Anti-error control system and method for switching process in chemical process

Abstract

The invention relates to the field of anti-misoperation control of a switching process in a chemical process, in particular to an anti-misoperation control system and method of the switching process in the chemical process. The intelligent key executing the operation order must execute the corresponding operation according to the corresponding operation prompt during the field operation so as to complete the correct operation process, otherwise, the operation is not allowed to be continuously executed; the operation prompt and the corresponding operation comprise means of monitoring reading of the verification card, state detection, waiting for observation, obtaining of an observation result, whether operation is carried out or not and the like. According to the invention, the operation process can be forcibly standardized through various technical means, and the safety management and control of the manual operation equipment during process switching in the chemical process are realized.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of automation control and process error prevention, in particular to an error prevention control method for switching process in chemical process. BACKGROUND

[0002] At present, in the error prevention management and control of power transmission and operation and maintenance, various electrical equipment is locked and controlled, and the interval where the electrical equipment is located is also locked and controlled. The operation and maintenance personnel complete the unlocking operation and the operation of the electrical equipment according to the operation ticket formed based on the operation task. In the chemical process, the main control objects are valves and start-stop switches. The valves include electrically controlled valves and manually controlled valves, and the start-stop switches include electrically controlled switches and manually controlled switches. The electrically controlled valves and the electrically controlled switches are remotely controlled and state monitored through the DCS system (Distributed Control System), while the manually controlled valves and the manually controlled switches are only simply controlled through locking.

[0003] As can be seen from the above, the error prevention management and control in the process of power transmission and operation and maintenance and the error prevention management and control in the switching process in the chemical process have some similarities. However, due to the difference in nature between electric energy and chemical industry, the basic ideas of the error prevention management and control are obviously different. The main differences are as follows: in the power transmission and operation and maintenance, each operation step is strictly executed by the operation and maintenance personnel, and there is no need for on-site supervisors. The operation in the power transmission and operation and maintenance is irreversible, and the consequences are immediately reflected once the operation is performed. In the error prevention management and control in the switching process in the chemical process, the operation of some manually operated points needs to be accompanied and monitored by a supervisor, and the operation step after completion needs to be observed and judged whether there is an abnormality and whether it needs to be reversed.

[0004] However, the existing error prevention management and control of the switching process in the chemical process only stays in the operation specification. The operator only takes the operation confirmation card (operation guide, paper) to the site to operate step by step according to the operation guide on the confirmation card, and it is impossible to supervise whether the operation is in place. That is, the existing technology does not control through technical means. When operating some manually operated valves, whether there is a supervisor accompanying, it is impossible to actually control. In addition, whether the operation step after completion has been observed, whether the operator has performed the step, or has left or has violated the next step, it is also impossible to actually control. SUMMARY

[0005] The present application aims to provide an error prevention control method for manually operated points in the switching process in the chemical process, which can effectively and safely control the operation of the manually operated equipment. The present application is realized by the following technical solutions:

[0006] An error prevention control method for manually operated points in the switching process in the chemical process based on an error prevention control system, comprising:

[0007] A control host is arranged in the control center.

[0008] A hand-operated device is arranged in the chemical process site, and includes a hand-operated valve and / or a hand-operated switch.

[0009] A device lock is arranged to control the hand-operated valve and / or the hand-operated switch, and has a readable identity, which is one-to-one corresponding to the hand-operated device; according to the risk level of the hand-operated device, the device lock is divided into two types, the first type is a lock with lock unlocking state detection, and the second type is a lock with both lock unlocking state detection and valve full opening / full closing state detection.

[0010] The smart key has a master control module, a communication module, a man-machine interaction module, an unlocking mechanism, a lock identity reading mechanism, a lock state reading mechanism, and a device state reading mechanism; the smart key is in communication connection with the control host through the communication module.

[0011] The monitoring verification card is carried by a monitoring personnel, and is used to verify through card information when an operator operates an operation item that needs to be confirmed; the smart key further includes a monitoring verification card reading mechanism.

