Localization transformation: Hollysys assisted in the successful transformation of the DCS system of the first Shell coal gasification unit in China

Since the reform and opening up, China's economy has developed rapidly, and many enterprises have improved production efficiency by introducing foreign production equipment and DCS systems. However, with the growth of the use years, many foreign DCS systems and equipment have gradually aged and are not suitable for the current production needs, and the localization and upgrading of them is a problem that many enterprises urgently need to solve.

In view of the pain points and problems such as incomplete design data, difficult interpretation of source system programs, and uncontrollable transformation period in the upgrading and transformation of foreign DCS systems that have been in operation for more than 10 years, Hollysys has formulated an automatic upgrade solution for foreign DCS systems to comprehensively and effectively help users realize the localization and upgrading of DCS systems with higher efficiency, shorter construction period and lower cost.

Recently, the first domestic production unit (1) designed by Wuhuan Chemical Engineering Co., Ltd., a subsidiary of China National Chemical Engineering Corporation, uses Shell pulverized coal gasification technology to produce coal chemical raw gas (1) - Hubei Shuanghuan Technology Co., Ltd. (hereinafter referred to as Hubei Shuanghuan Technology) The Shell coal gasification unit was successfully ignited after the upgrade, which is a typical case of Hollysys's "foreign DCS system automatic upgrade solution" to help the localization and upgrading of foreign DCS systems. It provides a model project for the subsequent localization transformation of foreign DCS systems in all industries, and sets an industry benchmark.

Localization transformation: Hollysys assisted in the successful transformation of the DCS system of the first Shell coal gasification unit in China

　　Localization transformation to solve the problem of "just need" of users

Hubei Shuanghuan Technology Co., Ltd., located in Yingcheng, Hubei Province, is a joint-stock large-scale chemical enterprise controlled by Hubei Yihua Group Company. The company adopts the advanced technology of "combined alkali production and combined heat and power" to produce soda ash and ammonium chloride, which started construction in 1970 and was officially put into operation in 1980. On May 17, 2006, the Netherlands Shell coal gasification unit using foreign DCS system introduced by Hubei Shuanghuan Technology was officially put into operation.

After years of use, the DCS system equipment of the device has been aging and damaged, so the system has been discontinued, the supplier no longer provides spare parts, and the hardware damage needs to be customized or second-hand products are purchased, which is expensive; In addition, the old system has poor program readability, complex logic, and difficult operation, which not only has high maintenance costs, but also cannot meet the latest production needs. In recent years, the state has paid attention to industrial safety and has always emphasized the safety and controllability of the core industrial control system, so the localization and upgrading of the DCS system of the device has become a "rigid need".

In September 2019, Hollysys stood out among many competitors and signed a contract with Hubei Shuanghuan Technology for the localization and upgrading of the DCS system of the device. Hangzhou Hollysys Automation Co., Ltd. (hereinafter referred to as Hollysys) attaches great importance to the localization transformation of Shell coal gasification unit, and will form a project team from five departments, including software design department, hardware design department, solution center, engineering design department and Wuhan liaison office, and quickly put into the project implementation to carry out the development of customized functional blocks, configuration translation, functional testing, on-site operation, etc.

Customized development technology to improve the efficiency of system transformation

In order to ensure the smooth replacement of the cabinet and take care of the customer's long-term operation habits, Hollysys basically achieves 1:1 restoration of the software and hardware of the original system. In terms of hardware, in order to connect with the 32-channel DI relay board of the original system, a Y-shaped cable was custom-developed; The function blocks and operation panels on the software are also developed as much as possible to achieve 1:1 transformation.

In the process of transformation, the efficiency of the old and new system configuration translation has become prominent. In fact, the most critical and complex process in the DCS system upgrade is to translate the original system configuration into the new system configuration. In the past, this work was done manually, which was not only very cumbersome and huge, but also had extremely high requirements for the design and configuration personnel, who needed to be proficient in the old and new configuration languages before they could translate, and the accuracy of the translation also varied from person to person.

However, the control logic and process of the Shell coal gasification unit in this project are more complex than those of similar devices, and the configuration translation is more difficult, and the transformation of the DCS system is extremely difficult. Moreover, the design data of this project is incomplete, and no paper or electronic data can be provided on site, which has also become a difficult problem for the project.

As a global supplier of automation system solutions that has always been at the forefront, Hollysys has developed automation auxiliary configuration software in the face of various pain points in the transformation of foreign DCS systems, which greatly improves work efficiency, and only needs to manually verify and modify the necessary changes in the later stage of the whole process, reducing the dependence on the original system design data.

High-quality technical services have been recognized by users

This project adopts the latest K-CU03 high-performance main controller module of Hollysys, K series hardware, MACSV6.5.4 general version software, a total of 5 IO control stations, 19 cabinets, a total of 3320 system physical points, a total of more than 30,000 system compilation points, and more than 70,000 lines of sequential control logic alone.

During the implementation of the project, the members of the Hollysys project team reorganized the entire process according to the characteristics of the Shell coal gasification unit. Because no paper or electronic data can be provided on site, the only thing that can be relied on is the original configuration backup, so the project team members enter the factory to check the program and screen with the user one by one, and repeatedly verify, feedback, develop and modify with the user in the system conversion function block. During the debugging process, the user's technical personnel are invited to participate in the whole process, so that they can be familiar with and proficient in the application of the new system.

On May 27, 2020, the factory was entered to check and verify the development process and screen.

On July 13, 2020, the simulation test of all programs was completed.

On April 9, 2021, the on-site parking was officially merged.

On April 20, 2021, the incoming device was jointly commissioned.

On May 8, 2021, the device was debugged overnight under pressure.

On May 9, 2021, an ignition was successfully put into operation.

After this upgrade, Hubei Shuanghuan Technology's Shell coal gasification unit DCS system has achieved the following improvements:

Improved program readability: It has changed the situation that the old system has low readability and difficult maintenance skills, and user technicians can basically master the maintenance skills of Hollysys DCS system after a short period of contact and learning.

System Maintainability Improvements:

1) It has changed the situation that any modification of the old system needs to be shut down, and realized the undisturbed bottom installation and offline installation.

2) It has changed the situation that it is difficult to confirm the cause of the problem after the old system has occurred, and realized the convenient search of the cause of the problem.

Reduced maintenance hardware costs: The original system equipment needs to be customized and the price is high, and Hollysys system products have sufficient spare parts and provide high-quality warranty services.

Up to now, Hollysys has been stable, safe and reliable, and has been highly recognized by users. Hubei Shuanghuan Science and Technology sent a special banner and a letter of thanks to Hollysys, fully affirmed the high-quality product technology of Hollysys, and highly praised the rigorous and responsible work attitude and excellent technical level of the project team.

As the first project of Hollysys to localize the DCS system of Shell coal gasification unit, the successful commissioning of Hubei Shuanghuan Technology's Shell coal gasification unit marks the successful practice of Hollysys' foreign DCS system automatic upgrade solution, which provides a strong basis and template for the subsequent localization transformation of Shell and even all foreign DCS systems of all devices, and enhances the customer's confidence in the localization of foreign DCS systems.

In the future, Hollysys will continue to uphold the tenet of "improving people's work, life and environment with automation", assume the social responsibility of high-tech enterprises, and continue to move forward in order to improve the production efficiency of user enterprises, strengthen the national strategic scientific and technological strength, and enhance the ability of the industrial chain and supply chain.

Localization transformation: Hollysys assisted in the successful transformation of the DCS system of the first Shell coal gasification unit in China

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