Methanol production process safety control system and method

Abstract

The invention discloses a safety control system and method for a methanol production process, relates to the technical field of production control, and solves the technical problems that threshold judgment is singly carried out on data, potential threats in the production process are not deeply analyzed, and production safety cannot be guaranteed. Through cooperation of the equipment parameter acquisition unit and the production safety analysis unit, equipment working data can be accurately acquired and compared with preset parameters, whether the production process is normal or abnormal is clearly judged, a basis is provided for subsequent analysis, and the normal production analysis unit performs periodic continuous monitoring and risk index calculation on normal results, so that the production safety is improved. Through combination of historical data, potential risks can be found in advance, the safety of the production process in a state similar to a normal state is guaranteed, accidents caused by accumulation of the potential risks are avoided, and when a production abnormality analysis unit faces an abnormal result, the influence of abnormality on production is reduced by deeply analyzing the relation between abnormal data and associated parameters and generating regulation and control information.

Description

Technical Field

[0001] The present invention relates to the technical field of production control, and in particular to a safety control system and method for a methanol production process. Background Art

[0002] In the industrial production process, the safe and stable operation of equipment is of vital importance. For the equipment in the production process, its various operating parameters (such as pressure, temperature, flow and liquid level, etc.) need to be accurately monitored and analyzed to ensure production safety.

[0003] According to publication number CN118244718A, a chemical production whole-process safety control system and method are disclosed, which uses artificial intelligence technology in the field of deep learning to obtain images of a rubber additive production workbench and temperature and humidity data and air quality at multiple predetermined time points within a predetermined time period to perform feature extraction and encoding to obtain a result indicating whether the rubber additive production workbench needs to be cleaned.

[0004] However, for different production processes, such as methanol production, when conducting safety control on methanol production, traditional monitoring methods often simply make threshold judgments on individual parameters, lack in-depth analysis of the correlation between parameters, and do not systematically evaluate the risks in the production process from both normal and abnormal states. At the same time, when faced with abnormal situations, it is difficult to accurately analyze the factors that cause the abnormality and provide effective control information, and the continuous monitoring of potential risks under normal conditions is not perfect enough, which cannot meet the needs of ensuring production safety in complex industrial production environments. Summary of the invention

[0005] In view of the deficiencies in the prior art, the present invention provides a methanol production process safety control system and method, which solves the problem of single threshold judgment on data, no in-depth analysis of potential threats in the production process, and failure to ensure production safety.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solutions: A methanol production process safety control system, comprising: The equipment parameter acquisition unit is used to acquire the working data of the equipment and transmit the acquired working data to the production safety analysis unit; A production safety analysis unit, used to compare the acquired working data with predetermined parameters, analyze the state of the production process, and generate a state analysis result, wherein the state analysis result includes a normal result and an abnormal result; The normal production analysis unit is used to analyze the normal results obtained. It continuously monitors the working data periodically, calculates the risk index corresponding to the working data, and analyzes the risk index in combination with historical data to generate continuous monitoring results. The specific continuous monitoring results include risk results and safety results. The production anomaly analysis unit is used to analyze the acquired abnormal results, analyze the associated parameters of the working parameters, adjust the abnormal results based on the influence of the associated parameters, and generate control information based on the comprehensive influencing factors.

[0007] As a further solution of the present invention, the working parameters acquired by the equipment parameter acquisition unit include pressure, temperature, flow rate and liquid level data, and are respectively acquired by corresponding sensors.

[0008] As a further solution of the present invention, the specific manner in which the production safety analysis unit generates the status analysis result is: Acquire working data and predetermined parameters at the same time, and compare the acquired working data with the predetermined parameters. If the working data is different from the predetermined parameters, it indicates that the state of the production process is abnormal, and an abnormal result is generated. On the contrary, if the working data is the same as the predetermined parameters, it indicates that the state of the production process is normal, and a normal result is generated; Then the generated normal result is transmitted to the production normal analysis unit, and the generated abnormal result is transmitted to the production abnormal analysis unit.

