Real-time monitoring and automatic injection control system for solving large time delay

Abstract

The invention relates to the technical field of production monitoring, in particular to a real-time monitoring and automatic injection control system for solving large time delay, which comprises a data collection module, a risk analysis module, an automatic injection module and an injection effect analysis module. According to the method, the corrosion risk change trend is accurately identified through trend analysis and time sequence prediction, potential hazards can be pre-judged before the risk reaches a critical value, the production stability is improved, and after the corrosion risk is identified, the chemical substance concentration is maintained within a specific range by dynamically adjusting the equipment parameters and the injection amount of the additive, so that the production efficiency is improved. According to the method, corrosion protection is more accurate, production potential safety hazards and resource waste caused by excessive or insufficient additives are reduced, based on real-time data feedback and tracking analysis of the injection effect, a maintenance decision has higher flexibility and timeliness, the equipment maintenance period can be optimized according to the additive effect, and the maintenance efficiency is improved. And unnecessary shutdown maintenance times are reduced.

Description

Technical Field

[0001] The invention relates to the technical field of production monitoring, and in particular to a real-time monitoring and automatic injection control system for solving large time lag. Background Art

[0002] The field of production monitoring technology focuses on real-time monitoring and control of industrial production processes through sensor technology, data acquisition systems and analytical tools. The field of production monitoring uses a variety of sensors to detect physical and chemical parameters on the production line, such as temperature, pressure, humidity, chemical composition, etc. By collecting data, the system can continuously observe the production process and promptly identify and predict potential production deviations or failures. In addition, production monitoring also includes the use of automation software and control algorithms to optimize production efficiency and quality, reduce energy consumption, and improve the operational safety of equipment.

[0003] Among them, the real-time monitoring and automatic injection control system that solves large time lags is designed to solve the corrosion monitoring and control challenges faced in extreme industrial environments such as chemical plants or refineries. The main purpose of the system is to quickly and accurately detect and respond to corrosion and other potential risks in the production process through real-time data monitoring. The system uses a sensor network to collect key indicator data in real time, such as temperature, chemical concentration, and flow rate, and predicts the corrosion risk of equipment through data analysis. When the risk reaches a certain threshold, the system can automatically adjust the operating parameters of industrial equipment or inject additives to prevent or reduce corrosion conditions, ensuring the continuity of the production process and the long-term operation stability of the equipment.

[0004] Traditional control systems rely on simple threshold judgments during the control process and are unable to accurately predict the development trend of corrosion risks, resulting in the system being able to respond only when the risk approaches or reaches a critical value, lacking the ability to take precautions in advance. In terms of corrosion control measures, traditional systems are difficult to accurately control the injection amount of chemical additives, which can cause uneven or excessive use of additives, increasing production costs and the instability of corrosion protection. Summary of the invention

[0005] The purpose of the present invention is to solve the shortcomings existing in the prior art and to propose a real-time monitoring and automatic injection control system that can solve the large time lag.

[0006] In order to achieve the above object, the present invention adopts the following technical solution: a real-time monitoring and automatic injection control system for solving large time delay, the system comprising: The data collection module is based on the sensor network of industrial equipment, and monitors the temperature, chemical concentration, and flow rate data of key parts of industrial equipment in real time. It automatically records the data and converts it into a time series format, removes outliers and cleans background noise from the time series data, and standardizes the cleaned data to unify the data format and range to obtain standardized real-time data. The risk analysis module is based on the standardized real-time data, analyzes the data within a period of time, identifies the data change trend, and evaluates the corrosion risk level in the future period according to the data change trend to obtain the corrosion risk assessment result; The automatic injection module adjusts the operating parameters of the equipment according to the risk level based on the corrosion risk assessment result, and calculates the amount of chemical additives added under the current environment. According to the calculation result, the injection amount of the additive is controlled by PID to maintain the concentration of the target substance within a predetermined range, and obtains the injection operation log; The injection effect analysis module evaluates the injection effect of the chemical additive based on the injection operation log by analyzing the real-time data, adjusts the maintenance cycle of the equipment according to the injection effect of the chemical additive, and obtains the equipment maintenance management information.

