Safety instrument function loop effectiveness monitoring method and system

Abstract

The invention belongs to the field of oil and gas pipeline engineering, particularly relates to a safety instrument function loop effectiveness monitoring method and system, and aims to solve the problem that a safety function instrument loop cannot be monitored on line in real time in the production process. The method comprises the steps that original instrument information of a safety instrument function loop is collected through a safety instrument function loop effectiveness monitoring system, and the original instrument information is stored in a system database; acquiring field safety function instrument diagnosis data through a bus, and inputting the field safety function instrument diagnosis data into a system database; performing fault judgment on the field safety function instrument diagnosis data in the system database according to a preset fault alarm information classification method to obtain a fault judgment result; when the fault judgment result is that a fault occurs, a safety instrument function loop fault alarm is given out; and when the fault judgment result is that no fault occurs, the safety instrument function loop is in a normal use state.

Description

Background Art

[0002] Safety instrument function loops are very important safety control and execution links in the production process. With the development of production process technology, the alarm information generated by the process industry has gradually shifted to centralized and hierarchical alarms. In the context of continuously improving the safety control capabilities of factories, people are paying more and more attention to the effectiveness monitoring of safety instrument function loops in factories. At present, the monitoring of safety instrument function loops in factories is carried out manually through on-site inspections of on-site detection instruments, controllers, and execution units and manual calculations by technicians. This is time-consuming and has poor timeliness.

[0003] The safety instrument function loop effectiveness monitoring method realizes real-time online monitoring of the safety instrument function loop, solves the problem that the safety function instrument loop cannot be monitored online in real time during the production process, improves the safety monitoring capability of the production process, and is an important technical means for safety management and control of the production process technology. Summary of the invention

[0004] In order to solve the above-mentioned problem in the prior art, that is, the problem that the safety function instrument loop cannot be monitored online in real time during the production process, the present invention provides a safety instrument function loop effectiveness monitoring method, the method comprising:

[0005] Step S100, collecting original instrument information of the safety instrument function loop through the safety instrument function loop effectiveness monitoring software, and storing the original instrument information in the system database;

[0006] Step S200, collecting on-site safety function instrument diagnostic data through the bus, and inputting the on-site safety function instrument diagnostic data into the system database;

[0007] Step S300, performing fault determination on the on-site safety function instrument diagnostic data in the system database according to a preset fault alarm information classification method to obtain a fault determination result;

[0008] Step S400: When the fault determination result is that a fault has occurred, a safety instrument function circuit fault alarm is issued; when the fault determination result is that no fault has occurred, the safety instrument function circuit is in a normal commissioning state.

[0009] In some preferred embodiments, the safety instrumented function loop effectiveness monitoring software specifically includes:

[0010] Support HAZOP analysis and SIL classification, output the safety instrument information generated during the work and automatically store it in the database;

[0011] It has equipment failure database and equipment fault database;

[0012] It has the functions of event recording, alarm classification, utilization rate statistics and circuit evaluation;

[0013] It supports document import and can adaptively generate relevant safety table information for each safety instrument function loop in the database.

[0014] In some preferred implementations, the bus specifically includes:

[0015] HART, FF, MODBUS RTU and MODBUSDP / PA multiple fieldbuses.

[0016] In some preferred embodiments, the system database specifically includes:

[0017] The system database has a unified data interface and supports the import of bus protocol parsing file packages FDT and EDDL files.

[0018] In some preferred implementations, the preset fault alarm information classification method specifically includes:

[0019] The fault information is divided into detection instrument fault information, controller fault information and execution unit fault information;

[0020] The fault information of the detection instrument includes sensor open circuit fault, sensor short circuit fault, sensor limit fault, upper limit fault, lower limit fault, ambient temperature fault and other hardware faults.

[0021] Controller fault information includes major fault flag, minor fault flag, communication line fault, module communication fault, voltage reference fault, common input circuit fault, common output circuit fault, auxiliary power connection fault, module configuration error and configuration information error;

[0022] The fault information of the actuator unit includes excessive load torque, excessive closing torque, excessive opening torque, power supply phase sequence detection error, motor temperature exceeding the protection value, handwheel push-in, actuator operation exceeding the limit and wrong operation direction.