[0009] As a further solution of the present invention, the specific method of analyzing the normal result by the normal production analysis unit is: Obtain work data, monitor the work data with time t as a period, obtain the change of work data within time period t, and calculate the change value corresponding to the work data, then obtain historical data similar to the change of work data and record it as similar records, and label them as i, where i=1, 2, ..., j, where j represents the number of similar records, and at the same time screen similar records i to obtain risk similar records a, where a=1, 2, ..., b, where b represents the number of risk similar records; Then obtain the change value corresponding to the risk similar record a, record it as Ka, and obtain the risk level value of the risk similar record a, record it as Fa, and substitute the obtained parameters into the formula The risk value Da corresponding to the risk-similar record a is calculated, where is the proportion of risk-similar records, It is a preset proportional coefficient, the value is set by the operator, and the average of the risk values ​​Da of all risk-similar records is calculated, and the calculated average is used as the risk index D1; Similarly, the above calculation method is used to calculate the risk index D2 corresponding to the work data, and the risk index D1 is compared with the risk index D2 to generate a continuous monitoring result.

[0010] As a further solution of the present invention, the specific method of the normal production analysis unit analyzing the risk index to generate the continuous monitoring result is: If the risk index D1 is greater than or equal to the risk index D2, a safety result is generated. Otherwise, if the risk index D1 is less than the risk index D2, a risk result is generated and the generated safety result or risk result is transmitted to the control information output unit.

[0011] As a further solution of the present invention, the specific manner in which the production abnormality analysis unit analyzes the abnormal result is: Analyze the generated abnormal results. First, obtain the corresponding working data, and obtain the abnormal data in the working data, record it as V. Then calculate the difference between the abnormal data and the predetermined parameter, record it as the difference to be adjusted, record it as B. At the same time, obtain historical data, analyze the associated data of the abnormal data based on the historical data, and then analyze the associated value between the abnormal data and the associated data, record it as Go, and o=1, 2, ..., p, where p represents different associated data labels. Substitute the obtained parameters into the formula The control parameter V1 is calculated, and The proportional coefficient is preset, and the specific value is set by the operator, and the generated control information is transmitted to the control information output unit.

[0012] As a further solution of the present invention, it also includes a control information output unit for displaying the acquired continuous monitoring results and control information to the corresponding operator.

[0013] A method for safety control of a methanol production process, the method specifically comprising the following steps: Step 1: Obtain working data and compare it with predetermined parameters to generate normal results or abnormal results; Step 2: Analyze the generated normal results by periodically monitoring the work data, calculating the risk index corresponding to the work data, and analyzing the risk index in combination with historical data to generate continuous monitoring results. The specific continuous monitoring results include risk results and safety results. Step 3: Analyze the generated abnormal results, analyze the associated parameters of the working parameters, and adjust the abnormal results based on the influence of the associated parameters, and generate control information based on the influencing factors; Step 4: Display the acquired risk results, safety results and control information to the corresponding operators.

[0014] The present invention provides a safety control system and method for a methanol production process. Compared with the prior art, it has the following beneficial effects: Through the cooperation of the equipment parameter acquisition unit and the production safety analysis unit, the present invention can accurately obtain the equipment working data, compare it with the preset parameters, and clearly judge whether the production process is normal or abnormal, providing a basis for subsequent analysis. The normal production analysis unit performs periodic continuous monitoring of normal results and calculates the risk index. Combined with historical data, it can discover potential risks in advance, ensure the safety of the production process in a seemingly normal state, and avoid accidents caused by the accumulation of potential risks. When facing abnormal results, the abnormal production analysis unit deeply analyzes the relationship between abnormal data and related parameters, comprehensively considers multiple factors to calculate control parameters, and generates accurate regulation information, which helps to quickly and effectively solve abnormal problems and reduce the impact of abnormalities on production. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 This is a block diagram of the system principle of the present invention; Figure 2 It is a flow chart of the steps of the present invention. DETAILED DESCRIPTION

[0016] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0017] For example, see Figure 1 The present application provides a methanol production process safety control system, including: an equipment parameter acquisition unit, a production safety analysis unit, a production normal analysis unit, a production abnormal analysis unit and a control information output unit, and at the same time combines Figure 1 It can be known that the above functional units are electrically connected in a unidirectional manner.

