Automatic metering and remote transmission control method for high-pressure nitrogen outlet flow

Abstract

The invention belongs to the field of electrical control, and relates to an automatic metering and remote transmission control method for high-pressure nitrogen outlet flow, which adopts a high-precision flow metering device and is matched with a temperature sensor, a pressure sensor and the like, so that the high-pressure nitrogen outlet flow can be accurately measured, and metering errors caused by fluid physical property changes can be effectively compensated. Real-time flow data is transmitted to a remote monitoring center by using an industrial Ethernet or a wireless communication technology. According to the invention, not only are the stability and the product quality of the production process improved, but also the production efficiency is improved, and the production cost and the energy consumption are reduced. The method is suitable for various industrial production fields such as gas separation, iron and steel smelting, chemical production and the like, and provides powerful technical support for production management and process control of enterprises.

Description

Technical Field

[0001] The present invention belongs to the field of electrical control and relates to an automatic metering and remote transmission control method for the flow rate of high-pressure nitrogen outlet. Background Art

[0002] In modern industrial production, the flow rate metering of high-pressure nitrogen is a crucial task, which is directly related to the stability of the production process, the reliability of product quality, and the rationality of energy consumption. However, in current industrial practices, there are still many deficiencies in the metering and remote transmission control of the high-pressure nitrogen outlet flow rate, which seriously restrict the improvement of production efficiency and management level.

[0003] I. Deficiencies in metering accuracy and precision

[0004] Currently, many industrial enterprises still use traditional throttling devices, such as orifice plates, nozzles, etc., in combination with differential pressure transmitters for flow rate measurement at the high-pressure nitrogen outlet. Although this method is simple and easy to implement, it is greatly affected by various factors such as fluid flow pattern, pipeline conditions, and medium physical properties, resulting in low metering accuracy and large errors. Especially under high-pressure and large-flow conditions, the limitations of this metering method are more prominent and it is difficult to meet the requirements of modern industrial production for high-precision metering.

[0005] In addition, due to improper selection of factors such as the installation position, angle, and direction of the metering device, it will also lead to deviations in the metering results. For example, if the installation position of the throttling device fails to meet the length requirements of the front straight pipe section and the rear straight pipe section, or the installation angle deviates from the vertical direction, it will cause metering errors. The accumulation of these errors will not only affect the stability of the production process, but also have a negative impact on product quality and energy consumption.

[0006] II. Deficiencies in real-time performance and response speed

[0007] Traditional flow rate metering systems mostly use analog signal transmission methods, and there are significant delays in the signal acquisition, processing, and display processes, and they cannot reflect the changes in the high-pressure nitrogen outlet flow rate in real time. This is undoubtedly a major defect for production processes that require rapid response. For example, in the steel smelting process, if the supply flow rate of high-pressure nitrogen cannot be adjusted in real time, it will cause fluctuations in the smelting temperature, affecting product quality and production efficiency.

[0008] In addition, due to the limited data processing ability of traditional flow rate metering systems, they cannot quickly analyze and process a large amount of real-time data, resulting in the production management department being unable to obtain useful information in a timely manner to guide production. This not only increases the workload of manual inspections, but also reduces the efficiency and accuracy of production management.

[0009] III. Lack of remote monitoring and data calling functions

[0010] With the continuous improvement of the level of industrial automation and informatization, the functions of remote monitoring and data retrieval have become an indispensable part of modern industrial production. However, in the current high-pressure nitrogen outlet flow measurement system, this function is often lacking or imperfect. The flow measurement systems of many enterprises still adopt the method of local display and recording, and cannot achieve remote monitoring and data retrieval. This not only limits the vision and decision-making ability of the production management department, but also increases the difficulty of data management and analysis.

[0011] For example, in some large chemical enterprises, due to the dispersion and large number of high-pressure nitrogen supply points, the traditional local display and recording method makes it impossible for the production management department to timely grasp the flow conditions of each supply point. This not only affects the formulation and adjustment of production plans, but also increases the waste of energy consumption and the improvement of production costs.

