Method for transforming and optimizing nitrogen compressor protection device

Abstract

The invention belongs to the field of industrial production, and relates to a nitrogen compressor protection device transformation and optimization method, which comprises the steps of replacing an old comprehensive protection device, redesigning an electrical control circuit, integrating multiple protection functions, configuring an advanced operation interface, establishing a temperature monitoring module and communication connection, optimizing spare part management and the like. The safety and reliability of the nitrogen compressor are remarkably improved, the risk of non-planned shutdown is reduced, the comprehensive operation efficiency of equipment is improved, and a powerful guarantee is provided for safe production and sustainable development of enterprises.

Description

Technical Field

[0001] The present invention belongs to the field of industrial production and relates to a method for the transformation and optimization of a nitrogen compressor protection device. Background Art

[0002] In the field of industrial production, the nitrogen compressor, as the core equipment for nitrogen boosting, transportation, and circulation, has long been responsible for the power supply tasks in industries such as petrochemical, air separation plants, and metallurgy. Its operating environment often faces extreme conditions such as high pressure, high temperature, and high load, and the reliability of the equipment is directly related to the safety and continuity of the production system. For example, in an air separation plant, the nitrogen compressor needs to boost low-pressure nitrogen to above 3.0 MPa. Once the shutdown is caused by the failure of the protection system, it may lead to gas leakage, mechanical component damage, or even explosion accidents. According to statistics, approximately 15% of the unplanned shutdowns in the chemical industry are related to compressor protection defects, and the direct economic loss caused by a single accident can reach several million yuan, and the indirect impact is even more related to the stability of the upstream and downstream of the industrial chain. In this context, the technical shortcomings of traditional nitrogen compressor protection devices have become increasingly prominent, becoming the key bottleneck restricting industrial intelligent upgrading and safe production.

[0003] Traditional nitrogen compressor protection devices are mostly based on early electromechanical relays or digital comprehensive protection equipment, and their technical architectures are difficult to meet the needs of modern industries. Taking the widely used ABB REF series or Siemens 7SJ series comprehensive protection devices as an example, their hardware design relies on discontinued special chips and sensors, resulting in prominent problems in the spare parts supply chain. Many enterprises are forced to adopt non-standard alternative solutions, which not only pose compatibility risks but may also cause protection misoperations due to parameter matching deviations. At the functional level, traditional devices only support basic protection functions such as overcurrent and short circuit, and lack the ability to jointly judge complex working conditions such as phase loss, grounding faults, and abnormal temperatures. For example, the overheating of the motor winding is often caused by sudden load changes, but because the traditional system does not integrate the correlation algorithm between temperature and current, it often triggers protection several minutes after the fault occurs, missing the best response time. In addition, the widespread use of closed communication protocols (such as RS-485, Profibus) has formed a data barrier between the protection device and the modern DCS system, and maintenance personnel cannot obtain key parameters such as vibration spectrum and bearing temperature in real time, severely restricting the implementation of predictive maintenance.

[0004] The high coupling of control logic and protection functions further amplifies system risks. In traditional designs, control modules such as motor soft starters and star-delta switching circuits, and protection devices are integrated in the same control cabinet. Although this architecture saves space, it poses a hidden danger of fault spread. A typical case is that in a chemical plant, due to the adhesion of the soft starter contacts, the protection device misjudged it as a short-circuit fault and triggered a false trip, resulting in an unplanned shutdown of the entire air separation system. Such coupled designs also significantly increase the maintenance difficulty. During maintenance, the entire control cabinet needs to be powered off, affecting production continuity; during the commissioning process, due to the lack of a standardized parameter template, engineers often rely on empirical values to set thresholds, resulting in inconsistent protection settings for similar devices, leaving hidden dangers for system stability.

