Chemical process safety monitoring device

Abstract

The invention belongs to the technical field of chemical process monitoring, and particularly relates to a chemical process safety monitoring device which comprises a central processing unit, a data acquisition unit, a data analysis unit, a human-computer interface unit and a warning module, through real-time monitoring, automatic alarm and intelligent control, potential problems can be recognized before danger occurs, and the safety of the chemical process is improved. Therefore, accidents are avoided or reduced, personnel safety and equipment safety are guaranteed, and the system can provide quick response before, when and even after accidents, effectively reduce accident loss and handle emergency situations such as leakage or explosion in time.

Description

Technical Field

[0001] The invention relates to the technical field of chemical process monitoring, in particular to a chemical process safety monitoring device. Background Art

[0002] The chemical production process involves a large number of hazardous chemicals, demanding production processes, and large-scale, continuous and automated production equipment. Once an accident occurs, the consequences will be extremely serious. Therefore, safety issues occupy a very important position in the chemical production process;

[0003] Historical experience shows that there are two ways to improve the safety level of enterprises: first, conduct in-depth and comprehensive safety analysis and verification to prevent dangers before they occur, that is, establish an effective prevention system; second, when danger really occurs, strive to improve the emergency response capabilities of operators, that is, establish an online real-time protection system. Prevention and protection are two complementary links in safety production. Effective prevention measures can eliminate safety hazards as early as possible. For this reason, it is urgent to propose a chemical process safety monitoring device. Summary of the invention

[0004] The purpose of this section is to summarize some aspects of the embodiments of the present invention and briefly introduce some preferred embodiments. Some simplifications or omissions may be made in this section and the specification abstract and the invention title of this application to avoid blurring the purpose of this section, the specification abstract and the invention title, and such simplifications or omissions cannot be used to limit the scope of the present invention.

[0005] Therefore, the purpose of the present invention is to provide a chemical process safety monitoring device, which can identify potential problems before danger occurs through real-time monitoring, automatic alarm and intelligent control, thereby avoiding or reducing accidents and ensuring the safety of personnel and equipment. In addition, the system can provide rapid response before, during, or even after an accident occurs, effectively reducing accident losses and promptly handling emergencies such as leakage or explosion. At the same time, the historical data and alarm logs recorded by the system can be used for accident investigation and analysis, making it easier to understand the root cause of the accident, thereby improving the process flow, optimizing safety measures, and preventing similar accidents from happening again.

[0006] To solve the above technical problems, according to one aspect of the present invention, the present invention provides the following technical solutions:

[0007] A chemical process safety monitoring device, comprising:

[0008] The central processing unit, as the command control end of the system, ensures that the machine executes the program in the prescribed order, generates operation signals for each instruction taken out from the memory, and sends various operation signals to the corresponding components, thereby controlling these components to act according to the requirements of the instructions;

[0009] The data acquisition unit is connected to the central processing unit and includes an acquisition module and a communication module, which is used to collect various data in the chemical process in real time through installed sensors and monitoring equipment, including temperature, pressure, flow, gas concentration, pH value, to ensure that the process parameters are always within a safe range;

[0010] The data analysis unit is connected to the central processing unit and includes an analysis module, an abnormality diagnosis module and an alarm module, which are used to perform comparisons based on real-time data and historical data, identify abnormal fluctuations in process parameters, issue early warning signals, predict potential failures or dangers, and remind operators to take measures in advance;

[0011] A human-machine interface unit, connected to the central processing unit, includes a display monitoring module and an alarm module;

[0012] The display monitoring module is used to display the real-time status of the chemical process through a graphical interface, including equipment status, process parameters, and alarm information. Through the interface, the process flow, environmental conditions, and equipment status can be understood in real time to perform effective operations and adjustments.

[0013] The warning module is used to execute. When the system detects dangerous factors, the HMI interface will remind the operator through visual or sound alarms to ensure timely response.

[0014] As a preferred solution of the chemical process safety monitoring device described in the present invention, the central processing unit is used to perform real-time monitoring and adjustment of the chemical process through PLC, DCS or SCADA to prevent dangerous situations from occurring.

[0015] As a preferred solution of a chemical process safety monitoring device described in the present invention, wherein: the central processing unit includes an emergency shutdown module and a leakage monitoring module;

[0016] The emergency stop module is used to execute the system to automatically trigger the emergency stop procedure when a danger is detected, cut off the dangerous process flow and avoid the expansion of the accident;

[0017] The leakage monitoring module is used to execute the system to cut off the gas source in time when a gas leakage occurs to prevent the leakage from expanding.