[0007] The present invention is improved in that the step of acquiring the standardized real-time data is: Based on the sensor network of industrial equipment, the temperature, chemical concentration and flow rate data of key parts of industrial equipment are monitored in real time, and the data are automatically recorded and converted into time series format to obtain time series conversion data; Convert the data based on the time series, by the formula: ; Calculate the normalized value of the data ,in, For the The standardized value of the data, Indicates data values, is the mean value of the data, is the standard deviation of the data, is the stability constant; Based on the normalized values ​​of the data , through the formula: ; Calculates the normalized value after range conversion , get standardized real-time data, where For the The standardized value of the data, For the The standardized value after data range conversion, is the stability constant, is the range coefficient.

[0008] The present invention is improved in that the method for identifying the data change trend is: Based on the standardized real-time data, extract data within a period of time, and obtain the timestamp corresponding to the data to obtain a data extraction result; Based on the data extraction results, the formula is: ; Calculate the data change rate and obtain the data change trend analysis results, where: and The time points and The data value of is the data change rate, is the base of natural logarithms, is the number of data points in the time window, is the attenuation coefficient.

[0009] The present invention is improved in that the steps of obtaining the corrosion risk assessment result are: Based on the data change trend analysis results, extract the change rates of the equipment temperature, chemical substance concentration and flow rate to obtain a change rate extraction result; Based on the change rate extraction result, combined with the time length of the target period and the current period, the formula is: ; Calculate the corrosion risk level value for the target period , and obtain the corrosion risk assessment results, where and are the rates of change of temperature, chemical concentration and flow rate, respectively. is the time length from the target period to the current period, and is the weight coefficient, is the corrosion risk level value.

[0010] The present invention is improved in that the method for adjusting the operating parameters of the equipment is: Based on the corrosion risk assessment results, combined with the temperature change rate, the formula: ; Calculating Temperature Adjustment ,in, Indicates the temperature adjustment amount, is the corrosion risk level, is the rate of change of temperature, is the temperature adjustment factor; Based on the corrosion risk assessment results, combined with the rate of change of flow velocity, the formula is: ; Calculate flow rate adjustment ,in, is the flow rate adjustment, is the flow rate adjustment factor, is the corrosion risk level, is the rate of change of flow velocity; Based on the temperature adjustment and flow rate adjustment , adjust the operating status of the equipment and obtain the equipment operation adjustment result.

[0011] The present invention is improved in that the steps of obtaining the injection operation log are: Based on the equipment operation adjustment results and the corrosion risk assessment results, extract the current operating temperature and flow rate, and extract the concentration change rate of the chemical substance to obtain dose correlation data; Based on the dose-related data, the formula: ; Calculate theoretical additive dosage ,in, is the base chemical additive dosage, is the corrosion risk level value, is the rate of change of chemical concentration, and are the current reaction temperature and flow rate, respectively. and is the adjustment factor, and are the adjustment indexes of temperature and flow rate, respectively. and are the reference temperature and reference flow rate, respectively, is the theoretical additive addition amount; Based on the theoretical additive addition amount , by controlling the injection amount of additives through PID, the concentration of target substances is maintained within the predetermined range, and the injection operation log is obtained.

[0012] The present invention is improved in that the method for evaluating the injection effect of chemical additives is: Based on the injection operation log, extract the real-time data in the reaction process, record the time point when the concentration of the chemical substance exceeds the predetermined range, calculate the duration when the concentration of the chemical substance exceeds the predetermined range, and obtain the duration recording result; Based on the duration recorded results, by the formula: ; Calculating injection effectiveness score , and get the injection effect evaluation results, where Score the injection effect. is the weight coefficient for exceeding the value, is the weight coefficient of the exceeded time, is the current chemical concentration, is the preset minimum concentration, is the preset maximum concentration, The duration that the preset range is exceeded.