[0023] In some preferred implementations, the method for classifying preset fault alarm information further includes:

[0024] Minor fault alarm and major fault alarm;

[0025] Among them, minor fault alarms are alarms that do not affect the realization of safety instrument functions, including diagnostic data and monitoring data exceeding thresholds or abnormal conditions;

[0026] Serious fault alarms are alarms indicating the failure of safety instrument functions, including sensor faults, controller faults, and power supply faults that appear in diagnostic data, which cause the safety instrument to be in a faulty state.

[0027] In some preferred implementations, the fault alarm specifically includes:

[0028] Partial failure alarm and failure alarm;

[0029] Among them, for safety function instruments with redundant or multiple selection mechanisms, partial failure alarm is issued when a single instrument in the safety instrument function loop is in a serious fault;

[0030] Failure alarm For safety instruments with single or redundant mechanisms, when one of the three safety instrument function loops, including the detection instrument, controller, and execution unit, fails, the safety instrument function loop will automatically issue a failure alarm.

[0031] In some preferred embodiments, the method of performing fault determination on the field safety function instrument diagnostic data in the system database according to a preset fault alarm information classification method further includes:

[0032] The failure rate of the equipment in the database, the loop failure rate of the safety instrument function loop and the failure rate of the safety instrument function loop introduced in the database are calculated and compared horizontally.

[0033] In some preferred embodiments, the system database further includes:

[0034] It has the management function of the entire life cycle of the safety instrument function loop, including the use of the safety instrument function loop design, equipment operation, re-calculation after failure, alarm and deactivation.

[0035] Another aspect of the present invention provides a system based on monitoring the effectiveness of safety instrument function loops, comprising: an original instrument information collection module, an on-site safety instrument information collection module, a fault determination module, and a fault alarm module.

[0036] an original instrument information collection module, configured to collect original instrument information of the safety instrument function loop through the safety instrument function loop effectiveness monitoring software, and store the original instrument information in a system database;

[0037] A field safety instrument information collection module is configured to collect field safety function instrument diagnostic data through a bus and input the field safety function instrument diagnostic data into a system database;

[0038] A fault determination module is configured to perform fault determination on the on-site safety function instrument diagnostic data in the system database according to a preset fault alarm information classification method to obtain a fault determination result;

[0039] The fault alarm module is configured to issue a safety instrument function circuit fault alarm when the fault determination result is that a fault has occurred; when the fault determination result is that no fault has occurred, the safety instrument function circuit is in a normal commissioning state.

[0040] Beneficial effects of the present invention: (1) The present invention completes the online real-time monitoring and effectiveness evaluation of the entire safety instrument function loop of the factory by online real-time monitoring of the safety function instrument loop in the production process, provides an effective monitoring and management method for the factory's safety risk control and safety instrument maintenance management, realizes the online real-time monitoring capability of the safety instrument function loop, and improves the safety monitoring capability of the production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Other features, objects and advantages of the present application will become more apparent by reading the detailed description of non-limiting embodiments made with reference to the following drawings:

[0042] Figure 1 It is a flow chart of a method for monitoring the effectiveness of a safety instrument function loop.

[0043] Figure 2 The invention is a judgment flow chart of a method for monitoring the effectiveness of a safety instrument function loop. DETAILED DESCRIPTION

[0044] The present application will be further described in detail below in conjunction with the accompanying drawings and embodiments. It is to be understood that the specific embodiments described herein are only used to explain the relevant invention, rather than to limit the invention. It is also necessary to explain that, for ease of description, only the parts related to the relevant invention are shown in the accompanying drawings.

[0045] It should be noted that, in the absence of conflict, the embodiments and features in the embodiments of the present application can be combined with each other. The present application will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0046] The present invention provides a method for monitoring the effectiveness of a safety instrument function loop, comprising:

[0047] Step S100, collecting original instrument information of the safety instrument function loop through the safety instrument function loop effectiveness monitoring software, and storing the original instrument information in the system database;

[0048] Step S200, collecting on-site safety function instrument diagnostic data through the bus, and inputting the on-site safety function instrument diagnostic data into the system database;

[0049] Step S300, performing fault determination on the on-site safety function instrument diagnostic data in the system database according to a preset fault alarm information classification method to obtain a fault determination result;

[0050] Step S400: When the fault determination result is that a fault has occurred, a safety instrument function circuit fault alarm is issued; when the fault determination result is that no fault has occurred, the safety instrument function circuit is in a normal commissioning state.

[0051] In order to more clearly explain the method of panoramic video display based on visual characteristics of the present invention, the following is combined with Figure 1 Each step in the embodiment of the present invention is described in detail.