[0012] IV. Difficulties in System Maintenance and Upgrade

[0013] Traditional flow measurement systems have a large number of components and complex wiring, which bring great difficulties to the maintenance and upgrade of the system. Once the system fails or needs to be upgraded, it often takes a lot of time and effort to troubleshoot and repair. This not only affects the normal progress of production, but also increases the maintenance costs and risks of enterprises.

[0014] In addition, due to the relatively backward software architecture and design concept of traditional flow measurement systems, it is difficult to achieve seamless integration and interoperability with other automation systems. This not only limits the expansion and upgrade of system functions, but also increases the difficulty and cost of enterprise informatization construction.

[0015] V. Inability to Meet Personalized and Customized Requirements

[0016] With the increasingly fierce market competition and the continuous change of customer needs, many enterprises have put forward higher personalized and customized requirements for the measurement and remote transmission control of high-pressure nitrogen outlet flow. However, in the current market, there are very few flow measurement systems that can meet these requirements. The flow measurement systems of many enterprises can only meet the basic measurement and display functions, and cannot be customized and optimized according to the actual needs and process characteristics of enterprises. This not only limits the production efficiency and product quality of enterprises, but also increases the operation costs and risks of enterprises.

[0017] In summary, the deficiencies of the existing automatic metering and remote transmission control methods for high-pressure nitrogen outlet flow are mainly reflected in the deficiencies of metering accuracy and accuracy, real-time performance and response speed, lack of remote monitoring and data calling functions, difficulties in system maintenance and upgrading, and inability to meet personalized and customized requirements. These deficiencies have severely restricted the development of modern industrial production and the improvement of management levels. Therefore, it is particularly important and urgent to develop an automatic metering and remote transmission control method for high-pressure nitrogen outlet flow with high precision, strong real-time performance, remote monitoring and data calling functions, easy maintenance and upgrading, and capable of meeting personalized and customized requirements. Summary of the Invention

[0018] In view of this, the purpose of the present invention is to provide an automatic metering and remote transmission control method for high-pressure nitrogen outlet flow to solve the existing deficiencies.

[0019] To achieve the above purpose, the present invention provides the following technical solutions: An automatic metering and remote transmission control method for high-pressure nitrogen outlet flow, comprising the following steps:

[0020] S1, install a standard orifice throttling device on the outlet pipeline of the high-pressure nitrogen compressor, and connect a differential pressure transmitter in a corner tapping manner;

[0021] S2, set a temperature sensor and a pressure transmitter downstream of the throttling device to collect working temperature and pressure signals in real time;

[0022] S3, input the differential pressure signal, temperature signal and pressure signal into the DCS / PLC control system through a data acquisition module;

[0023] S4, the DCS / PLC system calculates the standard state flow value in real time using a flow compensation formula, and the formula is:

[0024] qv = K × (ΔP × P / (t + 273.15))^0.5;

[0025] Where K is the device coefficient, ΔP is the differential pressure value, P is the absolute pressure, and t is the working temperature;

[0026] S5, the system automatically generates instantaneous flow display, cumulative flow statistics and historical trend curves;

[0027] S6, upload the metering data to the central management system through the Modbus communication protocol to achieve remote monitoring and data calling.

[0028] Optionally, the design parameters of the standard orifice throttling device include: the orifice ratio β is 0.49643 - 0.56556; the length of the front straight pipe section L1 ≥ 3.5 m, and the length of the rear straight pipe section L2 ≥ 0.7 m; the nominal diameter of the installation pipeline is DN100 - DN200; the working pressure is 3.0 MPa, and the temperature is 30 ± 5 °C.

[0029] Optionally, before implementing step S1, pipeline adaptability transformation is required, including: installing a stop valve at the compressor outlet to isolate the pipeline; adjusting the installation positions of the reflux regulating valve and the vent valve; using pipeline connection components with a PN40 flange standard.