[0013] The present invention is improved in that the step of acquiring the equipment maintenance management information is: Based on the injection effect evaluation result, current temperature, chemical substance concentration and flow rate data are collected, and basic maintenance cycle of the equipment is collected to obtain equipment maintenance related data; Based on the device maintenance associated data, through the formula: ; Calculate adjusted equipment maintenance cycles , get equipment maintenance management information, where, For the adjusted equipment maintenance cycle, As the basic maintenance cycle, is the current chemical concentration, is the current reaction temperature, is the current flow rate, and is the weight coefficient, Score the injection effect. is the attenuation coefficient, is the base of natural logarithms.

[0014] Compared with the prior art, the advantages and positive effects of the present invention are: In the present invention, through trend analysis and time series prediction, the trend of corrosion risk changes can be accurately identified, potential hidden dangers can be predicted before the risk reaches a critical value, and production stability can be improved. After the corrosion risk is identified, the equipment parameters and the injection amount of additives are dynamically adjusted to maintain the concentration of chemical substances within a specific range, making corrosion protection more accurate and reducing production safety hazards and resource waste caused by excessive or insufficient additives. Based on real-time data feedback and tracking analysis of injection effects, maintenance decisions have higher flexibility and timeliness, and the equipment maintenance cycle can be optimized according to the effect of additives to reduce unnecessary shutdown maintenance times. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a schematic diagram of the system module of the present invention; Figure 2 A flow chart for obtaining standardized real-time data for the present invention; Figure 3 A flow chart for identifying data change trends for the present invention; Figure 4 A flow chart for obtaining corrosion risk assessment results for the present invention; Figure 5 A flow chart for adjusting the operating parameters of the device for the present invention; Figure 6 A flow chart of obtaining an injection operation log for the present invention; Figure 7 A flow chart for evaluating the injection effect of chemical additives for the present invention; Figure 8 This is a flow chart of the present invention for obtaining equipment maintenance management information. DETAILED DESCRIPTION

[0016] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0017] In the description of the present invention, it should be understood that the terms "length", "width", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating positions or positional relationships, are based on the positions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, in the description of the present invention, the meaning of "multiple" is two or more, unless otherwise clearly and specifically defined.

[0018] See also Figure 1 The present invention provides a technical solution: a real-time monitoring and automatic injection control system for solving large time delays, the system comprising: The data collection module is based on the sensor network of industrial equipment, and monitors the temperature, chemical concentration, and flow rate data of key parts of industrial equipment in real time. It automatically records the data and converts it into a time series format, removes outliers and cleans background noise from the time series data, and standardizes the cleaned data to unify the data format and range to obtain standardized real-time data. The risk analysis module is based on standardized real-time data. By analyzing the data over a period of time, the data change trend is identified. According to the data change trend, the corrosion risk level in the future period is evaluated to obtain the corrosion risk assessment result. Based on the corrosion risk assessment results, the automatic injection module adjusts the equipment's operating parameters according to the risk level and calculates the amount of chemical additives added under the current environment. Based on the calculation results, the injection amount of the additives is controlled by PID to maintain the concentration of the target substance within the predetermined range and obtain the injection operation log; The injection effect analysis module is based on the injection operation log. By analyzing real-time data, it evaluates the injection effect of chemical additives, adjusts the maintenance cycle of the equipment according to the injection effect of the chemical additives, and obtains equipment maintenance management information.

[0019] Standardized real-time data includes temperature data series, chemical concentration data series and flow rate data series. The corrosion risk assessment results include corrosion trend prediction information, key influencing factor information and risk level classification. The injection operation log includes injection time, injection volume records and adjusted equipment operating parameters. Equipment maintenance management information includes maintenance cycle adjustment information and corresponding maintenance measures.

