CN-121028702-B - Automatic control system for instruments in caustic soda production process

CN121028702BCN 121028702 BCN121028702 BCN 121028702BCN-121028702-B

Abstract

The invention discloses an instrument automatic control system in a caustic soda production process, relates to the technical field of instrument automatic control, and aims to solve the problem of inaccurate control of different instrument devices in the caustic soda production process. The invention carries out multidimensional detection such as appearance inspection, mechanical function verification and the like by subdividing the technology, controlling and detecting the equipment types, ensures that the equipment is cooperated and reliable, ensures that the non-safety parameters are dynamically regulated by the DCS to maintain stable production, ensures that the safety parameters rapidly trigger forced actions such as shutdown and the like through the SIS, responds according to risk classification by the production environment and the liquid level control, monitors the state of the power equipment in real time, standardizes the interlocking logic modification and verification flow, integrates data to generate multidimensional reports, and realizes early warning of equipment faults.

Inventors

ZHU HAIFENG
YIN FENGLONG
LU LIQUAN

Assignees

安徽澄扬化工有限公司

Dates

Publication Date: 20260508
Application Date: 20250822

Claims (9)

1. The automatic control system of the appearance in the caustic soda production technology, characterized by, include: The equipment control management unit is used for confirming and detecting functions of equipment involved in the caustic soda production process; The key parameter data acquisition unit is used for acquiring key parameters in the caustic soda production process in real time according to related equipment; The conventional control unit is used for automatically adjusting non-safety interlocking parameters in the key parameter data acquired in real time; the safety interlocking control unit is used for automatically adjusting the safety interlocking type parameters in the key parameter data acquired in real time; The production environment monitoring unit is used for monitoring the concentration of combustible gas and toxic gas in the production environment in the caustic soda production process and carrying out graded alarm according to the concentration; The liquid level control unit is used for dynamically controlling the liquid level conditions of the storage tank and the reaction tank in the caustic soda production process; the equipment operation monitoring unit is used for monitoring the operation state of power equipment involved in the caustic soda production process; the interlocking logic management unit is used for carrying out logic configuration modification on the interlocking relationship between each procedure in the caustic soda production process by utilizing a logic configuration tool; The remote monitoring diagnosis unit is used for carrying out data arrangement and report generation on remote monitoring data and equipment fault diagnosis data of the caustic soda production process; The interlocking logic management unit includes: Firstly, the interlocking logic configuration data of each procedure is called from an SIS safety instrument system, logic relations are combed, and a logic list of each procedure is generated after the logic relations are combed; Starting a logic configuration tool in the SIS safety instrument system, and importing a logic list into the logic configuration tool to construct an interlocking logic diagram; Defining a mapping relation between input parameters and output actions in an interlocking logic building diagram, and setting a threshold value of an interlocking condition and action delay time; downloading the interlock logic diagram with the interlock condition set to the SIS safety instrument system; After the downloading is completed, centrifugal verification is carried out, wherein the centrifugal verification comprises static verification, dynamic verification and environment verification; and finishing the modification of the logic configuration after the centrifugal verification is finished and the centrifugal verification is qualified.
2. The automated control system for an instrument in a caustic soda production process according to claim 1, wherein the equipment control management unit comprises: the equipment involved in the caustic soda production process comprises process equipment, control equipment and detection equipment; the process equipment comprises electrolysis and chlor-alkali treatment equipment, chlorine treatment equipment, hydrogen chloride synthesis equipment, liquid chlorine liquefaction and packaging equipment and acid-alkali tank field equipment; the control equipment comprises a DCS control system, an SIS safety instrument system and a GDS combustible and toxic gas detection system; the detection device comprises a sensor and a gas detector, wherein the sensor comprises a pressure sensor, a flow sensor, a liquid level sensor, a temperature sensor, a pH sensor, a vibration sensor and a displacement sensor; The equipment involved in the caustic soda production process sequentially performs function detection, wherein the function detection comprises appearance and basic detection, mechanical part function detection, electrical and control system connection detection, functional parameter verification and equipment linkage function detection; All the equipment is detected and qualified, and then the next process flow is carried out.
