The basic equipment of a chemical water treatment system in a power plant is designed with excellent controllability. It is monitored and managed in real time using PLC (Programmable Logic Controller) and industrial control computers. The fundamental structure of the system is illustrated in Figure 1, which provides a clear overview of its components and interconnections.
Three Siemens SIMATIC S5-115U programmable controllers are used to manage the primary on-site equipment. The control system is divided into three independent units: #1 make-up water treatment, #2 make-up water treatment, and #3 condensate treatment. This division allows for localized control and efficient management of each process segment.
For operator interaction, two Advantech 586 industrial computers are employed. These computers run FIX5.5 configuration software from Intellution, a comprehensive platform for data acquisition, control, alarm handling, and graphic display. FIX5.5 operates under the Windows or Windows NT environment and features a user-friendly graphical interface, making it ideal for industrial automation applications.
The system uses the SINEC L2 network for data communication between the PLCs and the industrial computers. This token bus network supports both twisted pair and fiber optic cables, ensuring reliable and fast data transfer. Each node connects to the network through a bus connector, enabling seamless communication between the three PLCs and the two industrial computers.
Figure 1 illustrates the overall system structure, highlighting the integration of hardware and software components. The design reflects the advantages of a distributed control system, where control functions are decentralized while operation and management remain centralized. This approach enhances system reliability, improves response times, and simplifies maintenance due to its modular and redundant architecture.
In terms of PLC programming, the SIMATIC S5-115U uses STEP5 as its programming language, offering three methods: control system flow chart (CSF), ladder diagram (LAD), and statement table (STL). STL is preferred for its direct correspondence with internal machine logic and rich functionality. STEP5 also supports structured programming, providing standard function blocks that simplify complex tasks and improve code readability.
When designing large-scale programs, the system organizes the code into various block types such as organization blocks (OB), program blocks (PB), sequence blocks (SB), function blocks (FB), and data blocks (DB). These blocks allow for modular programming, making it easier to manage and maintain the system over time.
For the monitoring and management software, the FIX5.5 platform offers several key modules, including system configuration, data scanning, real-time database management, and graphical display. These tools enable operators to monitor and control the system efficiently, with dynamic visualizations and alarms that enhance situational awareness.
The system includes both host computer and analog disk monitoring modes, operating in a hot standby configuration. Users can switch between manual, automatic, and monitoring modes without disruption, ensuring continuous and stable operation. Whether through the host computer or the analog disk, the system maintains consistent control and response, supporting both automated and manual operations.
In conclusion, the integration of PLCs, industrial computers, and networked systems has significantly advanced the level of automation and management in industrial settings. This approach not only improves efficiency but also ensures greater flexibility and reliability in complex production environments. As technology continues to evolve, such integrated systems will become increasingly essential in modern industrial applications.
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