[0020] Target substances include phosphate, pH and dissolved oxygen: By controlling the phosphate concentration, the alkalinity of boiler water can be effectively adjusted to prevent the formation of hard scale by minerals such as calcium and magnesium. Hard scale accumulates on the inner wall of the boiler, which will reduce thermal efficiency and cause premature aging and damage to the equipment. Phosphates react with hard scale forming elements to form soluble complexes that are easily discharged, keeping the boiler clean and efficient. In addition, an appropriate amount of phosphate can also form a protective film on the metal surface to prevent corrosion and erosion. The phosphate concentration should be controlled at 3 to 5 mg / L.

[0021] Maintaining an appropriate pH value is essential to prevent acidic or alkaline corrosion and protect the metal parts in the boiler. A pH value that is too low will accelerate metal corrosion and damage boiler pipes and other parts, while a pH value that is too high will cause alkaline corrosion, which also threatens equipment safety. Regular monitoring and adjustment of the pH value can improve the safety and economic benefits of boiler operation, reduce maintenance costs, and extend the service life of equipment. The pH value of boiler water should be maintained between 10 and 11.

[0022] Dissolved oxygen in boiler feed water can promote metal oxidation and rust when it comes into contact with metal surfaces, damaging the integrity of boiler pipes and other metal structures. Effective control of dissolved oxygen is the key to preventing expensive equipment maintenance and repairs. By using deoxidizers, dissolved oxygen can be removed from boiler feed water, protecting the system from corrosion, extending equipment life, and ensuring efficient and safe operation of the boiler system. The concentration of dissolved oxygen should be less than 0.007 mg / L.

[0023] See also Figure 2 ,The steps for obtaining standardized real-time data are: Based on the sensor network of industrial equipment, the temperature, chemical concentration and flow rate data of key parts of industrial equipment are monitored in real time, and the data are automatically recorded and converted into time series format to obtain time series conversion data; Based on the time series conversion data, the formula is: ; Calculate the normalized value of the data ,in, For the The standardized value of the data, Indicates data values, is the mean value of the data, is the standard deviation of the data, is the stability constant; Normalized values ​​based on data , through the formula: ; Calculates the normalized value after range conversion , get standardized real-time data, where For the The standardized value of the data, For the The standardized value after data range conversion, is the stability constant, is the range coefficient.

[0024] formula: ; and ; Parameter details and how to obtain them: Mean : Data mean It is calculated by calculating the average of all the data points in a data set. This is the most basic calculation in statistics and is done by adding up all the values ​​in a data set and then dividing by the number of data points. The mean provides the central location of the data points in a data set and is a key reference value in the normalization process.

[0025] Standard Deviation : The standard deviation of a data set is a measure of how much the data points deviate from the mean and is calculated using the standard deviation formula.

[0026] Small constant and :constant and They are introduced to prevent division by zero during calculations. These constants are usually set to very small positive numbers to ensure the stability and continuity of mathematical operations.

[0027] Range factor :Used to control The value range is set according to requirements.

[0028] Calculation example: Set the data set to , calculate the normalized value of the data point.

[0029] Calculate the mean : ; Calculate standard deviation : ; Calculate the normalized value for each data point : for : ; for : ; for : ; Calculate the range-transformed normalized value for each data point : for : ; for : ; for : ; The calculation example shows that the original data points 10, 30, and 50 are converted to 0, 0.5, and 1 respectively after normalization and range conversion.

[0030] See also Figure 3 , the method to identify the trend of data changes is: Based on standardized real-time data, extract data within a period of time, obtain the timestamp corresponding to the data, and obtain the data extraction results; Based on the data extraction results, through the formula: ; Calculate the data change rate and obtain the data change trend analysis results, where: and The time points and The data value of is the data change rate, is the base of natural logarithms, is the number of data points in the time window, is the attenuation coefficient.

[0031] formula: ; Parameter details and how to obtain them: Data Value and : It is the data value of continuous time points, directly obtained from the standardized real-time data set. Indicates at a point in time The data value is used to calculate the next time point difference.

[0032] is the attenuation coefficient, a parameter used to adjust the curvature, usually set according to the characteristics of the data set. In data analysis, it is used to ensure that the weight of data decreases over time, but does not lose focus on early data too quickly.

