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PetroChina Southwest Fertilizer Plant (formerly Zepu Chemical Fertilizer Plant) is located in the Kashgar region of Xinjiang and is a professional manufacturer of urea. It is a new chemical fertilizer production unit based on the investment and expansion of the Tarim Oilfield Company. It is designed to produce 200,000 tons of synthetic ammonia and 340,000 tons of urea annually.
As a key project during the “Ninth Five-Year Plan†period of Xinjiang and China Petroleum, the construction procedures of the Southwest Fertilizer Plant are strictly regulated, the project management is scientific and efficient, the design management is in place, the advanced technology is used, the installation runs smoothly, the energy consumption and cost are low, and the product quality it is good.
The carbon dioxide regeneration tower and absorption tower are important production units of the plant. The height of the tower is about 40 meters. The pressure monitoring of the two CO2 regeneration towers and absorption towers is completed by ordinary differential pressure transmitters. It is located in the northwestern region, in the winter. The temperature is low, the pressure-inducing pipeline is often frozen (pressing line is as long as 50 meters), the instrument can not work normally, seriously affecting the safety production and normal operation of the process, resulting in product quality fluctuations, production decline, a great deal of benefit to the factory. loss. At the same time, due to the high installation position of the instrument, it has brought a lot of difficulties to the maintenance of the instrument. Accurate monitoring of carbon dioxide regeneration towers and absorption towers, which are important equipment in the plant, is a prerequisite for the stability of the factory's production.
For the actual situation of tower pressure measurement in Zep Fertilizer Plant, Emerson proposed adopting smart wireless technology to solve problems for users.
Emerson Smart Wireless Solutions, part of Emerson's PlantWeb® digital factory control network, employs a self-organizing network communications architecture that is reliable and secure. By means of wireless communication, it is possible to monitor equipment and areas where laying of cables is difficult, thereby effectively improving the maintenance level of the plant, avoiding accidental shutdowns, optimizing equipment performance, and reducing maintenance costs.
Using Emerson's smart device management software or web pages using the 1420 gateway, operators can monitor the operational status of wireless instruments in real time. The wireless meter battery adopts SmartPowerTM intelligent power management module. By using the multi-parameter function of the wireless Hart meter, the status of each battery can be monitored online by any manufacturer's DCS system to ensure that the wireless transmitter power supply is normal.
Emerson’s smart wireless network for the Zep Fertilizer Plant includes the 1420 Smart Wireless Gateway and the Rosemount® Smart Wireless Pressure Transmitter 3051S. Transmitters are installed at the top of the tower and at the bottom of the tower to measure the top and bottom of the tower. Differential pressure, send data to DCS system through Modbus/RTU mode, and then perform differential pressure calculation by DCS system.
With Emerson Smart Wireless Solutions, it is easy to solve the problem of measurement and maintenance brought about by the lower winter temperatures in the northwestern region; installation of wireless instruments during operation will not affect the normal operation of the device; data is continuously measured with wireless meters; data is continuously stable; wireless networks and The DCS system is seamlessly integrated and the configuration is simple.
Yang Songbai, instrument engineer of CNPC Southwest Fertilizer Plant, said: “We chose Emerson’s smart wireless technology in the retrofit project and used the smart wireless transmitter 3051S to measure the pressure at the top of the tower and at the bottom of the tower, so we don’t need to pull more than 40 meters. Cable to the top of the tower, and completed our renovation without shutting down the device, the wireless instrument has been installed and put into operation for nearly one year, the communication is stable, and the data is accurate. Problems with freezing and instrument maintenance."
Using smart wireless technology, in the implementation of the project, without increasing the installation cost, the original twisted pair cable is used for serial communication to realize the communication between the 1420 wireless gateway and the DCS system, so that the tower differential pressure can be measured reliably and accurately without the need of a press line. purpose.
The installation of wireless instruments is the same as the installation of conventional instruments, and the technicians do not need additional training, thereby accelerating the progress of wireless instrument installation and debugging. Emerson wireless meters follow the WirelessHart standard. Smart Wireless Hart transmitters have self-detection capabilities that make debugging easier and reduce the time required to debug the circuit much more than before. Compared with the use of wired meters, installation and commissioning time is greatly reduced, because the smart wireless network is easy to expand, providing the conditions for future network expansion. Zeng Guangsheng, director of instrument workshop of CNPC Southwest Fertilizer Plant, said: “Emerson's smart wireless products help us solve practical problems on the spot, and the expansion of wireless network is very convenient. In this way, we can add new measuring points to facilitate access during the transformation process. Existing network."
Since the project was put into operation in August 2008, the measurement results have been accurate and stable. The wireless network equipment has been operating normally. It has exceeded the user's expectations and brought great convenience to the operation and maintenance of the instrument. It has enhanced the use of Emerson Wireless.
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