3. The automated control system of the meters in the caustic soda production process of claim 2, wherein the key parameter data acquisition unit comprises: confirming the type of the parameter collected by each process equipment according to the operation requirement of the process equipment, wherein the operation requirement of the process equipment is called from a database; Corresponding detection equipment is confirmed according to the parameter types, and then the detection equipment is installed on monitoring points of the process equipment and is calibrated; The detection equipment monitors parameter change of equipment monitoring points of the process equipment and converts the measured value into an electric signal or a digital signal according to a preset frequency; Transmitting the converted electric signal or digital signal to a corresponding control device; The control equipment performs data preprocessing on the received data; and obtaining key parameter data after the data preprocessing is completed.
4. The automated control system for an instrument in a caustic soda production process according to claim 3, wherein the conventional control unit comprises: The non-safety interlocking parameters in the key parameter data are parameters which are displayed, alarmed and automatically regulated by a DCS system in the process equipment and do not trigger SIS safety interlocking; And automatically adjusting the non-safety interlocking parameters by using a DCS control system, wherein the automatic adjusting step comprises the following steps: s1, presetting normal operation ranges and adjustment thresholds of non-safety interlocking parameters in a DCS control system according to process requirements; S2, the DCS control system receives non-safety interlocking parameters acquired in real time and compares the received data with preset normal operation data; S3, confirming the deviation direction of the received data and the normal operation data according to the comparison result, and automatically generating a corresponding adjusting instruction; the regulation indexes comprise a flow parameter regulation instruction, a pressure parameter regulation instruction, a liquid level parameter regulation instruction, a temperature parameter regulation instruction and a storage tank liquid level regulation instruction; s4, the DCS control system sends the generated adjusting instruction to corresponding process equipment; s5, after the process equipment executes the instruction according to the adjusting instruction, the DCS control system continuously monitors parameter changes.
5. The automated control system of meters in a caustic soda production process of claim 4, wherein the safety interlock control unit comprises: the safety interlocking parameters in the key parameter data are parameters which are monitored by an SIS safety instrument system and trigger emergency safety actions when the parameters reach interlocking values; Automatically adjusting the safety interlocking parameters by using an SIS safety instrument system, wherein the automatic adjusting step comprises the following steps: S1, according to safety regulations, interlocking values of safety interlocking parameters and corresponding safety action logic in an SIS safety instrument system; S2, the SIS safety instrument system receives the safety interlocking parameters acquired in real time and compares the safety interlocking parameter values with preset interlocking values; S3, according to the comparison result, the SIS safety instrument system sends a forced instruction to the process equipment corresponding to the interlocking logic and executes the forced instruction; Wherein the forced instruction comprises stopping, cutting off materials and isolating; s4, after the process equipment performs instruction execution according to the forced instruction, feeding back an execution state to the SIS safety instrument system, and after the SIS safety instrument system confirms that the forced instruction is completed, synchronizing the interlocking information; S5, a worker performs field troubleshooting and manually performs interlocking reset operation on the SIS safety instrument system.
6. The automated control system of meters in a caustic soda production process of claim 5, wherein the production environment monitoring unit comprises: firstly, confirming a monitoring area of combustible gas and toxic gas in a production environment, wherein the combustible gas is hydrogen, the toxic gas is chlorine, and the monitoring area comprises a high-emission area, a closed or semi-closed space and a personnel activity dense area of equipment leakage; the gas detector monitors the gas in the monitoring area, wherein data are collected every 1-5 seconds, and the gas detector converts concentration values of the combustible gas and the toxic gas into 4-20mA electric signals or digital signals and transmits the electric signals or the digital signals to the GDS combustible and toxic gas detection system through a cable; the GDS combustible and toxic gas detection system carries out grading alarm on the received data; the early warning range of the combustible gas is primary warning and secondary warning, wherein the primary warning threshold value is 20% LEL, and the secondary warning threshold value is 40% LEL; the early warning range of the toxic gas is primary warning and secondary warning, wherein the primary warning threshold value is 1ppm, and the secondary warning value is 2ppm; the alarm execution is carried out after the confirmation of the grading alarm range is completed, wherein the alarm execution operation of the first-stage alarm is that a GDS combustible and toxic gas detection