[0033] The number of data points in the time window : This is the total number of data points considered in the analysis and can be determined based on the availability of data and the required accuracy of the analysis.

[0034] Calculation example: Set the data set to , the corresponding time point ,choose and To calculate the data change trend.

[0035] calculate : ; Calculate data weight (set the previous time point ): ; ; calculate : ; Calculation results This means that within the analyzed time window, the average rate of change of the data per time unit is 0.3. This weighted average method ensures that the contribution of recent data changes to the overall trend is appropriately emphasized, providing a quantitative indicator based on historical data for assessing the corrosion risk level in future periods.

[0036] See also Figure 4 , the steps to obtain the corrosion risk assessment results are: Based on the data change trend analysis results, the change rates of equipment temperature, chemical substance concentration and flow rate are extracted to obtain the change rate extraction results; Based on the change rate extraction results, combined with the time length of the target period and the current period, the formula is: ; Calculate the corrosion risk level value for the target period , and obtain the corrosion risk assessment results, where and are the rates of change of temperature, chemical concentration and flow rate, respectively. is the time length from the target period to the current period, and is the weight coefficient, is the corrosion risk level value.

[0037] formula: ; Parameter details and how to obtain them: Rate of change and : Rate represents the change of temperature, chemical concentration and flow rate with time, which is calculated by the previous method.

[0038] Weight Parameters and : The weight parameters are customized based on historical data and sensitivity analysis of corrosion risks. Each parameter is adjusted according to its corresponding monitoring variable (temperature, chemical concentration, flow rate) to ensure that the risk assessment model can accurately reflect the risk contribution of different factors.

[0039] The length of time from the future period to the current period : The parameter reflects the length from the current time point to the future time point.

[0040] Calculation example: Set the change rate to , , , the time length from the future period to the current period is 10 minutes. The weight parameter is set to , , .

[0041] Calculate the corrosion risk level: ; Calculation results , indicating that under the given parameters, the corrosion risk level in the future period is 0.0504, reflecting the risk assessment after considering the influence of monitoring parameters and time length.

[0042] See also Figure 5 , the method to adjust the operating parameters of the equipment is: Based on the corrosion risk assessment results and combined with the temperature change rate, the formula is: ; Calculating Temperature Adjustment ,in, Indicates the temperature adjustment amount, is the corrosion risk level, is the rate of change of temperature, is the temperature adjustment factor; Based on the corrosion risk assessment results and combined with the rate of change of flow velocity, the formula is: ; Calculate flow rate adjustment ,in, is the flow rate adjustment, is the flow rate adjustment factor, is the corrosion risk level, is the rate of change of flow velocity; Temperature-based adjustment and flow rate adjustment , adjust the operating status of the equipment and obtain the equipment operation adjustment result.

[0043] formula: ; and ; Parameter details and how to obtain them: Adjustment factor and :The coefficient is used to control the sensitivity of temperature and flow rate adjustment. In actual application, the setting of the coefficient depends on the response characteristics of the equipment and the stability of the operating environment. The coefficient is set based on previous operating experience and engineering judgment.

[0044] Corrosion risk level : Calculated by the previous method.

[0045] Rate of change of temperature and flow rate and : Calculate the degree of gain by the previous method.

[0046] Calculation example: Set adjustment factor and , corrosion risk level , temperature change rate , flow rate change rate .

[0047] Temperature adjustment calculation: ; Flow rate adjustment calculation: ; The calculation results show that it is necessary to cool down the system in response to the increase in temperature, and to increase the flow rate in response to the decrease in flow rate.