[0018] As a preferred solution of the chemical process safety monitoring device described in the present invention, wherein: the central processing unit is connected to the response recording unit, and the response recording unit includes an emergency module and a recording module;

[0019] The emergency module is used to implement chemical safety incidents and provide relevant emergency response plans, including automated emergency shutoff, leak detection, fire control functions, and timely notification of relevant personnel;

[0020] The recording module is used to automatically record various monitoring data, alarm events and emergency operations, and form detailed historical data reports for post-analysis, accident tracing and improvement.

[0021] As a preferred solution of the chemical process safety monitoring device described in the present invention, wherein: the acquisition module is used to acquire real-time data from sensors, including temperature, pressure, flow rate, and concentration parameters;

[0022] The communication module is used to transmit the collected data to the central processing unit through wireless, optical fiber, and Ethernet means to ensure real-time and efficient data transmission.

[0023] As a preferred solution of the chemical process safety monitoring device described in the present invention, the analysis module is used to perform real-time processing and analysis of a large amount of collected data, predict potential safety risks, and help operators make more effective decisions;

[0024] The abnormal diagnosis module is used to execute AI and machine learning algorithms to analyze changes in equipment status and process parameters, detect potential faults or abnormalities in advance, identify signs of system deviations from normal status through historical data and pattern recognition, and warn of possible safety hazards;

[0025] The alarm module is used to issue an alarm through sound and light when the system detects abnormal parameters or danger, and promptly notify the operator to take emergency measures.

[0026] As a preferred solution of the chemical process safety monitoring device described in the present invention, the acquisition module includes the following:

[0027] Temperature sensor: monitors temperature changes in reactors, pipelines or storage tanks to prevent fire or explosion caused by excessive reaction temperature;

[0028] Pressure sensor: used to monitor the pressure in containers and pipelines to prevent overpressure from causing container rupture or leakage;

[0029] Flow meter: used to monitor the flow of raw materials and chemicals to ensure that the flow rate during the reaction process is within a safe range;

[0030] Concentration sensors: monitor the concentration of chemicals in gases or liquids, especially volatile, toxic or flammable gases;

[0031] Gas detector: detects toxic, harmful or flammable gases that may leak in the environment, such as ammonia, carbon dioxide, carbon monoxide, and methane;

[0032] pH sensor: monitors the pH value of the reaction solution to avoid abnormal reaction or corrosion caused by excessively high or low pH.

[0033] Compared with the prior art, the present invention has the following beneficial effects:

[0034] 1. Improve process safety. Through real-time monitoring, automatic alarm and intelligent control, potential problems can be identified before danger occurs, thereby avoiding or reducing accidents and ensuring personnel and equipment safety;

[0035] 2. Reduce human errors. AI and automated control can reduce the impact of human errors on chemical process safety. Even if operators make mistakes, the system can make real-time adjustments and interventions to prevent accidents from expanding.

[0036] 3. Improve production efficiency. Through intelligent and automated monitoring and adjustment, the system can maintain optimal operating conditions, improve production efficiency and reduce energy waste;

[0037] 4. Timely emergency response: the system can provide rapid response before, during, or even after an accident occurs, effectively reducing accident losses and promptly handling emergencies such as leaks or explosions;

[0038] 5. Post-accident tracing and improvement: the historical data and alarm logs recorded by the system can be used for accident investigation and analysis, making it easier to understand the root cause of the accident, thereby improving the process, optimizing safety measures, and preventing similar accidents from happening again. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the present invention will be described in detail below in combination with the accompanying drawings and detailed embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative labor. Among them:

[0040] Figure 1 It is a schematic diagram of the system module of the present invention;

[0041] Figure 2 It is a schematic diagram of the expansion of the system module of the present invention. DETAILED DESCRIPTION

[0042] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the specific embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0043] In the following description, many specific details are set forth to facilitate a full understanding of the present invention, but the present invention may also be implemented in other ways different from those described herein, and those skilled in the art may make similar generalizations without violating the connotation of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0044] Secondly, the present invention is described in detail with reference to schematic diagrams. When describing the embodiments of the present invention in detail, for the sake of convenience, the cross-sectional diagrams showing the device structure will not be partially enlarged according to the general scale, and the schematic diagrams are only examples, which should not limit the scope of protection of the present invention. In addition, in actual production, the three-dimensional dimensions of length, width and depth should be included.