[0030] Optionally, the differential pressure transmitter adopts a double flange structure, with a measuring range of 0 - 60 kPa, an output signal of 4 - 20 mA analog quantity, and a protection level reaching IP67.

[0031] Optionally, the DCS / PLC system configuration includes: establishing a database of orifice characteristic parameters; configuring a flow calculation function block FC203; setting an anti-shake filtering algorithm for the cumulative value; developing a module with an adjustable data storage period.

[0032] Optionally, it also includes an abnormal condition handling mechanism: triggering an over-range alarm when the differential pressure value exceeds 110% of the maximum range; automatically switching to the safety compensation mode when abnormal temperature and pressure signals are detected; starting a data review program when the mutation of the cumulative value exceeds 5%.

[0033] Optionally, during installation and construction: using a laser alignment instrument to ensure that the coaxiality between the throttling device and the pipeline is ≤ 0.5°; the installation position of the instrument box is ≤ 15 m away from the throttling device; the signal cable uses double-layer shielded twisted pair; the grounding resistance value is ≤ 4 Ω.

[0034] The beneficial effects of the present invention are as follows:

[0035] 1) By adopting advanced metering technologies and equipment, such as a standard orifice throttling device, a high-precision differential pressure transmitter, etc., the method of the present invention can achieve high-precision metering of the flow rate at the high-pressure nitrogen outlet. At the same time, combined with compensation measures such as temperature and pressure, it effectively eliminates the influence of factors such as fluid flow pattern, pipeline conditions, and medium physical properties on the metering result, ensuring the accuracy and reliability of the metering result. This helps to improve the stability of the production process, reduce the unqualified product rate, and improve product quality.

[0036] 2) The present invention adopts digital signal transmission and processing technologies to achieve real-time monitoring and rapid response to the flow rate at the high-pressure nitrogen outlet. The production management department can immediately obtain the flow rate data and adjust the process parameters and equipment operating status in a timely manner according to production requirements. This not only improves the flexibility and adaptability of the production process but also helps to reduce energy consumption and production costs.

[0037] 3) By integrating the functions of remote monitoring and data calling, the present invention enables the production management department to access the flow data anytime and anywhere for remote monitoring and management. This not only broadens the vision and decision-making ability of the management department, but also helps improve the efficiency and accuracy of production management. At the same time, through data analysis and mining, the enterprise can discover potential problems and optimization points in the production process, providing strong support for continuous improvement and optimization of the production process.

[0038] 4) The present invention adopts a modular and standardized design concept, making the components of the flow measurement system more concise and the wiring more convenient. This not only reduces the difficulty and cost of system maintenance and upgrade, but also helps improve the reliability and stability of the system. In addition, by introducing advanced software architectures and design ideas, this method also achieves seamless integration and interoperability with other automation systems, providing strong support for the enterprise's informatization construction.

[0039] 5) The present invention has a high degree of flexibility and scalability, and can be customized and optimized according to different production requirements and process characteristics. The enterprise can select suitable metering devices and control strategies according to its actual situation to achieve personalized flow measurement and remote transmission control. This not only improves the production efficiency and product quality of the enterprise, but also enhances the market competitiveness and adaptability of the enterprise.

[0040] In summary, the implementation of an automatic high-pressure nitrogen outlet flow measurement and remote transmission control method has significant beneficial effects in improving production efficiency, enhancing the scientificity and accuracy of production management, optimizing the production process, reducing production costs, and improving economic benefits. This method is not only applicable to industries such as gas separation, steel smelting, and chemical production, but can also be widely applied to other fields that require high-precision flow measurement and remote transmission control.

[0041] 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 learned from the practice of the present invention. The objectives and other advantages of the present invention can be achieved and obtained through the following specification. Detailed Embodiments

[0042] The following specific examples illustrate the embodiments 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 embodiments, and 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.