[0048] See also Figure 6 , the steps to obtain the injection operation log are: Based on the equipment operation adjustment results and corrosion risk assessment results, the current operating temperature and flow rate are extracted, and the concentration change rate of the chemical substances is extracted to obtain the dose correlation data; Based on the dose-related data, the formula: ; Calculate theoretical additive dosage ,in, is the base chemical additive dosage, is the corrosion risk level value, is the rate of change of chemical concentration, and are the current reaction temperature and flow rate, respectively. and is the adjustment factor, and are the adjustment indexes of temperature and flow rate, respectively. and are the reference temperature and reference flow rate, respectively, is the theoretical additive addition amount; Based on theoretical additive dosage , by controlling the injection amount of additives through PID, the concentration of target substances is maintained within the predetermined range, and the injection operation log is obtained.

[0049] formula: ; Parameter details and how to obtain them: Benchmark chemical additive dosage : Based on manufacturer recommendations or determined from past operating experience. Represents the baseline amount of chemical additives required under standard conditions without considering additional corrosion risk factors.

[0050] Corrosion risk level : Calculated by the previous steps.

[0051] The rate of change of chemical concentration : Calculated by the previous steps.

[0052] Current reaction temperature and flow rate and Directly obtain sensor readings from field equipment, reflecting the temperature and flow conditions under which the equipment is currently operating.

[0053] Adjustment factors and indices and :The coefficients and indices are determined based on historical data analysis, equipment performance testing and chemical reaction kinetics research. The influence of each variable on the final additive dosage is adjusted to adapt to different operating conditions and environmental changes.

[0054] Reference temperature and reference flow rate and Usually set at a standard temperature and flow rate for equipment design or typical operating conditions and used as a reference point for calculations.

[0055] Calculation example: Setting a benchmark dose , corrosion risk level , the rate of change of chemical concentration , current temperature , reference temperature , current flow rate , reference flow rate , adjustment coefficient , ,index , .

[0056] Calculate the amount of chemical additives: ; ; Calculated dosage of chemical additives , which means that under current conditions, the baseline dose needs to be increased by approximately 23.72% to cope with the corrosion risk. The increase reflects the current corrosion risk, the rate of increase in chemical concentrations, and changes in environmental conditions.

[0057] See also Figure 7, the method for evaluating the injection effect of chemical additives is: Based on the injection operation log, extract the real-time data in the reaction process, record the time point when the concentration of the chemical substance exceeds the predetermined range, calculate the duration when the concentration of the chemical substance exceeds the predetermined range, and obtain the duration recording result; The results are recorded based on the duration, using the formula: ; Calculating injection effectiveness score , and get the injection effect evaluation results, where Score the injection effect. is the weight coefficient for exceeding the value, is the weight coefficient of the exceeded time, is the current chemical concentration, is the preset minimum concentration, is the preset maximum concentration, The duration that the preset range is exceeded.

[0058] formula: ; Parameter meaning and acquisition method: : Weight coefficient of the excess value, used to adjust the impact of the excess concentration value on the effect score, set according to needs.

[0059] : Weight coefficient of the exceeded time, used to adjust the impact of duration on the effect score, set according to demand.

[0060] :Current chemical concentration is obtained in real time through online monitoring instruments.

[0061] : The preset minimum concentration.

[0062] : The preset maximum concentration.

[0063] : Duration beyond the preset range, recorded through real-time monitoring data, and starts timing when the concentration exceeds the range.

[0064] Calculation example: set up , , , , , minute.

[0065] Calculate out-of-range values: ; Calculate the performance score: ; The injection effect score , indicating that the current injection effect of chemical additives is poor because its concentration exceeds the preset range and lasts for a long time, indicating that the injection strategy needs to be adjusted in time to optimize the injection effect of chemical substances and maintain the safety and stability of the equipment.

[0066] See also Figure 8 , the steps to obtain equipment maintenance management information are: Based on the injection effect evaluation results, collect the current temperature, chemical concentration and flow rate data, and collect the basic maintenance cycle of the equipment to obtain equipment maintenance related data; Based on the equipment maintenance related data, through the formula: ; Calculate adjusted equipment maintenance cycles , get equipment maintenance management information, where, For the adjusted equipment maintenance cycle, As the basic maintenance cycle, is the current chemical concentration, is the current reaction temperature, is the current flow rate, and is the weight coefficient, Score the injection effect. is the attenuation coefficient, is the base of natural logarithms.