[0012] The anti-misoperation control method includes: (1) the control host generates an electronic operation ticket containing operation step information according to an operation task, and sends the electronic operation ticket to the smart key; (2) the smart key sequentially executes the operation step information according to the electronic operation ticket; and (3) the smart key completes all operations of the electronic operation ticket and returns operation records.

[0013] The anti-misoperation control method includes: (1) the control host generates an electronic operation ticket containing operation step information according to an operation task, and sends the electronic operation ticket to the smart key; (2) the smart key sequentially executes the operation step information according to the electronic operation ticket; and (3) the smart key completes all operations of the electronic operation ticket and returns operation records.

[0014] As a specific technical solution, the step of reading the card verification is performed before the step of identity verification, and the step of identity verification includes: reading the readable identity of the device lock corresponding to the hand-operated device by the smart key, verifying whether it is the hand-operated device specified in the current operation step, and if yes, entering the step of reading the card verification, otherwise, re-performing the identity verification or prompting the identity verification error.

[0015] As a specific technical solution, when generating the electronic operation ticket, for the hand-operated point needing to be monitored, an observation prompt item is added in the corresponding step information; after the steps of reading the card verification and operation, the step of waiting for observation is further performed, including: (2B-1) judging whether the hand-operated device is the hand-operated device needing to be observed, if yes, entering step (2B-2), otherwise, entering step (2B-4); (2B-2) according to the set observation prompt item, controlling the smart key to wait for observation and obtain the observation result in a predetermined time period, if the observation result is normal, ending the current operation step, and if the observation result is abnormal, entering step (2B-3); (2B-3) the smart key re-unlocks the device lock corresponding to the hand-operated device, and the operator re-operates the hand-operated device and locks it; (2B-4) ending the current operation step.

[0016] As a specific technical solution, the way of the smart key obtaining the observation result is input by the operator or reading through the data interface.

[0017] As a specific technical solution, when the smart key re-unlocks the device lock corresponding to the hand-operated device, the unlocking and locking mechanism of the smart key is triggered by the secret key issued by the management host.

[0018] As a specific technical solution, when generating the electronic operation ticket, for the hand-operated point needing to be state detected, a device valve state detection prompt item is added in the corresponding step information; after the steps of reading the card verification and operation, the step of state detection is further performed, including: (2C-1) judging whether the hand-operated device is the hand-operated device needing to be monitored, if yes, entering step (2C-2), otherwise, entering step (2C-3); (2C-2) according to the set state detection prompt item, detecting the state of the hand-operated device, verifying whether it is the state required to be reached after operation in the step of the operation ticket, if yes, entering step (2C-3), otherwise, prompting to re-operate the hand-operated device; (2C-3) ending the current operation step.

[0019] As a specific technical solution, the specific steps of generating the electronic operation ticket include: (1-1) establishing an electronic process flowchart: establishing identity information for the manual operation point in the process flow, establishing a graphic model for the manual operation valve and the manual operation switch corresponding to the manual operation point, and forming an electronic process flowchart consistent with the field; (1-2) establishing a correlated operation state logic: establishing a one-to-one corresponding correlation between the identity information of the manual operation point and the locking lock in the field, setting a state detection prompt item for the manual operation device requiring state detection, setting a card reading prompt item for the manual operation device requiring monitoring completion, setting an observation prompt item for the manual operation device requiring waiting observation, and formulating a logical relationship of operation state requirements; (1-3) selecting a manual operation device graphic model and performing a simulated switching process operation; (1-4) the system automatically checks the operation sequence and the correlated operation state logic, and if yes, an electronic operation ticket is generated and issued to the intelligent key, otherwise, step (1-3) is returned.

[0020] As a specific technical solution, after the intelligent key completes all operations of the electronic operation ticket and returns the operation record, the management host also updates the graphic model state according to the returned record.