[0043] This embodiment introduces an automatic metering and remote transmission control method for the flow rate at the high-pressure nitrogen outlet, which is applicable to fields such as gas separation, iron and steel smelting, and chemical production that require high-precision flow rate metering and remote transmission control. This method realizes real-time monitoring, accurate metering, and remote control of the flow rate at the high-pressure nitrogen outlet by integrating advanced flow rate metering technology, remote monitoring technology, and automatic control technology.

[0044] Specific Embodiment 1

[0045] The system composition includes:

[0046] Flow rate metering device:

[0047] A standard orifice throttling device is used as the flow rate measurement element, and a high-precision differential pressure transmitter is used to convert the differential pressure signal into an electrical signal.

[0048] Temperature and pressure sensors are introduced to compensate for the influence of factors such as fluid flow state, pipeline conditions, and medium physical properties on the metering result.

[0049] Data acquisition and processing system:

[0050] A high-performance data acquisition card is used to collect the electrical signals output by the flow rate metering device in real time.

[0051] Advanced data processing software is equipped to filter, amplify, linearize, etc. the collected data to obtain an accurate flow rate value.

[0052] Remote monitoring system:

[0053] Based on industrial Ethernet or wireless communication technology, a remote monitoring network is established.

[0054] Servers and monitoring software are deployed in the monitoring center to realize real-time access and management of on-site flow rate data.

[0055] Automatic control system:

[0056] According to the preset flow rate control strategy, the on-site equipment is remotely controlled through a PLC (Programmable Logic Controller) or DCS (Distributed Control System).

[0057] The PID (Proportional-Integral-Derivative) control algorithm is introduced to realize precise control of the flow rate at the high-pressure nitrogen outlet.

[0058] Specific Embodiment 2

[0059] The implementation steps include:

[0060] System installation and commissioning:

[0061] Install the flow rate metering device on the high-pressure nitrogen outlet pipeline to ensure that the installation position meets the length requirements of the front straight pipe section and the rear straight pipe section.

[0062] Connect the data acquisition and processing system, conduct equipment debugging and parameter setting to ensure the accuracy and real-time nature of data acquisition.

[0063] Establish a remote monitoring network, connect the monitoring center and on-site equipment, and conduct network debugging and communication testing.

[0064] Flow measurement and data processing:

[0065] Start the flow measurement device and the data acquisition and processing system to start real-time acquisition of flow data.

[0066] The data acquisition card transmits the collected electrical signals to the data processing software for processing such as filtering, amplification, and linearization to obtain accurate flow values.

[0067] The processed flow data is transmitted to the monitoring center through the remote monitoring network for real-time access and management by the production management department.

[0068] Remote monitoring and control:

[0069] The production management department views the on-site flow data in real time through the server and monitoring software of the monitoring center.

[0070] According to production requirements, remotely control the on-site equipment through the automatic control system to adjust the high-pressure nitrogen outlet flow.

[0071] Introduce the PID control algorithm, automatically adjust the control parameters according to the preset flow control strategy, and achieve precise control of the high-pressure nitrogen outlet flow.

[0072] System maintenance and upgrade:

[0073] Regularly inspect and maintain the flow measurement device, data acquisition and processing system, remote monitoring system, and automatic control system to ensure the normal operation of the system.

[0074] According to production requirements and technological development, upgrade and optimize the system to improve the performance and reliability of the system.

[0075] Technical features and advantages include:

[0076] High-precision measurement: Adopt a standard orifice plate throttling device and a high-precision differential pressure transmitter, combined with temperature and pressure compensation measures, to achieve high-precision measurement of the high-pressure nitrogen outlet flow.

[0077] Real-time remote monitoring: Based on industrial Ethernet or wireless communication technology, establish a remote monitoring network to achieve real-time access and management of on-site flow data.

[0078] Precise Automatic Control: Introduce the PID control algorithm, and automatically adjust the control parameters according to the preset flow control strategy to achieve precise control of the high-pressure nitrogen outlet flow rate.

[0079] Modular Design: The system adopts a modular design with simple components and convenient wiring, facilitating maintenance and upgrading.