[0005] Currently, the wave of Industry 4.0 is driving the transformation of equipment management towards intelligence and digitization, but the upgrading and transformation of traditional protection devices still face multiple obstacles. Most enterprises adopt local optimization strategies. For example, simply replacing the comprehensive protection device without reconstructing the control logic results in communication conflicts between the new device and the original PLC system; or externally installing an independent temperature monitoring unit, which instead causes electromagnetic interference due to redundant signal cables. More notably, some transformation solutions overly rely on the proprietary protocols of specific manufacturers, trapping enterprises in a new technological binding dilemma. An electronic materials enterprise once adopted a customized protection module of a certain brand. During later expansion, it was found that its communication interface was incompatible with the newly built MES system, and it was forced to add millions of yuan for secondary transformation. Although these fragmented improvements can alleviate problems in the short term, they have not fundamentally broken through systematic bottlenecks such as data islands, high operation and maintenance costs, and difficult fault tracing. Summary of the Invention

[0006] In view of this, the purpose of the present invention is to provide a method for transforming and optimizing a nitrogen compressor protection device to solve the existing problems.

[0007] To achieve the above purpose, the present invention provides the following technical solution: A method for transforming and optimizing a nitrogen compressor protection device, including the following steps:

[0008] (a) Replace the discontinued comprehensive protection device in the original high-voltage cabinet with the Intek PA150 general comprehensive protection device;

[0009] (b) Redesign the electrical control circuit to meet the original protection functions and starting procedures, and achieve physical separation of the starting control module and the protection module;

[0010] (c) Integrate multiple protection functions such as overload protection, short-circuit protection, phase loss protection, and ground protection in the comprehensive protection device;

[0011] (d) Configure an operation interface with a menu-based protection mode selection function, supporting protection measurement and control of 6 - 10 kV feeder lines, motors, capacitors, transformers, and bus-coupling devices;

[0012] (e) Establish a communication connection with the DCS system to achieve real-time transmission of protection alarm signals.

[0013] Optionally, step (b) includes: adopting a split installation architecture, setting the starting control module on the operation console, and dispersedly installing the protection modules in the switchgear; using independent wiring terminals to achieve signal isolation between modules.

[0014] Optionally, step (c) further includes: setting a hierarchical overload protection threshold, triggering a first-level alarm when the load reaches 110% of the rated value, and performing a delayed tripping protection when it reaches 130%.

[0015] Optionally, step (d) is specifically implemented as: configuring a programmable logic controller, providing a motor starting characteristic curve setting function through the HMI interface; setting a protection parameter configuration template to support the quick parameter copying function.

[0016] Optionally, it further includes integrating a temperature monitoring module in the comprehensive protection device to collect motor winding temperature and bearing temperature data in real time; establishing a temperature-load correlation protection algorithm to trigger a warning when the temperature rise rate exceeds the set threshold.

[0017] Optionally, step (e) specifically includes: docking with the upper computer system using the Modbus RTU communication protocol; setting the SOE event recording function to store the last 1000 protection action events and corresponding waveform data.

[0018] Optionally, it further includes a spare parts management optimization plan: establishing a standardized spare parts library, uniformly selecting the Intek PA150 series as the general protection device for multi-model nitrogen compressors; implementing a spare parts sharing mechanism to reduce the inventory types by more than 50%.

[0019] Optionally, the transformed system should meet: the mean time between failures (MTBF) of the protection device ≥ 50000 hours; the protection action response time ≤ 35 ms; the equipment interchange installation time ≤ 2 hours.

[0020] The beneficial effects of the present invention are as follows:

[0021] 1) Through the dynamic protection algorithm of multi-parameter fusion, cross-verifying data such as current, temperature, and vibration in real time, significantly shortening the fault response time, and avoiding equipment damage or safety accidents caused by protection lag. The modular design realizes physical isolation of control and protection functions, reducing the risk of system-level fault spread.

[0022] 2) Integrating a standardized communication protocol to achieve in-depth data interaction with the upper-layer system, supporting real-time monitoring and predictive maintenance of equipment status. Through mechanical condition monitoring and fault warning, latent defects are identified in advance, the life of key components is extended, and the comprehensive operation efficiency of the equipment is improved.

[0023] 3) Generalized hardware modules and open architectures reduce the dependence on spare parts, shorten the maintenance cycle and downtime. The dynamic energy efficiency optimization algorithm automatically adjusts the load rate according to the working conditions, reduces energy waste in the inefficient operation stage, and achieves long-term energy conservation and consumption reduction.

