Mr. Liu Zhiqiang of Guixi Smelt discusses the benefits of having FOUNDATION fieldbus in their smelting plant application and how intelligent field instrumentation allowed for decentralized control functions. He also reviews the economical savings of FOUNDATION fieldbus.

1. 现场总线技术在闪速冶炼中的应用
Fieldbus Technology Application in
Flash Smelting
刘志强
Mr. Liu Zhiqiang
计控车间生产副主任
Deputy Director, Control Workshop
江铜贵溪冶炼厂
Guixi Smelter of Jiangxi Copper
Corporation

2. 成立于１９７９年的江西铜业集团公司，为目前中国
最大的阴极铜生产商，世界铜行业第二大企业。公司
在铜以及相关有色金属领域，拥有勘探、采矿、冶
炼、加工为一体的完整产业链。江铜为国内铜精矿自
给率最高的公司，是国内最大、最现代化的铜生产和
加工基地，黄金、白银、硒、碲、铼等稀贵金属和硫
化工的重要生产基地。
Established in 1979, Jiangxi Copper Corporation
(JCC) has gone through 30 years development, and
is now the largest copper producer and copper
fabricator in China, also a fundamental supplier for
gold, silver, selenium, tellurium, rhenium, as well as
sulphide chemicals.
江铜贵溪冶炼厂始建于1979年，是世界上产能最大的单个铜冶炼工厂，中国最大的硫化工、
稀贵金属产品生产基地。工厂拥有两台闪速炉，两套铜酸生产系统，年产阴极铜100万吨以
上。
Guixi Smelter is the largest single copper smelting factory capacity in the world, China's
largest sulfur chemicals, precious metal products production base. The factory has two
flash furnace, two sets of copper acid production system, more than one million tons
annual output of copper cathodes

3. 为了应对国内外铜市场的需求和竞争，贵溪冶
炼厂扩建了一套30万吨级铜冶炼系统，采用世
界上最先进的闪速炼铜工艺技术。整个工程于
2005年12月2日开工建设，2007年8月1日建成
投产。闪速炉、硫酸主工艺流程选用艾默生公
司的Deltav Ff总线控制系统，主要的配套装置
空分系统选用横河公司的CS3000 Ff总线控制系
统。自动化仪表控制系统投运至今，运行稳定、
可靠。这也标志着Ff现场总线控制技术在江铜
30万吨级铜冶炼应用获得了成功。
In response to market demand and competition in
domestic and overseas market, Guixi Smelter
expanded a 300KT/a copper smelting project with
most advanced copper flash smelting technology. The
entire project started construction on December 2,
2005, put into operation on August 1, 2007.
Emerson’s DeltaV Fieldbus control system was chose
in Flash furnace and sulfuric process units. And
Yokogawa’s CS3000 fieldbus control system was
chose in air separation unit. Till now, the a control
systems are stable and reliable running. This also
marks the Ff fieldbus control technology in JCC
300KT/a copper smelting applications have been
successful.

4. 系统总体要求与选择Overall System Requirements
 系统总体设计关键在于：
 现场总线选择及布线实现方式；
 基于多现场总线的控制系统设计（系统需要和
一些Profibus设备连接）；
 基于多现场总线控制系统的安全联锁技术等。
 选择综合性价比高，适于对象过程控制与设备
管理的系统。
 The key points of overall system design：
 Fieldbus selection and wiring implementations；
 Based on multi-fieldbus control system design
(Ff for process monitor and control, Profibus
for electric device communication);
 Safety interlock technology based on multi-
fieldbus control system
• Select the system with high performance /
price ratio and suitable for the process control
and device management system.

5. 考虑的要素 Keys to be Considered
 系统规模大小；
 整体经济性或长期成本：设备投资和运行维护费用；
 适应性：所适用的控制对象类型、可挂接设备的种类；
 施工便利性：布线方式与现场配置，组态与调试等；
 系统运行的可靠性与稳定性；
 互联的开放性：
 冗余与可扩展性：
 易维护性与操作性：
 技术先进性
结合企业内部仪表控制的机构设置、人员水平、地域分布、设备类型等多状况，考虑到控制分散风险、
管理信息集中的要求，设计应用了美国Emerson公司采用PlantWeb结构的Delta V系统。
 System size；
 The long term cost: equipment investment and operation, maintenance
 Adaptability: the type of control objects, the type of device can be hooked up;
 Construction convenience： wiring, field configuration, staging etc.
 Reliability, stability;
 Interconnected openness;
 Redundancy and scalability;
 Ease of maintenance and operability;
 Advance of technology
Plus, considering combined with the internal instrument settings, staffing levels, geographical
distribution, device type and other multi-situation, taking into account the control of risk diversification
requirements, centralized management information, we chose Emerson's PlantWeb DeltaV system.