[0021] The present application provides targeted operation prompts for the manual operation device of a specific manual operation point when generating an operation ticket, so that the intelligent key must perform corresponding operations according to the corresponding operation prompts during field operation, so as to complete the correct operation process, otherwise the operation is not allowed to continue; the operation prompts and the corresponding operations include reading of a monitoring verification card, state detection, and means such as waiting observation, observation result acquisition, and operation issuance. The present application can forcibly standardize the operation process through various technical means, and realizes safe management and control of the manual operation device during switching process in the chemical process. BRIEF DESCRIPTION OF DRAWINGS

[0022] Figure 1 A constitution block diagram of the anti-misoperation control system provided by the embodiment of the present application is provided.

[0023] Figure 2 A main flowchart of the anti-misoperation control method provided by the embodiment of the present application is provided.

[0024] Figure 3 A sub-flow of generating an electronic operation ticket in the anti-misoperation control method provided by the embodiment of the present application is provided.

[0025] Figure 4 A control sub-flow of the intelligent key reading and verifying the manual operation device requiring monitoring completion in the anti-misoperation control method provided by the embodiment of the present application is provided.

[0026] Figure 5 A control sub-flow of the intelligent key waiting and observing the manual operation device requiring waiting observation in the anti-misoperation control method provided by the embodiment of the present application is provided.

[0027] Figure 6 The control sub-process of the anti-misoperation control method provided in the embodiment of the present invention is a control process for the smart key to perform status detection on the hand-operated device that requires status detection.

[0028] Figure 7 The control sub-process of the smart key for the hand-operated device that simultaneously requires identity verification, monitoring card swipe verification, status detection and waiting observation is provided in the anti-misoperation control method of the present invention. Detailed Implementation

[0029] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings:

[0030] like Figure 1 As shown in this embodiment, the anti-misoperation control system for manual operation points during process switching in a chemical process includes a control host, a smart key, manual operation equipment, equipment locks, and a monitoring and verification card. The control host, acting as the host computer, is located in the control center. Manually operated devices, including manually operated valves and / or switches, are located at the chemical process site. Equipment locks control the locking and unlocking of these devices. Each lock has a readable identification identifier, which corresponds one-to-one with the corresponding manually operated device. Based on the risk level of the manually operated device, the locks are divided into two categories: the first category has lock locking / unlocking status detection, and the second category has both lock locking / unlocking status detection and valve full-open / full-close status detection. A monitoring verification card is carried by monitoring personnel and used to verify the operator's actions when confirmation is required. A smart key is carried by the operator and includes a main control module, a communication module, a human-machine interface module, a locking / unlocking mechanism, a lock identification reading mechanism, a lock status reading mechanism, an equipment status reading mechanism, and a monitoring verification card reading mechanism. The smart key communicates with the control host via the communication module. In this embodiment, the smart key's locking / unlocking function requires relevant verification before it can be activated, as detailed below.

[0031] Based on the corresponding control method of the above control system, its main flow is as follows: Figure 2 As shown, it includes: (1) the control host generates an electronic operation ticket according to the operation task and sends it to the smart key; (2) the smart key executes the operation steps according to the electronic operation ticket sequence; (3) the smart key completes all operations of the electronic operation ticket and sends back the operation record.

[0032] like Figure 3As shown, the specific steps of generating the electronic operation ticket include: (1-1) establishing an electronic process flowchart: establishing identity information for the manual operation points in the process flow, establishing a graphic model for the manual operation valves and switches corresponding to the manual operation points, and forming an electronic process flowchart consistent with the field; (1-2) establishing associated operation state logic: establishing a one-to-one corresponding association between the identity information of the manual operation point equipment and the field lock, setting a state detection prompt item for the manual operation equipment that needs state detection, setting a card reading prompt item for the manual operation equipment that needs to be monitored, setting an observation prompt item for the manual operation equipment that needs to be observed, and formulating the logical relationship of the operation state requirements; (1-3) selecting the manual operation equipment graphic model and performing a simulated switching process operation; (1-4) checking the operation sequence and associated operation state logic, and if yes, generating an electronic operation ticket and issuing it to the smart key, otherwise returning to step (1-3).