system triggers workshop audible and visual alarm, alarm information is displayed on a monitoring interface, and the alarm information is automatically pushed to a person on duty; The alarm execution of the secondary alarm is that the GDS combustible and toxic gas detection system triggers workshop high-intensity audible and visual alarm, the alarm information is highlighted on a monitoring interface, an emergency event is marked, meanwhile, the emergency event is automatically pushed to a corresponding safety responsible person, and finally, the linkage ventilation system carries out ventilation treatment; the final GDS combustible and toxic gas detection system synchronizes alarm events to the DCS control system in real time, wherein the alarm events comprise gas types, concentration values, occurrence time, areas and alarm levels, and automatically records and stores alarm whole-process data, and the alarm whole-process data comprises a concentration change curve, alarm duration and processing record data.
7. The automated control system of meters in a caustic soda production process of claim 6, wherein the liquid level control unit comprises: Confirming the normal range of liquid levels, alarm values and interlocking values of the storage tank and the reaction tank according to the process requirements of the storage tank and the reaction tank; the liquid level sensor monitors the liquid levels of the storage tank and the reaction tank in real time, converts the liquid level value into an electric signal according to a preset frequency, transmits the electric signal to the DCS control system, and performs filtering treatment and displays the current liquid level values and trend curves of the storage tank and the reaction tank in real time on a monitoring interface after the DCS control system receives data; Configuring control logic of liquid levels of a storage tank and a reaction tank in a DCS control system, and confirming corresponding actions of different liquid level intervals; The control logic comprises a normal range, an alarm range and an interlocking range, wherein when the corresponding action of the normal range is that the liquid level is in a normal interval, the current feeding or discharging state is maintained, when the corresponding action of the alarm range is that the liquid level reaches an alarm value, the adjustment action is started, and when the corresponding action of the interlocking range is that the liquid level reaches the interlocking value, the emergency action is triggered; Finally, the liquid level dynamic control of the storage tank and the reaction tank is completed.
8. The automated control system of meters in a caustic soda production process of claim 7, wherein the plant operation monitoring unit comprises: the power equipment comprises pumps, compressors, rectifiers and motors; Confirming the monitored key parameters according to the type and the operation characteristics of the power equipment; according to the types of key parameters, installing corresponding sensors at the monitoring part of the power equipment, wherein the sensors comprise a temperature sensor, a vibration sensor, a displacement sensor and a pressure sensor; Each sensor collects operation data of the power equipment according to preset frequency, converts physical quantity of the collected operation data into 4-20mA electric signals or digital signals, and transmits converted information to a DCS control system; The DCS control system receives the transmitted data, configures a monitoring threshold value of each monitoring data after receiving the data, and associates corresponding alarm logic; The DCS control system compares the collected operation data with a preset threshold according to the corresponding result of the alarm logic association, and adjusts the operation state of the power equipment according to the comparison result, wherein after the staff receives an alarm, the DCS control system invokes the historical data and the trend chart of the alarm equipment, and adjusts the operation state of the power equipment by combining the abnormal reasons of the field inspection.
9. The automated control system of meters in a caustic soda production process of claim 8, wherein the remote monitoring and diagnostic unit comprises: The remote monitoring data are monitoring data of process equipment, control equipment and detection equipment, and comprise real-time values and historical trends of all process parameters, equipment running state data, alarm records and process interlocking action records; The equipment fault diagnosis data is alarm data in remote monitoring data, and comprises fault equipment numbers and types, fault phenomena, fault moment related parameters and fault processing processes; Firstly, carrying out data preprocessing on remote monitoring data and equipment fault diagnosis data, including data cleaning, data standardization and data unification; Carrying out data classification after the data preprocessing is completed, wherein the data classification comprises process link classification, data type classification and equipment classification; Carrying out data analysis according to the data classification result, including trend analysis, association analysis and statistical analysis; generating a report according to the data analysis result, wherein the generated report comprises an operation report, a set fault diagnosis report and a summary report; And manually auditing the generated report, converting visual data after the auditing is finished and qualified, and transmitting the converted visual data to a display terminal for report display.