6. 控制系统的选择：Ff总线方案
Choice of Control System: Ff Solution
采用现场总线技术可以促进现场仪表的智能化、控制功能分散化、控制系统开放化，符合工业控
制系统领域的技术发展趋势。
Fieldbus technology can promote intelligent field instrumentation, control functions
decentralized and control system to open up, in line with the trends of the technology in the
field of industrial control systems.
在系统中，现场总线使自控系统与设备加入工厂信息网络，成为企业信息网络底层，是支撑现
场级与车间级信息集成的技术基础，使企业信息沟通的覆盖范围一直延伸到生产现场。
Fieldbus system make automatic control systems and equipment to join the plant information
network, to be the base of enterprise information network. It’s the technical foundation to
support field level workshop level information integration, coverage has been extended to the
production site of the enterprise information communication.
基金会现场总线下的设备管理系统还有如下优点：
Foundation Fieldbus device management system also has the following advantages:
全分布式，智能化与自诊断 Fully distributed, intelligent and self-diagnosis
多功能仪表 Multifunction Meters
易操作和维护 Easy operation and maintenance
开放性 Open
经济性 Economy
全数字化，双向传输 All-digital, two-way transmission
节省布线及控制室空间 Wiring and control room space savings
开放性与互操作性 Openness and interoperability
扩展方便 Expansion is convenient

7. 系统概况 System Architecture

8. 系统概况 System Overview
 现场总线控制卡采用30对冗余总线控制卡和5
块非冗余总线控制卡。
 使用的网段中平均每条带有6台Ff设备，配置
最少的一条网段为4台Ff设备，配置最多的一
条网段为8台Ff设备。
 网段辅助设备全部采用P+F公司的产品。
 30 pairs of redundant H1 card and 5 simplex
H1 cards.
 Average 6 Ff devices each segment, least 4
Ff devices in a segment, and most 8 Ff
device in a segment
 Segment auxiliary equipment used P+F
products

9. 系统概况 Device Summary
厂商
Supplier
数量
Quantity Yokogawa Emerson ABB E+H Honeywell Invensys
仪表类型
Device Type
温度变送器
Temperature Transmitter 7 4
流量变送器
Flowmeter Transmitter 9 2
压力变送器 15
Pressure Transmitter 15 70 3 2
多参量变送器
Multi-parameter Transmitter 1
多路温度变送器
Multi-channel Temperature 99
transmitter
阀门定位器 1
Valve Positioner 39
电导率变送器
Conductivity Transmitter 3

10. Ff现场仪表的连接与配置Conductivity Transmitter
 采用P&F总线电源调节器和分线箱
 270台Ff设备
- Rosemount 3051压力变送器
- Rosemount 848T 8路输入转换器
- MicroMotion 2700质量流量计
- Fisher DVC6000阀门定位器
…
 40个控制回路中, 大部分以单回路为主,其控制作用
(PID)放在阀门定位器中执行
 Use P&F power regulator and splitter box
 270 FF devices
- Rosemount 3051 pressure transmitter
- Rosemount 848T 8-input converter
- MicroMotion 2700 mass flowmeter
- Fisher DVC6000 Valve positioner
…
 40 control loop, majority is single-loop whic PID
is executed in valve postioner

11. Ff实际应用概况－节省 Ff Application Overview - Saving
模拟量信号电缆减少75%,I/O卡件和底板也有了相应的减少
省去中间端子,相比一系统的控制系统减少了一半机柜
 Analog signal cable reduce by 75%, has also been a corresponding reduction in the I / O card and
backplane
 Eliminating the need for intermediate terminal, cabinet reduction by half compared to a system
control system cabinet

12. Ff实际应用概况－简便易用
Ff Application Overview – Easy to Use
 Ff仪表的现场安
装和常规仪表一
样,对施工人员
毋需特别培训
 Ff meter on-site
installation has
no difference
with traditional
instruments.
Construction
workers do not
need special
training

13. Ff实际应用概况－简便易用
Ff Application Overview – Easy to Use
现场增加测控点简单省时： Ff电缆去
 比如设备部门根据需要安装新增一台 控制室
压缩机时，机上的8点温度需引入控 Ff wiring to
制系统。这时只需从现场总线接线盒 control room
的分支上增添一个848T就实现了。
It’s easy and simple to add monitoring
and control points in the field:
 For example, if the equipment
department need to install a new 848T
compressor, 8 temperature signal
should be connected to system, we
only need to add a 848T to fieldbus
junction box.

14. Ff实际应用概况－简便易用
Ff Application Overview – Easy to Use
 控制策略组态中
功能块调用和常
规组态很类似,所
见即所得
 Ff Function block
used in control
strategy
configuration is
similar to
conventional
configuration.
控制在现场

15. Ff实际应用概况－调试
Ff Application Overview – Loop Test
 利用Ff仪表的唯
一性的ID标识来
作回路测试，快
捷准确
 Use Ff
instrument
unique ID to
identify for the
loop test, fast
and accurate

16. Ff实际应用概况－提高性能
Ff Application Overview – Improving Performance
80%空余内存
 控制回路下放到现 80% free memory
场分散执行，在提
高控制安全的同时
降低了控制器的内 70%空闲时间
存使用和运行负荷 70% idle time
 Decentralize the
control loop to
execute in field, to
improve the
security control at
the same time
reduce the memory
usage and load of
controller.