[0024] 4) Built-in data storage and edge computing functions completely record the device operation data, providing support for fault tracing and process optimization. The standardized interface design is compatible with the industrial Internet of Things platform, helping to build a full life cycle management system for devices and improving the accuracy of operation and maintenance decisions.

[0025] 5) By reducing unplanned shutdowns and gas leaks, effectively control pollutant emissions and meet the requirements of environmental protection regulations. The improvement of equipment stability simultaneously reduces raw material waste, indirectly reduces the carbon footprint, and promotes the realization of the green manufacturing goal.

[0026] Other advantages, objectives and features of the present invention will be described to some extent in the subsequent specification, and to some extent, will be obvious to those skilled in the art based on the study of the following text, or can be taught from the practice of the present invention. The objectives and other advantages of the present invention can be realized and obtained through the following specification. Detailed implementation manners

[0027] The following uses specific specific examples to illustrate the implementation manners of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific implementation manners. Various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention.

[0028] This embodiment is based on the nitrogen compressor in the air separation unit of a large chemical enterprise. The original comprehensive protection device based on early electromechanical relay technology can no longer meet the safety and continuity requirements of modern industrial production due to equipment aging, difficult spare parts supply, and single protection function. To improve the equipment reliability and reduce the risk of unplanned shutdowns, it is decided to transform and optimize the protection device of this nitrogen compressor.

[0029] Specific embodiment 1

[0030] In this embodiment, the transformation and optimization steps specifically include:

[0031] Replacement of the comprehensive protection device (step a)

[0032] Replace the discontinued comprehensive protection device in the original high-voltage cabinet with the InTelai PA150 type general comprehensive protection device. This device has advanced protection functions, high reliability and good scalability, and can meet the complex protection requirements of the nitrogen compressor.

[0033] Redesign of the electrical control circuit (Step b)

[0034] Adopt a split installation architecture, set the starting control module on the operation console, and disperse the protection modules in the switchgear cabinet. This design realizes the physical separation of the starting control module and the protection module, reducing the risk of fault spread.

[0035] Use independent wiring terminals to achieve signal isolation between modules, ensuring the accuracy and stability of signal transmission.

[0036] Integration of multiple protection functions (Step c)

[0037] Integrate multiple protection functions such as overload protection, short-circuit protection, phase loss protection, and grounding protection in the comprehensive protection device.

[0038] Set hierarchical overload protection thresholds: trigger a first-level alarm when the load reaches 110% of the rated value to remind the operator; perform a delayed tripping protection when it reaches 130% to prevent equipment overload damage.

[0039] Configuration of the operation interface (Step d)

[0040] Configure an operation interface with a menu-based protection mode selection function, supporting the protection and measurement control of 6 - 10kV feeder lines, motors, capacitors, transformers, and bus-tie equipment.

[0041] Configure a programmable logic controller (PLC), and provide a motor starting characteristic curve setting function through the HMI interface, facilitating the operator to adjust the starting parameters according to actual needs.

[0042] Set up a protection parameter configuration template, supporting a quick parameter copying function to improve the debugging efficiency of the protection device.

[0043] Integration of the temperature monitoring module (extra step)

[0044] Integrate a temperature monitoring module in the comprehensive protection device to collect real-time data on the motor winding temperature and bearing temperature.

[0045] Establish a temperature-load correlation protection algorithm, trigger an early warning when the temperature rise rate exceeds the set threshold, and take measures in advance to prevent equipment overheating damage.

[0046] Establishment of communication connection (Step e)

[0047] Adopt the Modbus RTU communication protocol to interface with the upper computer system to achieve real-time transmission of protection alarm signals.

[0048] Set the SOE (Sequence of Events) event recording function, store the last 1000 protection action events and corresponding waveform data, providing strong support for fault tracing.

[0049] Specific Embodiment 2

[0050] Optimization of Spare Parts Management (Additional Steps)

[0051] Establish a standardized spare parts library, and uniformly select the INTELEC PA150 series as the general protection device for multi-model nitrogen compressors to reduce the types and inventory of spare parts.

[0052] Implement a spare parts sharing mechanism to reduce the inventory types by more than 50%, and improve the utilization rate and response speed of spare parts.