Description

Automatic control system for instruments in caustic soda production process Technical Field The invention relates to the technical field of instrument automation control, in particular to an instrument automation control system in a caustic soda production process. Background The instrument control system of the existing caustic soda production process has the defects that equipment function detection is on one side, all types of equipment and linkage performance are not covered, production fluctuation is easily caused by hidden faults of the equipment, critical parameter acquisition lacks standard equipment matching and calibration processes, data distortion rate is high, control adjustment deviation is caused, unsafe and safe parameter regulation is mixed, response is delayed, gas monitoring and early warning are fuzzy in grades, liquid level control logic is simple, production continuity and safety are difficult to balance, and systematic optimization is needed. Disclosure of Invention The invention aims to provide an instrument automation control system in a caustic soda production process, which is used for realizing multidimensional detection such as appearance inspection, mechanical function verification and the like through subdivision process, control and detection of equipment types, ensuring that equipment is cooperated and reliable, dynamically adjusting unsafe parameters by DCS, maintaining stable production, enabling safe parameters to rapidly trigger forced actions such as shutdown and the like through SIS, monitoring the state of power equipment according to risk grading response through production environment and liquid level control in real time, standardizing interlocking logic modification and verification flow, integrating data to generate multidimensional reports, realizing early warning of equipment faults and solving the problems in the prior art. In order to achieve the above purpose, the present invention provides the following technical solutions: an instrument automation control system in a caustic soda production process, comprising: The equipment control management unit is used for confirming and detecting functions of equipment involved in the caustic soda production process; The key parameter data acquisition unit is used for acquiring key parameters in the caustic soda production process in real time according to related equipment; The conventional control unit is used for automatically adjusting non-safety interlocking parameters in the key parameter data acquired in real time; the safety interlocking control unit is used for automatically adjusting the safety interlocking type parameters in the key parameter data acquired in real time; The production environment monitoring unit is used for monitoring the concentration of combustible gas and toxic gas in the production environment in the caustic soda production process and carrying out graded alarm according to the concentration; The liquid level control unit is used for dynamically controlling the liquid level conditions of the storage tank and the reaction tank in the caustic soda production process; the equipment operation monitoring unit is used for monitoring the operation state of power equipment involved in the caustic soda production process; the interlocking logic management unit is used for carrying out logic configuration modification on the interlocking relationship between each procedure in the caustic soda production process by utilizing a logic configuration tool; and the remote monitoring and diagnosing unit is used for carrying out data arrangement and report generation on remote monitoring data and equipment fault diagnosis data of the caustic soda production process. Preferably, the device control management unit includes: the equipment involved in the caustic soda production process comprises process equipment, control equipment and detection equipment; the process equipment comprises electrolysis and chlor-alkali treatment equipment, chlorine treatment equipment, hydrogen chloride synthesis equipment, liquid chlorine liquefaction and packaging equipment and acid-alkali tank field equipment; the control equipment comprises a DCS control system, an SIS safety instrument system and a GDS combustible and toxic gas detection system; the detection device comprises a sensor and a gas detector, wherein the sensor comprises a pressure sensor, a flow sensor, a liquid level sensor, a temperature sensor, a pH sensor, a vibration sensor and a displacement sensor; The equipment involved in the caustic soda production process sequentially performs function detection, wherein the function detection comprises appearance and basic detection, mechanical part function detection, electrical and control system connection detection, functional parameter verification and equipment linkage function detection; All the equipment is detected and qualified, and then the next process flow is carried out. Preferably, the key paramete