17. Ff实际应用概况－设备管理
Ff Application Overview –Device Management
 使用AMS设备管理
软件,实现仪表远程
调试、组态与故障诊
断，可以让仪表人员
足不出户就能解决许
多疑难杂诊。
 AMS Device
Manager, realize
remote debugging,
configuration and
fault diagnosis, it
allows maintainance
engineer to solve
miscellaneous
issues from control
room.

18. Ff实际应用概况－设备管理
Ff Application Overview –Device Management
 40个调节阀
远程调校,减
少近80%的
时间
 40 remote
control
valves
remote
adjustment
in control
room, which
can reduce
nearly 80%
time

19. Ff实际应用概况－设备管理
Ff Application Overview –Device Management
 使用DeltaV
Inspect、
ValveLink等软
件,快速了解现
场设备健康状况
 Use DeltaV
Inspect,
AMS,ValveLink
etc. to quickly
understand the
health status of
field devices

20. 使用现场总线带来了…
With Ff Technology, We Can…
 便于操作，提高效率
 减少不必要的现场巡检次
数，减少维护成本，人员减
少80%。
 Easy to operate, improve
efficiency
 Reduce unnecessary on-site
inspection, reduce
maintenance costs, and
80% reduction in man hour.

21. 使用现场总线带来了…
With Ff Technology, We Can…
 设备自诊断功能,在故障发生之前就能预先侦察到
 设备在线增加更容易，节约施工量
 控制系统检修不影响现场控制
2012年度大修，在控制系统由8.4.1英文版升级到10.1中文版过程中，现
场炉体保温相关设备保持正常控制运行。
 Device self-diagnostic function, before a failure occurs will be able to
pre-detected
 Easier to add equipment online, saving implementation cost
 The control system maintainence does not affect the on-site control
Among 2012 annual overhaul, we upgrade the control system from
V8.4.1 to V10.1 online without plant shutdown, the process equipment
field furnace insulation to maintain a normal running.

22. 经济性分析(定性)
Benefit Analysis (Qualitative)
 系统投资：由于Ff总线系统采用的模块数量相对减少，节省了机柜、控制室的空间，故其系统
投资与按常规DCS系统设计的系统投资相差不大。
 仪表及安装费用：Ff总线型变送器和阀门定位器等仪表设备的投资目前虽较常规/带HART协议
变送器的投资多10%~30% ，但由于Ff总线系统使用的安装材料（电缆、桥架等）大大节省，
安装工作量明显减少，而且随着点数增多,这方面的优越性会体现得越是明显。在通常的大型装
置中，I/O总点数一般总是成百上千安装费用和时间通常可减少三到四成，所以这项费用不仅不
会增加，实际还会有所减少。
 调试费用：由于采用总线技术给调试带来的诸多便利，调试的工期缩短，投入的人工成本大大
降低，故可节约投资在50%以上。
 维护费用：由于采用AMS和嵌入诊断功能的Ff现场仪表设备，可节省50~70% 的维护时间和费
用。
 System investment: Because the Ff system uses relatively less modules which can save
cabinets, control room space. So the investment is near with conventional DCS system .
 Instruments and installation costs: Ff transmitters and valve positioners costs are 10% to
30% higher compared with conventional / HART transmitters , but since there are huge
saving in the Ff bus system installation materials ( cables, bridge, etc.) ,man-hours, the total
cost does not increase, even can decrease, especially in large projects.
 Commissioning costs: As a result of the intelligent bus technology, it’s easy to
commission, shorten the commission duration greatly, reduce the labor costs of the
investment, and finally save more than 50% of the investment.
 Maintenance costs: As a result of the AMS and embedded diagnostic function in Ff field
instrumentation, we can save 50 to 70% of maintenance time and costs.

23. 总结 Summary
通过现场总线技术的运用，实现了真正的集中管理、分散控制，提高了管理效率，为
实现预防维修打下了坚实的基础。
至今，Ff现场总线技术已经有了大量的成功应用案例，它在提升工厂的运行管理水平
上发挥着举足轻重的作用。在满足装置测量控制要求的同时，现场总线控制系统还具
有很好的性能价格比，在初期投资、安装调试和日后维护等各个方面都能节省不少的
费用开支及人力资本。这一切都决定了Ff现场总线技术将在未来的工程项目建设与装
置扩产改造中被得到进一步的推广和应用。在今年实施的1#闪速炉工艺优化改造中，
我们也采用了现场总线技术。
Through the use of fieldbus technology, We can realize a truly centralized
management, decentralized control, and improve the management efficiency, and
laid a solid foundation for preventive maintenance.
So far, Ff fieldbus technology has a lot of successful application cases, it has played
an important role in enhancing plant operation and management level. Fieldbus
control system also has a very good performance / cost ratio while meet the control
requirements of the device measurement. There’s lots of saving in initial investment,
installation and commissioning and future maintenance expense and human capital.
All these determine that Ff fieldbus technology will be further promoted in the future.
During the #1 flash furnace process optimization, we continue to use the fieldbus
technology.

24. 报告完毕
谢谢!
Thank you