[0052] A method for monitoring the effectiveness of a safety instrument function loop according to a first embodiment of the present invention is as follows: Figure 1 As shown, each step is described in detail as follows:

[0053] Step S100, collecting original instrument information of the safety instrument function loop through the safety instrument function loop effectiveness monitoring software, and storing the original instrument information in the system database;

[0054] In this embodiment, the safety instrument function loop is arranged in oil and gas pipeline engineering, oil and gas field surface engineering, petrochemical engineering, metallurgical engineering and municipal gas engineering, etc.

[0055] In this embodiment, the safety instrument function loop effectiveness monitoring software specifically includes:

[0056] Supports B / S architecture and C / S architecture, and supports access to various types of safety function instruments;

[0057] Support HAZOP analysis and SIL classification, output the safety instrument information generated during the work and automatically store it in the database;

[0058] The SIL classification adopts IEC61508 to divide SIL into 4 levels, namely SIL1, SIL2, SIL3 and SIL4; the SIL level of the safety-related system should be obtained through risk analysis, that is, through the analysis of the severity of risk consequences, risk exposure time and frequency, the probability of not being able to avoid risks and the probability of unexpected events. According to the SIL level classification principle, the higher the level, the lower the probability of dangerous failure.

[0059] HAZOP analysis is used to determine what safety functions are needed, but as a qualitative analysis method, it has certain limitations. That is, when a risk with a high severity of consequences is identified, HAZOP analysis cannot accurately determine the degree of risk reduction of various measures, nor can it determine the gap between the residual risk and the risk acceptance standard. In the SIL rating process, methods such as layer of protection (LOPA) analysis are further used to evaluate and confirm the frequency of occurrence of initial events, the severity of consequences, and the risk reduction value of each independent protection measure, and ultimately determine the risk reduction target that needs to be assigned to the SIF loop, that is, the integrity level (SIL) requirement of the SIF loop;

[0060] It has equipment failure database and equipment fault database;

[0061] It has the functions of event recording, alarm classification, utilization rate statistics and circuit evaluation;

[0062] It supports document import and can adaptively generate relevant safety table information for each safety instrument function loop in the database.

[0063] Step S200, collecting on-site safety function instrument diagnostic data through the bus, and inputting the on-site safety function instrument diagnostic data into the system database;

[0064] In this embodiment, the bus specifically includes:

[0065] HART, FF, MODBUS RTU and MODBUSDP / PA multiple fieldbuses.

[0066] In this embodiment, the system database specifically includes:

[0067] The system database has a unified data interface, supports the import of bus protocol parsing file packages FDT and EDDL files, and supports the access of multiple different types of instruments.

[0068] It also includes management functions for the entire life cycle of safety instrument function loops, including the use of safety instrument function loop design, equipment operation, re-calculation after failure, alarm and deactivation.

[0069] Step S300, performing fault determination on the on-site safety function instrument diagnostic data in the system database according to a preset fault alarm information classification method to obtain a fault determination result;

[0070] In this embodiment, the preset fault alarm information classification method specifically includes:

[0071] The fault information is divided into detection instrument fault information, controller fault information and execution unit fault information;

[0072] The fault information of the detection instrument includes sensor open circuit fault, sensor short circuit fault, sensor limit fault, upper limit fault, lower limit fault, temperature compensation fault, communication fault, and memory fault.

[0073] Controller fault information includes major fault flag, minor fault flag, communication line fault, module communication fault, voltage reference fault, common input circuit fault, common output circuit fault, auxiliary power connection fault, module configuration error and configuration information error;

[0074] The fault information of the actuator unit includes excessive load torque, excessive closing torque, excessive opening torque, power supply phase sequence detection error, motor temperature exceeding the protection value, handwheel push-in, actuator operation exceeding the limit and wrong operation direction.

[0075] In this embodiment, the method for classifying the preset fault alarm information further includes:

[0076] Minor fault alarm and major fault alarm;

[0077] Among them, minor fault alarms are alarms that do not affect the realization of safety instrument functions, including diagnostic data and monitoring data exceeding thresholds or abnormal conditions;

[0078] Serious fault alarms are alarms indicating the failure of safety instrument functions, including sensor faults, controller faults, and power supply faults that appear in diagnostic data, which cause the safety instrument to be in a faulty state.