[0067] formula: ; Detailed explanation of formula parameters: : Basic maintenance cycle, usually provided by the equipment manufacturer, reflects the recommended maintenance frequency of the equipment under normal operating conditions. For example, the basic maintenance cycle of a certain equipment is 180 days.

[0068] : Current chemical concentration, obtained through the online monitoring system, for example, 2PPM.

[0069] : Current reaction temperature, obtained through real-time monitoring.

[0070] : Current flow rate, obtained through real-time monitoring.

[0071] and : Weight coefficient, which indicates the impact of each factor on the risk and is set according to demand.

[0072] : Injection effect score, obtained through previous deployment calculation.

[0073] : Attenuation coefficient, which determines how the damage risk affects the maintenance cycle. It is adjusted and set according to needs to control the sensitivity of the exponential part.

[0074] Calculation example: Set the maintenance period of a certain equipment to be calculated. The known data are as follows: sky, , , , , , , , .

[0075] Calculate the adjusted maintenance interval : ; Calculation results Days means that under the current environment and conditions, the maintenance cycle of the equipment should be adjusted to approximately 122 days to maintain equipment performance and extend its service life. This cycle adjustment is based on the current operating conditions of the equipment, the effectiveness of chemical additives, and the potential risk of damage.

[0076] The above are only preferred embodiments of the present invention and are not intended to limit the present invention in other forms. Any technician familiar with the profession may use the technical contents disclosed above to change or modify them into equivalent embodiments with equivalent changes and apply them to other fields. However, any simple modification, equivalent change and modification made to the above embodiments based on the technical essence of the present invention without departing from the technical solution of the present invention still falls within the protection scope of the technical solution of the present invention.

Claims

1. A real-time monitoring and automatic injection control system for solving large time delays, characterized in that: The system comprises: The data collection module is based on the sensor network of industrial equipment, and monitors the temperature, chemical concentration, and flow rate data of key parts of industrial equipment in real time. It automatically records the data and converts it into a time series format, removes outliers and cleans background noise from the time series data, and standardizes the cleaned data to unify the data format and range to obtain standardized real-time data. The risk analysis module is based on the standardized real-time data, analyzes the data within a period of time, identifies the data change trend, and evaluates the corrosion risk level in the future period according to the data change trend to obtain the corrosion risk assessment result; The automatic injection module adjusts the operating parameters of the equipment according to the risk level based on the corrosion risk assessment result, and calculates the amount of chemical additives added under the current environment. According to the calculation result, the injection amount of the additive is controlled by PID to maintain the concentration of the target substance within a predetermined range, and obtains the injection operation log; The injection effect analysis module evaluates the injection effect of the chemical additive based on the injection operation log by analyzing the real-time data, adjusts the maintenance cycle of the equipment according to the injection effect of the chemical additive, and obtains the equipment maintenance management information.

2. The real-time monitoring and automatic injection control system for solving large time delay according to claim 1 is characterized in that: The steps for obtaining the standardized real-time data are as follows: Based on the sensor network of industrial equipment, the temperature, chemical concentration and flow rate data of key parts of industrial equipment are monitored in real time, and the data are automatically recorded and converted into time series format to obtain time series conversion data; Convert the data based on the time series, by the formula: ； Calculate the normalized value of the data ,in, For the The standardized value of the data, Indicates data values, is the mean value of the data, is the standard deviation of the data, is the stability constant; Based on the normalized values ​​of the data , through the formula: ； Calculates the normalized value after range conversion , get standardized real-time data, where For the The standardized value of the data, For the The standardized value after data range conversion, is the stability constant, is the range coefficient.