[0018] Equipment parameter acquisition unit, which is used to acquire the working data of the equipment, and the working data is acquired by different sensors. The specific working data includes pressure, temperature, flow and liquid level data. At the same time, the acquired working data is transmitted to the production safety analysis unit.

[0019] A production safety analysis unit is used to compare the acquired working data with predetermined parameters, analyze the state of the production process, and generate state analysis results, wherein the state analysis results include normal results and abnormal results.

[0020] The working data is obtained, and the predetermined parameters are obtained at the same time. The specific values ​​of the predetermined parameters here are set by the operator. For example, the methanol synthesis reaction is generally carried out between 230-280°C, and its operating pressure is generally 5-10MPa. The obtained working data is compared with the predetermined parameters. If the working data is different from the predetermined parameters, it means that the state of the production process is abnormal and an abnormal result is generated. On the contrary, if the working data is the same as the predetermined parameters, it means that the state of the production process is normal and a normal result is generated.

[0021] In a specific example, if the temperature value in the working data is lower than 230°C or higher than 280°C, or the pressure value is lower than 5MPa or higher than 10MPa, these situations mean that there is an abnormality in the state of the production process. For example, if the working data shows that the temperature is 300°C, which obviously exceeds the predetermined temperature range, the system will generate a corresponding abnormal result.

[0022] Then the generated normal result is transmitted to the production normal analysis unit, and the generated abnormal result is transmitted to the production abnormal analysis unit.

[0023] The normal production analysis unit is used to analyze the normal results obtained by periodically monitoring the working data, calculating the risk index corresponding to the working data, and analyzing the risk index in combination with historical data to generate continuous monitoring results. The specific continuous monitoring results include risk results and safety results.

[0024] Obtain working data, and monitor the working data with time t as a period, obtain the change of working data within time period t, and calculate the change value corresponding to the working data, and the change value here represents the change value of all working data, such as temperature change value, pressure change value, etc. Then obtain historical data similar to the change of working data and record it as similar record, and label it as i, and i=1, 2, ..., j, where j represents the number of similar records, and the specific similar record is represented as the historical data with the same change value as the current working data, and the same change value means that the change values ​​of the two are within a predetermined range. For example, the change value of the temperature of the current working data is 10°C, and the data obtained in the historical data that differs from the change value of 10°C by 5°C is recorded as a similar record, and the similar record i is screened to obtain the risk similar record a, and a=1, 2, ..., b, where b represents the number of risk similar records, and the specific risk similar record a is represented as a record with potential risk, and the specific risk is set by the operator; Then obtain the change value corresponding to the risk similar record a, recorded as Ka, and the change value here is the change value in the same time, and the change value Ka here is the sum of the change values ​​of all acquired data, and obtain the risk level value of the risk similar record a, recorded as Fa, and the risk level value here is obtained according to the corresponding risk level. The risk level is set by the operator, where the risk level is from level one to level three, and the specific corresponding values ​​are 1, 2 and 3. At the same time, substitute the obtained parameters into the formula The risk value Da corresponding to the risk-similar record a is calculated, where is the proportion of risk-similar records, It is a preset proportional coefficient, the value is set by the operator, and the average of the risk values ​​Da of all risk-similar records is calculated, and the calculated average is used as the risk index D1; Similarly, the above calculation method calculates the risk index D2 corresponding to the working data, and compares the risk index D1 with the risk index D2. If the risk index D1 is greater than or equal to the risk index D2, it means that the working data is normal within the time period t, and a safety result is generated. Otherwise, if the risk index D1 is less than the risk index D2, it means that the working data is abnormal within the time period t, and a risk result is generated. The generated safety result or risk result is transmitted to the control information output unit.

