System Overview
The KJ1201 mining drainage monitoring system is one of the main systems for mine production and a strong guarantee for mine safety production. The efficient and safe operation of mines, unmanned operation, and modern management are important trends in development. Adhering to the safety production policy of "people-oriented, safety first, comprehensive management," the goal is to create "green mines" and "smart mines." To meet the growing needs of mines, our company has independently developed an automated centralized control system for mine pump rooms.
This system integrates a water pump automatic control system, remote monitoring system, and remote video surveillance system, combining industrial intelligent control technology with mature software technology to ensure the stability and reliability of the system. It also features a standard Ethernet interface, providing standard TCP/IP protocol integration with the full coal mine automation system. Using a B/S structure, the system's main parameters are accessible via a local area network, ultimately achieving automatic operation and self-diagnosis without human intervention.
The system utilizes Siemens' S7 series programmable logic controllers (PLC) from Germany as the control core, with proprietary intelligent electric gate valve control boxes for precise control of electric gate valves. It combines water level, flow, and pressure intelligent sensors for real-time online monitoring of the drainage system. Depending on the volume of mine drainage, it can automatically select the number of water pumps to activate. To avoid unnecessary wear on important drainage equipment such as water pumps and main drainage pipelines, an "automatic rotation" control mechanism can also be applied to the drainage system's pipelines and pump equipment, ensuring the mine drainage system operates in an energy-efficient, safe, and effective manner.
System Composition
Industrial Computer and Upper Machine Software：Facilitates remote control, remote data display, remote operational status monitoring, and video surveillance; supports web browsing and can interface with the mine's automation system platform.
H12(A) Mining Intrinsically Safe Console: Acts as the centralized control, monitoring, data display, and status monitoring center on-site.
KXJ127(A) Mining Explosion-Proof and Intrinsically Safe Programmable Control Box: Serves as the centralized control, monitoring, data processing, and system calculation center.
KXBC-3×15/660 (380)DZ Mining Explosion-Proof Electric Actuator Control Box: The core of the automated safety control for electric gate valves.
Mining Explosion-Proof Integrated Electric Gate Valve, Mining Explosion-Proof Electric Gate Valve, Mining Electric Ball Valve: Core of water flow direction and safety control in the drainage system.
Water Level, Flow, Positive/Negative Pressure, Temperature, Vibration Sensors: Central to real-time status monitoring and safety protection of the drainage system.
Video Surveillance System: Provides real-time monitoring of the pump room conditions and the operational status of each device, serving as the core of remote monitoring.
System Functions
1. Automatic Data Collection and Detection
Data collection and detection are divided into two types: analog data and digital data, read through the PLC's analog and digital modules, ensuring data accuracy and response time.
Analog data includes: motor operating current, voltage, water tank level, drainage pipe flow, water pump temperature, vibration, pressure output of each pump, and vacuum level of suction pipes, as well as the opening degree of gate valves.
Digital data includes: water pump operational status (working, fault, standby, or maintenance), start and stop status of the pumps, operational status and position of electric gate valves, and the operational status and switch position confirmation for dedicated valves of jet pumps.
The automatic data collection system transforms water level change signals, performs real-time monitoring, thereby assessing the mine's water influx and controlling the start/stop of drainage pumps based on different water level conditions.
Sensors for motor temperature, vibration, and transducers for current and voltage are primarily used to monitor the operational condition of pumps and motors, providing limits and alarms to prevent damage.
The digital input module of the PLC collects various discrete (on/off) signals into the PLC as conditions and bases for data processing, controlling the start and stop of the water pumps.
2. Pump and Valve Control
Valve control is crucial within the system; the main control components include electric gate valves (with integrated electric valves as an option) and electric ball valves. All valves can be controlled via the mining intrinsically safe console and mining explosion-proof valve electric actuator control box.
If the pressure inside the drainage pipe reaches a set value within a certain time after the pump starts, the system will automatically open the electric valve to a preset degree.
3. Automatic Control
In remote automatic control mode, by automatically detecting the water tank level and related parameters, the system controls the start and stop of the pumps based on dynamic water level conditions and adjusts the number of pumps according to the water inflow and outflow.
Rational scheduling of pump rotation, remote monitoring, fault alarms, and water condition warnings achieve energy savings, reduced manpower, and increased efficiency.
In automatic operation mode, the mine's water inflow conditions can be assessed based on the number of pumps in use and water level changes. Depending on the relative amounts of water inflow and capacity, the system automatically starts and stops pumps and decides the number of pumps to operate or stop. The system can optimize operations for energy saving by adjusting to peak and off-peak times. Following a rotation principle, the system automatically rotates the operation of pumps to prevent faults due to long-term operation of a single pump.
4. Dynamic Display and Screen Monitoring
The system dynamically displays the operating status of water pumps, electric gate valves, and electric ball valves using graphical changes in color or flashing to signal accident alarms. It visually shows the open or closed position of the valves and displays the vacuum condition and pressure values of the pumps in real time.
Water levels in the tank are displayed accurately and in real-time using trend graphs or numeric displays, with pre-warning signals emitted at specific water levels for starting and stopping pumps. It also provides segmented alarms for low, very low, high, and very high water levels.
Pressure in various pipelines, pump shaft temperature, and motor temperature are also dynamically displayed in an intuitive manner using trend graphs or numeric formats. Over-limit alarms automatically record the type of fault, time, and other historical data, and a dedicated alarm display page is established to remind operators to conduct timely inspections to prevent damage to pumps and motors.
The upper machine monitoring system also allows operators to send commands to control the system's operation, input operational data, modify control parameters, and execute control commands based on different authority levels, controlling devices corresponding to their response permissions. Operators are able to conduct real-time monitoring, surveillance, and necessary control of drainage equipment.