3. The real-time monitoring and automatic injection control system for solving large time delay according to claim 2 is characterized in that: The method for identifying data change trends is: Based on the standardized real-time data, extract data within a period of time, and obtain the timestamp corresponding to the data to obtain a data extraction result; Based on the data extraction results, the formula is: ； Calculate the data change rate and obtain the data change trend analysis results, where: and The time points and The data value of is the data change rate, is the base of natural logarithms, is the number of data points in the time window, is the attenuation coefficient.

4. The real-time monitoring and automatic injection control system for solving large time delay according to claim 1 is characterized in that: The steps for obtaining the corrosion risk assessment results are: Based on the data change trend analysis results, extract the change rates of the equipment temperature, chemical substance concentration and flow rate to obtain a change rate extraction result; Based on the change rate extraction result, combined with the time length of the target period and the current period, the formula is: ； Calculate the corrosion risk level value for the target period , and obtain the corrosion risk assessment results, where and are the rates of change of temperature, chemical concentration and flow rate, respectively. is the time length from the target period to the current period, and is the weight coefficient, is the corrosion risk level value.

5. The real-time monitoring and automatic injection control system for solving large time delay according to claim 1 is characterized in that: The method for adjusting the operating parameters of the equipment is: Based on the corrosion risk assessment results, combined with the temperature change rate, the formula: ； Calculating Temperature Adjustment ,in, Indicates the temperature adjustment amount, is the corrosion risk level, is the rate of change of temperature, is the temperature adjustment factor; Based on the corrosion risk assessment results, combined with the rate of change of flow velocity, the formula is: ； Calculate flow rate adjustment ,in, is the flow rate adjustment, is the flow rate adjustment factor, is the corrosion risk level, is the rate of change of flow velocity; Based on the temperature adjustment and flow rate adjustment , adjust the operating status of the equipment and obtain the equipment operation adjustment result.

6. The real-time monitoring and automatic injection control system for solving large time delay according to claim 5 is characterized in that: The steps for obtaining the injection operation log are: Based on the equipment operation adjustment results and the corrosion risk assessment results, extract the current operating temperature and flow rate, and extract the concentration change rate of the chemical substance to obtain dose correlation data; Based on the dose-related data, the formula: ； Calculate theoretical additive dosage ,in, is the base chemical additive dosage, is the corrosion risk level value, is the rate of change of chemical concentration, and are the current reaction temperature and flow rate, respectively. and is the adjustment factor, and are the adjustment indexes of temperature and flow rate, respectively. and are the reference temperature and reference flow rate, respectively, is the theoretical additive addition amount; Based on the theoretical additive addition amount , by controlling the injection amount of additives through PID, the concentration of target substances is maintained within the predetermined range, and the injection operation log is obtained.

7. The real-time monitoring and automatic injection control system for solving large time delay according to claim 1 is characterized in that: The method for evaluating the injection effect of chemical additives is: Based on the injection operation log, extract the real-time data in the reaction process, record the time point when the concentration of the chemical substance exceeds the predetermined range, calculate the duration when the concentration of the chemical substance exceeds the predetermined range, and obtain the duration recording result; Based on the duration recorded results, by the formula: ； Calculating injection effectiveness score , and get the injection effect evaluation results, where Score the injection effect. is the weight coefficient for exceeding the value, is the weight coefficient of the exceeded time, is the current chemical concentration, is the preset minimum concentration, is the preset maximum concentration, The duration that the preset range is exceeded.

8. The real-time monitoring and automatic injection control system for solving large time delay according to claim 7 is characterized in that: The steps for obtaining the equipment maintenance management information are as follows: Based on the injection effect evaluation result, current temperature, chemical substance concentration and flow rate data are collected, and basic maintenance cycle of the equipment is collected to obtain equipment maintenance related data; Based on the device maintenance associated data, through the formula: ； Calculate adjusted equipment maintenance cycles , get equipment maintenance management information, where, For the adjusted equipment maintenance cycle, As the basic maintenance cycle, is the current chemical concentration, is the current reaction temperature, is the current flow rate, and is the weight coefficient, Score the injection effect. is the attenuation coefficient, is the base of natural logarithms.

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