[0080] Highly Customizable: Provide personalized flow measurement and remote control solutions according to different production requirements and process characteristics.

[0081] By implementing this method, enterprises can achieve real-time monitoring, precise measurement, and remote control of the high-pressure nitrogen outlet flow rate, improving the stability of the production process and product quality. At the same time, through remote monitoring and data analysis, enterprises can timely discover potential problems in the production process, optimize the production process, and reduce production costs. In addition, this method also has high flexibility and scalability, and can meet the needs of different industries and application scenarios.

[0082] 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 purpose and scope of the present technical solution, and they should all be covered by the scope of the claims of the present invention.

Claims

1. An automatic metering and remote transmission control method for high-pressure nitrogen outlet flow rate, characterized in that, It includes the following steps: S1. Install a standard orifice throttling device on the outlet pipeline of the high-pressure nitrogen compressor, and connect a differential pressure transmitter by means of corner tapping; S2. Set a temperature sensor and a pressure transmitter downstream of the throttling device to collect working temperature and pressure signals in real time; S3. Input the differential pressure signal, temperature signal and pressure signal into the DCS / PLC control system through a data acquisition module; S4. The DCS / PLC system calculates the standard state flow value in real time by using a flow compensation formula, and the formula is: qv=K×(ΔP×P / (t+273.15))^0.5; where K is the device coefficient, ΔP is the differential pressure value, P is the absolute pressure, and t is the working temperature; S5. The system automatically generates instantaneous flow display, cumulative flow statistics and historical trend curves; S6. Upload the measurement data to the central management system through the Modbus communication protocol to achieve remote monitoring and data call.

2. The automatic metering and remote transmission control method for the high-pressure nitrogen outlet flow rate according to claim 1, characterized in that: The design parameters of the standard orifice throttling device include: the orifice ratio β is 0.49643 - 0.56556; the length of the front straight pipe section L1≥3.5m, and the length of the rear straight pipe section L2≥0.7m; the nominal diameter of the installation pipeline is DN100 - DN200; the working pressure is 3.0MPa, and the temperature is 30±5°C.

3. The automatic metering and remote transmission control method for the high-pressure nitrogen outlet flow rate according to claim 1, characterized in that: Before implementing step S1, pipeline adaptability transformation is required, including: adding a stop valve at the compressor outlet to isolate the pipeline; adjusting the installation positions of the reflux regulating valve and the vent valve; using pipeline connection components with a PN40 flange standard.

4. A method for automatically measuring and remotely transmitting the flow rate of a high-pressure nitrogen outlet, according to claim 1, characterized in that: The differential pressure transmitter adopts a double-flange structure, with a range of 0 - 60kPa, an output signal of 4 - 20mA analog quantity, and a protection level reaching IP67.

5. A method for automatic measurement and remote transmission control of the high-pressure nitrogen outlet flow rate according to claim 1, characterized in that: The configuration of the DCS / PLC system includes: establishing a database of orifice characteristic parameters; configuring a flow calculation function block FC203; setting an anti-shake filtering algorithm for the cumulative value; developing a module with an adjustable data storage period.

6. The automatic metering and remote transmission control method for the high-pressure nitrogen outlet flow rate according to claim 1, characterized in that: It also includes an abnormal condition handling mechanism: when the differential pressure value exceeds 110% of the maximum range, an over-range alarm is triggered; when abnormal temperature and pressure signals are detected, it automatically switches to the safety compensation mode; when the mutation of the cumulative value exceeds 5%, a data review program is started.

7. A method for automatic measurement and remote transmission control of high-pressure nitrogen outlet flow rate according to claim 1, characterized in that: During installation and construction: use a laser alignment instrument to ensure that the coaxiality between the throttling device and the pipeline is ≤0.5°; the installation position of the instrument box is ≤15m away from the throttling device; the signal cable uses double-layer shielded twisted pair; the grounding resistance value is ≤4Ω.