[0025] A control information output unit is used to display the acquired safety results or risk results to the corresponding operator.

[0026] Embodiment 2, as Embodiment 2 of the present invention, is implemented on the basis of Embodiment 1, and differs from Embodiment 1 in that: The production abnormality analysis unit is used to analyze the abnormal results obtained, analyze the associated parameters of the working parameters, adjust the abnormal results based on the influence of the associated parameters, and generate control information based on the comprehensive influencing factors.

[0027] Analyze the generated abnormal results. First, obtain the corresponding working data, and obtain the abnormal data in the working data and record it as V. The abnormal parameters here represent data that is different from the predetermined parameters. Then calculate the difference between the abnormal data and the predetermined parameters and record it as the difference to be adjusted and record it as B. At the same time, obtain historical data, and analyze the associated data of the abnormal data based on the historical data. For example, the abnormal data here is temperature. Through the analysis of historical data, it is found that the associated data of temperature is pressure, then the pressure is marked as associated data. Then analyze the associated value between the abnormal data and the associated data and record it as Go, and o=1, 2, ..., p, where p represents different associated data labels. The associated value here represents the change of the associated data corresponding to the change of the abnormal data, and they are all changes under unit values. Substitute the obtained parameters into the formula The control parameter V1 is calculated, and It is a preset proportional coefficient, and the specific value is set by the operator; The control information is generated based on the obtained control parameter V1, and the adjustment is performed according to the control, and the adjusted production process is continuously monitored. The specific monitoring process is the same as the processing method in Example 1, and then the generated control information is transmitted to the control information output unit.

[0028] A control information output unit is used to display the acquired control information to the corresponding operator.

[0029] Embodiment 3, as the embodiment 3 of the present invention, focuses on combining the implementation processes of embodiment 1 and embodiment 2 for implementation.

[0030] Example 4, please refer to Figure 2 The present application provides a method for safety control of a methanol production process, which specifically comprises the following steps: Step 1: Obtain working data and compare it with predetermined parameters to generate normal results or abnormal results; Step 2: Analyze the generated normal results by periodically and continuously monitoring the working data, calculating the risk index corresponding to the working data, and analyzing the risk index in combination with historical data to generate continuous monitoring results. The specific continuous monitoring results include risk results and safety results, and the specific analysis method is the same as the processing method of the production normal analysis unit in Example 1; Step 3: Analyze the generated abnormal result, analyze the associated parameters of the working parameters, and adjust the abnormal result in combination with the influence of the associated parameters, and generate control information based on the influencing factors. The specific analysis method is the same as the processing method of the production abnormality analysis unit in Example 2; Step 4: Display the acquired risk results, safety results and control information to the corresponding operators.

[0031] Meanwhile, the contents not described in detail in this specification belong to the prior art known to those skilled in the art.

[0032] The above embodiments are only used to illustrate the technical method of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical method of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical method of the present invention.

Claims

1. Methanol production process safety control system, characterized by: include: The equipment parameter acquisition unit is used to acquire the working data of the equipment and transmit the acquired working data to the production safety analysis unit; A production safety analysis unit, used to compare the acquired working data with predetermined parameters, analyze the state of the production process, and generate a state analysis result, wherein the state analysis result includes a normal result and an abnormal result; The normal production analysis unit is used to analyze the normal results obtained. It continuously monitors the working data periodically, calculates the risk index corresponding to the working data, and analyzes the risk index in combination with historical data to generate continuous monitoring results. The specific continuous monitoring results include risk results and safety results. The production anomaly analysis unit is used to analyze the acquired abnormal results, analyze the associated parameters of the working parameters, adjust the abnormal results based on the influence of the associated parameters, and generate control information based on the comprehensive influencing factors.