[0033] The smart key executes the operation step information according to the electronic operation ticket sequence, mainly referring to the identity verification, unlocking operation, etc. of the smart key on the corresponding equipment lock of the manual operation equipment, so that the operator can perform specific operations on the manual operation equipment, such as valve opening and closing operation or switch opening and closing operation. When the smart key performs the unlocking operation on the equipment lock, it first identifies the identity of the equipment lock. Only when the identity verification is passed, the smart key will trigger its unlocking mechanism to act. The following describes several specific application modes:

[0034] Figure 4 As shown, the control sub-process of the smart key on the manual operation equipment that needs to be monitored includes the steps of identity verification and card reading verification and operation. The identity verification includes: reading the readable identity of the equipment lock corresponding to the manual operation equipment through the smart key, verifying whether it is the manual operation equipment specified in the current operation step (the manual operation equipment and the lock identity are one-to-one corresponding), and if yes, entering the card reading verification and operation step, otherwise re-performing identity verification. The card reading verification and operation step includes: (2A-1) judging whether the manual operation equipment is the manual operation equipment that needs to be monitored, if yes, entering step (2A-2), otherwise the smart key directly unlocks the related equipment lock and enters step (2A-3); (2A-2) according to the set card reading prompt item, reading the monitoring verification card carried by the related monitor through the smart key, and if the card information verification is passed, allowing the smart key to unlock the related equipment lock; (2A-3) the operator operates and locks the manual operation equipment; (2A-4) ends the current operation step.

[0035] Figure 5The control sub-process of the smart key to the hand-operated device requiring observation includes the identity verification and operation step and the observation step. The identity verification and operation step includes: reading the readable identity of the device lock corresponding to the hand-operated device by the smart key, verifying whether it is the hand-operated device specified in the current operation step (the hand-operated device and the lock identity are one-to-one corresponding), and if yes, the smart key unlocks the related device lock. The operator operates the hand-operated device, locks it and enters the observation step. If no, the identity verification is re-performed or an identity verification error is prompted. The observation step includes: (2B-1) judging whether the hand-operated device is the hand-operated device requiring observation, and if yes, entering step (2B-2), otherwise entering step (2B-4); (2B-2) controlling the smart key to wait for observation and obtain an observation result according to the set observation prompt item within a predetermined time period. If the observation result is normal, the current operation step is ended. If the observation result is abnormal, step (2B-3) is entered. (2B-3) The smart key unlocks the device lock corresponding to the hand-operated device again. The operator operates the hand-operated device again and locks it. (2B-4) The current operation step is ended.

[0036] The abnormal observation result includes, for example, leakage, pressure abnormality, temperature abnormality, etc. At this time, the operation needs to be returned to the previously operated step for reverse operation. The smart key obtains the observation result in the form of operator input or reading by the smart key through an interface. In addition, when the smart key unlocks the device lock corresponding to the hand-operated device again, the smart key is triggered to actuate the unlocking and locking mechanism of the smart key by the secret key issued by the host computer.

[0037] Figure 6 The control sub-process of the smart key to the hand-operated device requiring state detection includes the identity verification and operation step and the state detection step. The identity verification and operation step includes: reading the readable identity of the device lock corresponding to the hand-operated device by the smart key, verifying whether it is the hand-operated device specified in the current operation step (the hand-operated device and the lock identity are one-to-one corresponding), and if yes, the smart key unlocks the related device lock. The operator operates the hand-operated device, locks it and enters the state detection step. If no, the identity verification is re-performed or an identity verification error is prompted. The state detection step includes:

[0038] (2C-1) judging whether the hand-operated device is the hand-operated device requiring monitoring, and if yes, entering step (2C-2), otherwise entering step (2C-3); (2C-2) detecting the state of the hand-operated device according to the set state detection prompt item, verifying whether it is the state required by the operation ticket in the step, and if yes, entering step (2C-3), otherwise prompting to operate the hand-operated device again; (2C-3) ending the current operation step.​

[0039] It can be understood that, Figure 4 , Figure 5 , Figure 6 The control sub-processes can be fused with each other, that is, a certain hand-operated device can exist in the situation of identity authentication, monitoring card verification, state detection and waiting for observation at the same time, as shown in Figure 7 In addition, in step (3), the smart key completes all operations of the electronic operation ticket and returns the operation record, and the management host also updates the graphic model state according to the returned record.

[0040] The beneficial effects of the present application are:

[0041] The present application establishes a graphic model for hand-operated valves and hand-operated switches in the process flow of the device through system management software, and establishes identity information to form an electronic process flow chart consistent with the field; the hand-operated valves and hand-operated switches in the field are forcibly locked through device locks, and the identity information of the hand-operated point is associated with the closed lock in a one-to-one correspondence, and the logical relationship of the operation state requirements is formulated.

[0042] For very critical hand-operated valves, in addition to locking, lock state detection and device state detection are also added, and only when the sequence and state are consistent can the next two steps be performed, so as to avoid misoperation due to human factors.

[0043] For particularly critical hand-operated points, the device operation needs to be confirmed by the monitoring personnel on site before the operation ticket is formed, and once the setting is completed, the corresponding personnel need to swipe the card to confirm the identity before unlocking and operating.

[0044] For repeated operations in abnormal situations: during the process flow operation, after the process operation ticket flow is executed, some steps usually need to be observed by instruments or observed by the running state of the device, and once there is an abnormal situation, such as leakage, abnormal pressure, abnormal temperature, etc., the previous step that has been operated needs to be returned to for reverse operation. The present application sets the observation time, observation result determination standard and observation prompt information by force, and determines whether the next step can be operated or the current step needs to be reversed according to the observation result after the observation time is over. At the same time, the password needs to be input on the key before the reverse operation can be performed, so as to avoid too easy reverse operation.

[0045] The above examples are only for full disclosure and not limitation of the present application, and any equivalent technical features based on the creative spirit of the present application and obtained without creative labor should be considered as the scope disclosed by the present application.