[0053] In the invention, the performance of the transformed system: the mean time between failures (MTBF) of the protection device ≥ 50,000 hours, significantly improving the reliability of the equipment. The protection action response time ≤ 35 ms, quickly responding to fault situations and reducing the risk of equipment damage. The equipment interchange and installation time ≤ 2 hours, facilitating the quick replacement of faulty equipment and shortening the downtime. Through real-time monitoring and predictive maintenance, the life of key components is effectively extended, and the comprehensive operation efficiency of the equipment is improved. Integrate a standardized communication protocol to achieve in-depth data interaction with the upper-level system, supporting remote monitoring and intelligent operation and maintenance.

[0054] The transformation effect of the present invention: The nitrogen compressor protection device after transformation operates stably and reliably, effectively improving the safety and continuity of the equipment. Through multiple protection functions and real-time monitoring means, the risks of unplanned shutdown and equipment damage are significantly reduced. At the same time, the optimization of spare parts management also improves the maintenance efficiency and response speed, and reduces the operation and maintenance costs. The overall transformation effect reaches the expected goal, providing a strong guarantee for the safe production and sustainable development of the enterprise.

[0055] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that the technical solutions of the present invention can be modified or equivalently replaced without departing from the spirit and scope of the present technical solution, and they should all be covered within the scope of the claims of the present invention.

Claims

1. A method for the transformation and optimization of a nitrogen compressor protection device, characterized in that, It includes the following steps: (a) Replace the discontinued comprehensive protection device in the original high-voltage cabinet with the InTellect PA150 general comprehensive protection device; (b) Redesign the electrical control circuit to meet the original protection function and start-up process, and achieve the physical separation of the start control module and the protection module; (c) Integrate multiple protection functions such as overload protection, short-circuit protection, phase-loss protection, and ground protection in the comprehensive protection device; (d) Configure an operation interface with a menu-based protection mode selection function, and support the protection measurement and control of 6-10 kV feeder lines, motors, capacitors, transformers, and bus-tie equipment; (e) Establish a communication connection with the DCS system to achieve real-time transmission of protection alarm signals.

2. The transformation and optimization method of a nitrogen compressor protection device according to claim 1, characterized in that, The step (b) includes: adopting a split installation architecture, setting the start control module on the operation console, and dispersedly installing the protection module in the switch cabinet; using independent wiring terminals to achieve signal isolation between modules.

3. The transformation and optimization method of a nitrogen compressor protection device according to claim 1, characterized in that, The step (c) further includes: setting a hierarchical overload protection threshold, triggering a first-level alarm when the load reaches 110% of the rated value, and performing a delayed tripping protection when it reaches 130%.

4. A method for the transformation and optimization of a nitrogen compressor protection device according to claim 1, characterized in that, The step (d) is specifically implemented as: configuring a programmable logic controller, providing a motor start characteristic curve setting function through the HMI interface; setting a protection parameter configuration template to support the quick parameter replication function.

5. A method for reforming and optimizing a nitrogen compressor protection device according to claim 1, characterized in that, It also includes integrating a temperature monitoring module in the comprehensive protection device to collect motor winding temperature and bearing temperature data in real time; establishing a temperature-load correlation protection algorithm to trigger an early warning when the temperature rise rate exceeds the set threshold.

6. A method for reforming and optimizing a nitrogen compressor protection device according to claim 1, characterized in that, The step (e) specifically includes: docking with the upper computer system using the Modbus RTU communication protocol; setting the SOE event recording function to store the last 1000 protection action events and the corresponding waveform data.

7. A method for the transformation and optimization of a nitrogen compressor protection device according to claim 1, characterized in that, It also includes an optimized spare parts management solution: establishing a standardized spare parts library, uniformly selecting the InTellect PA150 series as the general protection device for multi-type nitrogen compressors; implementing a spare parts sharing mechanism to reduce the inventory types by more than 50%.

8. A method for reforming and optimizing a nitrogen compressor protection device according to claim 1, characterized in that, The reformed system should meet: the mean time between failures (MTBF) of the protection device ≥ 50000 hours; the protection action response time ≤ 35 ms; the equipment interchange installation time ≤ 2 hours.