[0045] To make the objectives, technical solutions and advantages of the present invention more clear, the embodiments of the present invention will be further described in detail below with reference to the accompanying drawings.

[0046] The present invention provides a chemical process safety monitoring device, please refer to Figure 1-2 ,include:

[0047] The central processing unit, as the command control end of the system, ensures that the machine executes the program in the prescribed order, generates operation signals for each instruction taken out from the memory, and sends various operation signals to the corresponding components, thereby controlling these components to act according to the requirements of the instructions;

[0048] The data acquisition unit is connected to the central processing unit and includes an acquisition module and a communication module, which is used to collect various data in the chemical process in real time through installed sensors and monitoring equipment, including temperature, pressure, flow, gas concentration, pH value, to ensure that the process parameters are always within a safe range;

[0049] The data analysis unit is connected to the central processing unit and includes an analysis module, an abnormality diagnosis module and an alarm module, which are used to perform comparisons based on real-time data and historical data, identify abnormal fluctuations in process parameters, issue early warning signals, predict potential failures or dangers, and remind operators to take measures in advance;

[0050] A human-machine interface unit, connected to the central processing unit, includes a display monitoring module and an alarm module;

[0051] The display monitoring module is used to display the real-time status of the chemical process through a graphical interface, including equipment status, process parameters, and alarm information. Through the interface, the process flow, environmental conditions, and equipment status can be understood in real time to perform effective operations and adjustments.

[0052] The warning module is used to execute when the system finds dangerous factors. The HMI interface will remind the operator through visual or sound alarms to ensure timely response;

[0053] The central processing unit is used to perform real-time monitoring and adjustment of chemical process through PLC, DCS or SCADA to prevent dangerous situations.

[0054] The central processing unit includes an emergency shutdown module and a leakage monitoring module;

[0055] The emergency stop module is used to execute the system to automatically trigger the emergency stop procedure when a danger is detected, cut off the dangerous process flow and avoid the expansion of the accident;

[0056] The leakage monitoring module is used to execute the system to cut off the gas source in time when a gas leakage occurs to prevent the leakage from expanding.

[0057] The central processing unit is connected to the response recording unit, and the response recording unit includes an emergency module and a recording module;

[0058] The emergency module is used to implement chemical safety incidents and provide relevant emergency response plans, including automated emergency shutoff, leak detection, fire control functions, and timely notification of relevant personnel;

[0059] The recording module is used to automatically record various monitoring data, alarm events and emergency operations, and form detailed historical data reports for post-analysis, accident tracing and improvement.

[0060] The acquisition module is used to collect real-time data from sensors, including temperature, pressure, flow, and concentration parameters;

[0061] The communication module is used to transmit the collected data to the central processing unit through wireless, optical fiber, and Ethernet means to ensure real-time and efficient data transmission;.

[0062] The analysis module is used to process and analyze the large amount of collected data in real time, predict potential safety risks, and help operators make more effective decisions;

[0063] The abnormal diagnosis module is used to execute AI and machine learning algorithms to analyze changes in equipment status and process parameters, detect potential faults or abnormalities in advance, identify signs of system deviations from normal status through historical data and pattern recognition, and warn of possible safety hazards;

[0064] The alarm module is used to execute the alarm through sound and light when the system detects abnormal parameters or danger, and promptly notify the operator to take emergency measures;

[0065] The acquisition modules include the following:

[0066] Temperature sensor: monitors temperature changes in reactors, pipelines or storage tanks to prevent fire or explosion caused by excessive reaction temperature;

[0067] Pressure sensor: used to monitor the pressure in containers and pipelines to prevent overpressure from causing container rupture or leakage;

[0068] Flow meter: used to monitor the flow of raw materials and chemicals to ensure that the flow rate during the reaction process is within a safe range;

[0069] Concentration sensors: monitor the concentration of chemicals in gases or liquids, especially volatile, toxic or flammable gases;

[0070] Gas detector: detects toxic, harmful or flammable gases that may leak in the environment, such as ammonia, carbon dioxide, carbon monoxide, and methane;

[0071] pH sensor: monitors the pH value of the reaction solution to avoid abnormal reaction or corrosion caused by excessively high or low pH.