5. Communication Interface
The PLC system is equipped with an RS485 communication module and a standard TCP/IP protocol Ethernet interface to facilitate connections with smart power supply equipment or other smart devices on site, enabling data read/write functions.
Communication between the PLC system and the surface-level upper machine is achieved via fiber optic transmission.
The entire network uses open Ethernet standard technology from the industrial automation field. Devices can be connected from the field level up to the management level. The system facilitates communication within its scope and supports mine-wide engineering and configuration up to the field level, all adhering to IT standards. This enhances the usability and maintainability of the product. Real-time Ethernet communication is used, with channel data response times of less than 150 milliseconds.
6. System Protection Functions
The pump control includes multiple protection functions. When a protection action is triggered, the main station processes it accordingly and provides voice alarm notifications.
(1) Motor Fault Protection
The power grid system provides parameters for the high-voltage switch of the underground water pump. The upper machine and PLC monitor electrical faults such as current in real-time and control accordingly.
(2) Pump Startup Protection
During startup, the pump first undergoes air evacuation, monitoring the negative pressure in the vacuum pipeline. When the pressure reaches the set value, the pump motor starts, and the vacuum pipeline ball valve closes. After the pump starts, the system monitors the pressure inside the drainage pipe. If the pressure does not reach the set value within a certain time, the system will automatically stop the pump and emit a fault alarm signal.
(3) Pump Operation Protection
The operation time of the pumps is accumulated, with each startup targeting the pump with the least accumulated operating time. This strategy ensures even wear of the pumps, avoids frequent use of any single pump causing equipment fatigue, and prevents corrosion from long periods of disuse.
(4) Over-Temperature Protection
During prolonged operation, if the bearing temperature or the stator temperature exceeds the set values, the system will emit a fault alarm signal and shut down the pump if necessary.
(5) Electric Gate Valve Protection
After a control valve is operated, the electric valve sends a status signal back to the PLC. If there is a discrepancy between the control signal and the feedback, the system will issue an alert and display the alarm information on the upper machine.
(6) Authorization Protection
Before adjusting parameters, user login is required to modify settings, effectively preventing unauthorized personnel from making adjustments.
7. Voice Communication System
The ground monitoring center is equipped with voice intercom software that allows voice communication and music playback with the underground drainage pump room.
Communication Method: Ethernet communication is used between the ground monitoring center and the underground drainage pump room. This ensures reliable and clear communication for effective management and emergency response.
8. Historical Data Query Function
The system's upper machine and PLC electronic control host support historical fault records, equipment operation records, equipment run logs, and equipment run time data report query functions. The upper machine system offers a one-click export and printing feature. The system data can be stored for at least one year or more.
9. Video Surveillance System
Video cameras collect live image data using fiber optic communication media to upload to the control room, facilitating remote automated control of the pumps and enabling unattended operation, which further enhances the system's reliability and safety. Cameras use a fiber optic cascade connection to directly upload to the ground monitoring center.
Main Functions
(1) Information Collection: Camera-captured image signals are transmitted to the display screen in real-time.
(2) Video Split Control Management: Enables simultaneous monitoring of multiple different video signals, providing remote monitoring, remote access, and alarm linkage.
(3) Surveillance Function: Any video signal can be monitored through the display screen.
(4) Playback Function: Allows real-time querying and playback of images stored on the digital video recorder.
(5) Recording Function: The digital video recorder conducts real-time and scheduled video recording.
(6) Switching Function: Automatically cycles through set images based on a time schedule.
(7) Preview Function: Users can directly access IP cameras or video servers through an IE browser.
(8) Video File Query Function: Video files from all cameras can be searched based on time, alarm records, etc.
10. Upper Machine Remote Monitoring System
An automated drainage unattended remote monitoring station is set up in the dispatch center, equipped with high-performance industrial computers, displays, upper machine software, configuration software, audio systems, and gigabit switches. The industrial computer runs the upper machine configuration software, enabling real-time display of the automated drainage system's operational parameters such as positive pressure, negative pressure, liquid level, flow rate, motor temperature, vibration, and other parameters as well as equipment operational status, fault information, and video linkage. This system also allows display, storage, remote operation, and interaction with underground equipment for dialing, communication, and music playback.
System Equipment
1.Control Equipment
KJS12 Mining Intrinsically Safe Input/Output Module: Used in conjunction with the control main host, it can collect thermocouple input signals and analog signals, and handle data collection for signals such as winding temperature, bearing temperature, and motor vibration of electromechanical equipment.
KXBC-3×15/660 (380)DZ Mining Explosion-Proof Electric Valve Actuator Control Box: This device has two modes of operation: local control and remote control. In local control mode, it can operate the open, close, and stop functions of multiple gate valves; in remote control mode, it can be controlled indirectly by the PLC to operate the gate valves. It comes with three independent displays that can show the positions and fault information of three gate valves in real time. It supports RS485 communication.
2.Actuators and Sensors
(1) Electric Gate Valves: In the control of water pump valves in coal mines, manual gate valve control can no longer meet the precise control requirements of coal mine automation. In the automation upgrade and retrofit of mine drainage systems, the electric gate valves used by our company are convenient to install. These valves feature a compact structure, high starting torque, precise control accuracy, comprehensive functions, reliable performance, easy installation and adjustment, no installation direction requirement, bidirectional sealing, easy maintenance, and a long service life. In cases where existing manual valves are present in coal mine underground settings, they can be directly retrofitted to electric valves, enhancing automation control without affecting normal coal mine production.