[0079] Step S400: When the fault determination result is that a fault has occurred, a safety instrument function circuit fault alarm is issued; when the fault determination result is that no fault has occurred, the safety instrument function circuit is in a normal commissioning state.

[0080] In this embodiment, the fault alarm specifically includes:

[0081] Partial failure alarm and failure alarm;

[0082] Among them, for safety function instruments with redundant or multiple selection mechanisms, partial failure alarm is issued when a single instrument in the safety instrument function loop is in a serious fault;

[0083] Failure alarm For safety instruments with single or redundant mechanisms, when one of the three safety instrument function loops, including the detection instrument, controller, and execution unit, fails, the safety instrument function loop will automatically issue a failure alarm.

[0084] In this embodiment, when a fault alarm occurs in the safety function instrument diagnostic data, an alarm message is issued.

[0085] In this embodiment, the alarm information is displayed on a configuration screen or an external sound and light alarm is used for alarm.

[0086] In this embodiment, the method of performing fault determination on the field safety function instrument diagnostic data in the system database according to the preset fault alarm information classification method also includes:

[0087] The failure rate of the equipment in the database, the loop failure rate of the safety instrument function loop and the failure rate of the safety instrument function loop introduced in the database are calculated and compared horizontally.

[0088] Although the various steps in the above embodiment are described in the above-mentioned order, those skilled in the art can understand that in order to achieve the effect of this embodiment, different steps do not have to be executed in such an order. They can be executed simultaneously (in parallel) or in a reverse order. These simple changes are within the scope of protection of the present invention.

[0089] A system based on monitoring the effectiveness of a safety instrument function loop according to a second embodiment of the present invention includes: an original instrument information collection module, an on-site safety instrument information collection module, a fault determination module, and a fault alarm module.

[0090] an original instrument information collection module, configured to collect original instrument information of the safety instrument function loop through the safety instrument function loop effectiveness monitoring software, and store the original instrument information in a system database;

[0091] A field safety instrument information collection module is configured to collect field safety function instrument diagnostic data through a bus and input the field safety function instrument diagnostic data into a system database;

[0092] A fault determination module is configured to perform fault determination on the on-site safety function instrument diagnostic data in the system database according to a preset fault alarm information classification method to obtain a fault determination result;

[0093] The fault alarm module is configured to issue a safety instrument function circuit fault alarm when the fault determination result is that a fault has occurred; when the fault determination result is that no fault has occurred, the safety instrument function circuit is in a normal commissioning state.

[0094] Those skilled in the art can clearly understand that, for the convenience and brevity of description, the specific working process and related instructions of the system described above can refer to the corresponding process in the aforementioned method embodiment, and will not be repeated here.

[0095] It should be noted that the above embodiment provides a system based on monitoring the effectiveness of safety instrument function loops, and only uses the division of the above functional modules as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the modules or steps in the embodiments of the present invention can be decomposed or combined. For example, the modules in the above embodiments can be combined into one module, or further divided into multiple sub-modules to complete all or part of the functions described above. The names of the modules and steps involved in the embodiments of the present invention are only for distinguishing the modules or steps, and are not regarded as improper limitations of the present invention.

[0096] The terms "first", "second", etc. are used to distinguish similar objects rather than to describe or indicate a particular order or sequence.

[0097] The term "comprise" or any other similar term is intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus / device that includes a list of elements includes not only those elements but also other elements not expressly listed, or also includes elements inherent to such process, method, article, or apparatus / device.

[0098] So far, the technical solutions of the present invention have been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it is easy for those skilled in the art to understand that the protection scope of the present invention is obviously not limited to these specific embodiments. Without departing from the principle of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will fall within the protection scope of the present invention.

Claims

1. A method for monitoring the effectiveness of a safety instrument function loop, characterized in that: The method comprises: Step S100, collecting original instrument information of the safety instrument function loop through the safety instrument function loop effectiveness monitoring software, and storing the original instrument information in the system database; Step S200, collecting on-site safety function instrument diagnostic data through the bus, and inputting the on-site safety function instrument diagnostic data into the system database; Step S300, performing fault determination on the on-site safety function instrument diagnostic data in the system database according to a preset fault alarm information classification method to obtain a fault determination result; Step S400, when the fault determination result is that a fault has occurred, a safety instrument function circuit fault alarm is issued; when the fault determination result is that no fault has occurred, the safety instrument function circuit is in a normal commissioning state, and the on-site safety function instrument diagnostic data in the system database continues to be fault determined according to the preset fault alarm information classification method.