[0072] Although the present invention has been described above with reference to the embodiments, various modifications may be made thereto and parts thereof may be replaced by equivalents without departing from the scope of the present invention. In particular, as long as there is no structural conflict, the various features in the embodiments disclosed in the present invention may be used in combination with each other in any manner, and the fact that these combinations are not exhaustively described in this specification is only for the sake of omitting space and saving resources. Therefore, the present invention is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A chemical process safety monitoring device, characterized in that: include The central processing unit, as the command control end of the system, ensures that the machine executes the program in the prescribed order, generates operation signals for each instruction taken out from the memory, and sends various operation signals to the corresponding components, thereby controlling these components to act according to the requirements of the instructions; The data acquisition unit is connected to the central processing unit and includes an acquisition module and a communication module, which is used to collect various data in the chemical process in real time through installed sensors and monitoring equipment, including temperature, pressure, flow, gas concentration, pH value, to ensure that the process parameters are always within a safe range; The data analysis unit is connected to the central processing unit and includes an analysis module, an abnormality diagnosis module and an alarm module, which are used to perform comparisons based on real-time data and historical data, identify abnormal fluctuations in process parameters, issue early warning signals, predict potential failures or dangers, and remind operators to take measures in advance; A human-machine interface unit, connected to the central processing unit, includes a display monitoring module and an alarm module; The display monitoring module is used to display the real-time status of the chemical process through a graphical interface, including equipment status, process parameters, and alarm information. Through the interface, the process flow, environmental conditions, and equipment status can be understood in real time to perform effective operations and adjustments. The warning module is used to execute. When the system detects dangerous factors, the HMI interface will remind the operator through visual or sound alarms to ensure timely response.

2. A chemical process safety monitoring device according to claim 1, characterized in that: The central processing unit is used to perform real-time monitoring and adjustment of the chemical process through PLC, DCS or SCADA to prevent dangerous situations from occurring.

3. A chemical process safety monitoring device according to claim 2, characterized in that: The central processing unit includes an emergency shutdown module and a leakage monitoring module; The emergency stop module is used to execute the system to automatically trigger the emergency stop procedure when a danger is detected, cut off the dangerous process flow and avoid the expansion of the accident; The leakage monitoring module is used to execute the system to cut off the gas source in time when a gas leakage occurs to prevent the leakage from expanding.

4. A chemical process safety monitoring device according to claim 3, characterized in that: The central processing unit is connected to a response recording unit, and the response recording unit includes an emergency module and a recording module; The emergency module is used to implement chemical safety incidents and provide relevant emergency response plans, including automated emergency shutoff, leak detection, fire control functions, and timely notification of relevant personnel; The recording module is used to automatically record various monitoring data, alarm events and emergency operations, and form detailed historical data reports for post-analysis, accident tracing and improvement.

5. A chemical process safety monitoring device according to claim 4, characterized in that: The acquisition module is used to acquire real-time data from sensors, including temperature, pressure, flow rate, and concentration parameters; The communication module is used to transmit the collected data to the central processing unit through wireless, optical fiber, and Ethernet means to ensure real-time and efficient data transmission.

6. A chemical process safety monitoring device according to claim 5, characterized in that: The analysis module is used to perform real-time processing and analysis of a large amount of collected data, predict potential safety risks, and help operators make more effective decisions; The abnormal diagnosis module is used to execute AI and machine learning algorithms to analyze changes in equipment status and process parameters, detect potential faults or abnormalities in advance, identify signs of system deviations from normal status through historical data and pattern recognition, and warn of possible safety hazards; The alarm module is used to issue an alarm through sound and light when the system detects abnormal parameters or danger, and promptly notify the operator to take emergency measures.

7. A chemical process safety monitoring device according to claim 6, characterized in that: The acquisition module includes the following: Temperature sensor: monitors temperature changes in reactors, pipelines or storage tanks to prevent fire or explosion caused by excessive reaction temperature; Pressure sensor: used to monitor the pressure in containers and pipelines to prevent overpressure from causing container rupture or leakage; Flow meter: used to monitor the flow of raw materials and chemicals to ensure that the flow rate during the reaction process is within a safe range; Concentration sensors: monitor the concentration of chemicals in gases or liquids, especially volatile, toxic or flammable gases; Gas detector: detects toxic, harmful or flammable gases that may leak in the environment, such as ammonia, carbon dioxide, carbon monoxide, and methane; pH sensor: monitors the pH value of the reaction solution to avoid abnormal reaction or corrosion caused by excessively high or low pH.

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