to support redundant Ethernet communication and automatic transmission communication.
● RS232 communication port, complete configuration software upload or download, Modbus/RTU protocol
● RS422 communication port, can be used to connect with the local operation panel, Modbus/RTU protocol
● RS485 communication port, can realize long-distance communication, Modbus/RTU protocol
● Ethernet communication port, can support 10 PC remote communication, Modbus/TCP protocol
● RS422 communication port, can be used to connect with the local operation panel, Modbus/RTU protocol
● RS485 communication port, can realize long-distance communication, Modbus/RTU protocol
● Ethernet communication port, can support 10 PC remote communication, Modbus/TCP protocol
The C70R controller communicates with its PC interface via a 100Base-T communication network using Modbus/TCP (an open interface protocol that can be used in most popular HMI software packages). The C70R can support up to 10 master connections simultaneously, and the host can perform control monitoring and data acquisition via Ethernet.
2.1.2 I/O Modules
The HC900 controller supports plugging and unplugging I/O modules directly from the card slot without powering down. After the card is inserted, the controller will automatically recognize whether it is valid and configure it automatically.
The controller communicates with five I/O bays via 100 Base-T Ethernet physical communication links. When the system uses more than one I/O rack, a hub is required. The two expansion communication ports of the expansion module are respectively connected to a hub. By using two Ethernet hubs, the connection distance can reach up to 300 meters.
The HC900 remote I/O communicates with the main CPU module and performs data processing through the remote I/O expansion module.
Plug-in I/O modules with hot-swappable support
The HC900 has a complete range of IO modules to adapt to different application requirements. In this project:
AI module (16 channels/card) can receive various types of analog input, just select the input model type during configuration
DI module (16 channels/card) can accept passive contact input
DO module (16 channels/card) can output passive contact or 24VDC/220VAC output
Key words:
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