2. The method for monitoring the effectiveness of a safety instrument function loop according to claim 1, characterized in that: The safety instrument function loop effectiveness monitoring software specifically includes: Support HAZOP analysis and SIL classification, output the safety instrument information generated during the work and automatically store it in the database; It has equipment failure database and equipment fault database; It has the functions of event recording, alarm classification, utilization rate statistics and circuit evaluation; It supports document import and can adaptively generate relevant safety table information for each safety instrument function loop in the database.

3. The method for monitoring the effectiveness of a safety instrument function loop according to claim 1, characterized in that: The bus specifically includes: HART, FF, MODBUS RTU and MODBUSDP / PA multiple fieldbuses.

4. The method for monitoring the effectiveness of a safety instrument function loop according to claim 1, characterized in that: The system database specifically includes: The system database has a unified data interface, supports the import of bus protocol parsing file packages FDT and EDDL files, and supports the access of multiple different types of instruments.

5. The method for monitoring the effectiveness of a safety instrument function loop according to claim 1, characterized in that: The preset fault alarm information classification method specifically includes: The fault information is divided into detection instrument fault information, controller fault information and execution unit fault information; The fault information of the detection instrument includes sensor open circuit fault, sensor short circuit fault, sensor limit fault, upper limit fault, lower limit fault, temperature compensation fault, communication fault, and memory fault. Controller fault information includes major fault flag, minor fault flag, communication line fault, module communication fault, voltage reference fault, common input circuit fault, common output circuit fault, auxiliary power connection fault, module configuration error and configuration information error; The fault information of the actuator unit includes excessive load torque, excessive closing torque, excessive opening torque, power supply phase sequence detection error, motor temperature exceeding the protection value, handwheel push-in, actuator operation exceeding the limit and wrong operation direction.

6. The method for monitoring the effectiveness of a safety instrument function loop according to claim 1, characterized in that: The method for classifying the preset fault alarm information further includes: Minor fault alarm and major fault alarm; Among them, minor fault alarms are alarms that do not affect the implementation of safety instrument functions, including diagnostic data and monitoring data exceeding thresholds or abnormal conditions; A serious fault alarm is an alarm indicating the failure of the safety instrument function, including sensor faults, controller faults, and power supply faults that appear in the diagnostic data, causing the safety instrument to be in a fault state.

7. The method for monitoring the effectiveness of a safety instrument function loop according to claim 1, characterized in that: The fault alarm specifically includes: Partial failure alarm and failure alarm; Among them, for safety function instruments with redundant or multiple selection mechanisms, partial failure alarm is issued when a single instrument in the safety instrument function loop is in a serious fault; Failure alarm For safety instruments with single or redundant mechanisms, when one of the three failures in the safety instrument function loop, including the detection instrument, controller or execution unit, fails, the safety instrument function loop will automatically issue a failure alarm.

8. The method for monitoring the effectiveness of a safety instrument function loop according to claim 1, characterized in that: The method of performing fault determination on the on-site safety function instrument diagnostic data in the system database according to the preset fault alarm information classification method also includes: The failure rate of the equipment in the database, the loop failure rate of the safety instrument function loop and the failure rate of the safety instrument function loop introduced in the database are calculated and compared horizontally.

9. The method for monitoring the effectiveness of a safety instrument function loop according to claim 1, characterized in that: The system database also includes: It has the management function of the entire life cycle of the safety instrument function loop, including the use of the safety instrument function loop design, equipment operation, re-calculation after failure, alarm and deactivation.

10. A system based on monitoring the effectiveness of a safety instrument function loop, characterized in that: The system comprises: an original instrument information collection module, configured to collect original instrument information of the safety instrument function loop through the safety instrument function loop effectiveness monitoring software, and store the original instrument information in a system database; A field safety instrument information collection module is configured to collect field safety function instrument diagnostic data through a bus and input the field safety function instrument diagnostic data into a system database; A fault determination module is configured to perform fault determination on the on-site safety function instrument diagnostic data in the system database according to a preset fault alarm information classification method to obtain a fault determination result; The fault alarm module is configured to issue a safety instrument function circuit fault alarm when the fault determination result is that a fault has occurred; when the fault determination result is that no fault has occurred, the safety instrument function circuit is in a normal commissioning state.

Images