Claims

1. A method for preventing errors in switching processes in chemical processes, based on a system for preventing errors, comprising: a control host set in a control center; a hand-operated device set in a chemical process site, comprising a hand-operated valve and / or a hand-operated switch; a device lock for controlling the unlocking and locking of the hand-operated valve and / or the hand-operated switch, the device lock having a readable identity, and the identity corresponding to the hand-operated device one by one; according to the risk level of the hand-operated device, the device lock is divided into two categories, the first category is a lock with lock unlocking and locking state detection, and the second category is a lock with both lock unlocking and locking state detection and valve full opening / closing state detection; an intelligent key having a main control module, a communication module, a human-computer interaction module, an unlocking and locking mechanism, a lock identity reading mechanism, a lock state reading mechanism, and a device state reading mechanism; the intelligent key is in communication connection with the control host through the communication module; a monitoring verification card carried by a monitoring personnel, used for verifying through card information when an operator operates an operation item that needs to be confirmed; the intelligent key further comprises a monitoring verification card reading mechanism; the method for preventing errors comprises: (1) the control host generates an electronic operation ticket containing operation step information according to an operation task and sends it to the intelligent key; (2) the intelligent key executes the operation step information according to the electronic operation ticket in sequence; (3) the intelligent key completes all operations of the electronic operation ticket and returns the operation record; characterized in that, when generating the electronic operation ticket, a card reading prompt item is added in the corresponding operation step information of the hand-operated point that needs to be monitored and completed; when the intelligent key executes the related operation step of the electronic operation ticket, a card reading verification and operation step is performed, which comprises: (2A-1) judging whether the hand-operated device involved in the operation step is a hand-operated device that needs to be monitored and completed, if yes, entering step (2A-2), otherwise, the intelligent key directly unlocks the related device lock and enters step (2A-3); (2A-2) reading the monitoring verification card carried by the related monitoring personnel through the intelligent key according to the set card reading prompt item, and allowing the intelligent key to unlock the related device lock if the card information verification is passed; (2A-3) locking after the operator operates the hand-operated device; (2A-4) ending the current operation step; when generating the electronic operation ticket, an observation prompt item is added in the corresponding step information of the hand-operated point that needs to be monitored and completed; after the card reading verification and operation step, a waiting observation step is further performed, which comprises: (2B-1) judging whether the hand-operated device is a hand-operated device that needs to be waited for observation, if yes, entering step (2B-2), otherwise, entering step (2B-4); (2B-2) controlling the intelligent key to wait for observation and obtain the observation result in a predetermined time period according to the set observation prompt item, ending the current operation step if the observation result is normal, and entering step (2B-3) if the observation result is abnormal; (2B-3) the intelligent key unlocks the device lock corresponding to the hand-operated device again, and the operator operates the hand-operated device again and then locks it; (2B-4) ending the current operation step. When the electronic operation ticket is generated, a state detection prompt item is added in the corresponding step information of the hand-operated point requiring state detection; after the card reading verification and operation steps, a state detection step is performed, including: (2C-1) judging whether the hand-operated device is a hand-operated device requiring monitoring completion, if yes, going to step (2C-2), otherwise going to step (2C-3); (2C-2) detecting the state of the hand-operated device according to the set state detection prompt item, verifying whether it is the operation state required by the operation ticket step, if yes, going to step (2C-3), otherwise prompting to re-operate the hand-operated device; (2C-3) ending the current operation step.

2. The method according to claim 1, wherein the method is characterized in that, Before the card reading verification step, an identity verification step is performed, including: reading the readable identity of the device lock corresponding to the hand-operated device by the smart key, verifying whether it is the hand-operated device specified in the current operation step, if yes, going to the card reading verification step, otherwise re-performing identity verification or prompting identity verification error.

3. The method according to claim 1, wherein the method is characterized in that, The observation result obtaining mode of the smart key is operator input or reading through a data interface.

4. The method of claim 1, wherein the method further comprises: determining whether the process is a switching process; and if the process is a switching process, determining whether the switching process is a switching process of a chemical process. When the smart key unlocks the device lock corresponding to the hand-operated device again, the smart key is triggered to actuate the unlocking mechanism by the secret key issued by the control host.

5. The method of claim 1, wherein the method further comprises: determining whether the process is a switching process; and if the process is a switching process, determining whether the switching process is a switching process of a chemical process. The specific steps of generating the electronic operation ticket include: (1-1) establishing an electronic process flowchart: establishing identity information of the hand-operated point in the process flow, establishing a graph model of the hand-operated valve and the hand-operated switch corresponding to the hand-operated point, and forming an electronic process flowchart consistent with the field; (1-2) establishing associated operation state logic: establishing a one-to-one association between the identity information of the hand-operated point and the locking lock in the field, setting a state detection prompt item for the hand-operated device requiring state detection, setting a card reading prompt item for the hand-operated device requiring monitoring completion, setting an observation prompt item for the hand-operated device requiring observation, and formulating the logical relationship of operation state requirements; (1-3) selecting a hand-operated device graph model and performing a simulated switching process operation; (1-4) verifying the operation sequence and the associated operation state logic, if yes, generating an electronic operation ticket and issuing it to the smart key, otherwise returning to step (1-3).

6. The method according to claim 5, wherein the method is characterized in that, After the smart key completes all operations of the electronic operation ticket and returns the operation record, the control host also updates the graph model state according to the returned record.

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