2. The methanol production process safety control system according to claim 1, characterized in that: The working parameters acquired by the equipment parameter acquisition unit include pressure, temperature, flow rate and liquid level data, which are acquired by corresponding sensors respectively.

3. The methanol production process safety control system according to claim 1, characterized in that: The specific method of generating the status analysis result by the production safety analysis unit is as follows: Acquire working data and predetermined parameters at the same time, and compare the acquired working data with the predetermined parameters. If the working data is different from the predetermined parameters, it indicates that the state of the production process is abnormal, and an abnormal result is generated. On the contrary, if the working data is the same as the predetermined parameters, it indicates that the state of the production process is normal, and a normal result is generated; Then the generated normal result is transmitted to the production normal analysis unit, and the generated abnormal result is transmitted to the production abnormal analysis unit.

4. The methanol production process safety control system according to claim 1, characterized in that: The specific method for the normal production analysis unit to analyze the normal results is: Obtain work data, monitor the work data with time t as a period, obtain the change of work data within time period t, and calculate the change value corresponding to the work data, then obtain historical data similar to the change of work data and record it as similar records, and label it as i, where i=1, 2, j, where j represents the number of similar records, and at the same time screen the similar record i to obtain risk similar record a, where a=1, 2, ..., b, where b represents the number of risk similar records; Then obtain the change value corresponding to the risk similar record a, record it as Ka, and obtain the risk level value of the risk similar record a, record it as Fa, and substitute the obtained parameters into the formula The risk value Da corresponding to the risk-similar record a is calculated, where is the proportion of risk-similar records, It is a preset proportional coefficient, the value is set by the operator, and the average of the risk values ​​Da of all risk-similar records is calculated, and the calculated average is used as the risk index D1; Similarly, the above calculation method is used to calculate the risk index D2 corresponding to the work data, and the risk index D1 is compared with the risk index D2 to generate a continuous monitoring result.

5. The methanol production process safety control system according to claim 4, characterized in that: The specific method for the normal production analysis unit to analyze the risk index and generate continuous monitoring results is: If the risk index D1 is greater than or equal to the risk index D2, a safety result is generated. Otherwise, if the risk index D1 is less than the risk index D2, a risk result is generated and the generated safety result or risk result is transmitted to the control information output unit.

6. The methanol production process safety control system according to claim 1, characterized in that: The specific method for the production abnormality analysis unit to analyze the abnormal result is: Analyze the generated abnormal results. First, obtain the corresponding working data, and obtain the abnormal data in the working data, record it as V. Then calculate the difference between the abnormal data and the predetermined parameter, record it as the difference to be adjusted, record it as B. At the same time, obtain historical data, analyze the associated data of the abnormal data based on the historical data, and then analyze the associated value between the abnormal data and the associated data, record it as Go, and o=1, 2, ..., p, where p represents different associated data labels. Substitute the obtained parameters into the formula The control parameter V1 is calculated, and The proportional coefficient is preset, and the specific value is set by the operator, and the generated control information is transmitted to the control information output unit.

7. The methanol production process safety control system according to claim 1, characterized in that: It also includes a control information output unit for displaying the acquired continuous monitoring results and control information to corresponding operators.

8. A methanol production process safety control method, used to implement the methanol production process safety control system according to any one of claims 1 to 7, characterized in that: The method specifically comprises the following steps: Step 1: Obtain working data and compare it with predetermined parameters to generate normal results or abnormal results; Step 2: Analyze the generated normal results by periodically monitoring the work data, calculating the risk index corresponding to the work data, and analyzing the risk index in combination with historical data to generate continuous monitoring results. The specific continuous monitoring results include risk results and safety results. Step 3: Analyze the generated abnormal results, analyze the associated parameters of the working parameters, and adjust the abnormal results based on the influence of the associated parameters, and generate control information based on the influencing factors; Step 4: Display the acquired risk results, safety results and control information to the corresponding operators.

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