DCS or SIS-based on-line monitoring auxiliary engine refueling management method and system

Abstract

The invention relates to the technical field of safe operation monitoring of an auxiliary engine motor and a pump bearing of a thermal power plant, and discloses a DCS or SIS-based online monitoring auxiliary engine refueling management method and system, and the method comprises the steps: displaying the information of auxiliary engine equipment needing grease lubrication in a DCS or SIS monitoring picture in a square form; the operation duration of the auxiliary engine motor is counted in real time, and the remaining time from next refueling is dynamically calculated; when the remaining time is less than or equal to 20% of the refueling period, triggering a first-stage alarm; when the remaining time is smaller than or equal to 10% of the refueling period, second-stage alarm is triggered; and after the equipment responsible person finishes refueling, the system is reset through password verification, and running duration statistics is reset. The method can prevent the rotating machine or the motor bearing from being damaged, ensures the safe operation of the generator set, and prevents the thermal power plant from being economically damaged.

Description

Technical Field

[0001] This invention relates to the field of monitoring the safe operation of auxiliary motors and pump bearings in thermal power plants, and particularly to a method and system for managing auxiliary equipment refueling based on DCS or SIS online monitoring. Background Technology

[0002] For thermal power plants and large industrial and mining enterprises, ensuring the safe operation of the main equipment relies heavily on the safe operation of related auxiliary equipment. Most, if not over 90%, of the auxiliary equipment in thermal power plants consists of rotating machinery. The safe operation of rotating machinery depends on the lubrication of shaft bearings, which are mainly lubricated by oil or grease. Auxiliary pump bearings generally use oil lubrication, while motor bearings generally use grease lubrication. Oil lubrication takes various forms, such as dripping oil from an oil cup, oil ring lubrication, or forced oil circulation lubrication by an oil pump. It can remove heat and is suitable for high-speed, heavy-load, or high-temperature conditions. Grease lubrication uses grease, which has good adhesion, simple sealing, and is waterproof and dustproof. It is commonly used in low-to-medium speed, light-load, and maintenance-difficult situations, especially for motor bearing lubrication. Oil lubrication usually has oil level monitoring; oil can be added promptly when needed. However, grease lubrication requires adding oil according to the manufacturer's specified intervals based on operating hours to ensure the safe operation of auxiliary equipment. However, for grease-lubricated turbines, the operating time can only be roughly estimated by the person in charge using paper records. It is not possible to accurately lubricate according to the operating hours given by the manufacturer. This often results in some turbine motors running for too long, causing bearing damage, or grease waste or leakage due to over-lubrication. Currently, all thermal power plants in China use this method, and all of them suffer from turbine motor bearing damage due to failure to lubricate in time after running for too long, which threatens the safe operation of the main unit and has a certain impact on the economics of thermal power plants. Summary of the Invention

[0003] In view of the aforementioned existing problems, the present invention is proposed.

[0004] Therefore, this invention provides an auxiliary machine refueling management method based on DCS or SIS online monitoring, which can accurately record the auxiliary machine's running time through the DCS system or SIS system, and promptly remind the person in charge of the equipment to refuel on time when the time required for refueling given by the manufacturer is approaching.

[0005] To address the aforementioned technical problems, this invention provides the following technical solution: a method for managing auxiliary equipment lubrication based on online monitoring using DCS or SIS, comprising: displaying information about auxiliary equipment requiring grease lubrication in a block format on the DCS or SIS monitoring screen; real-time statistics of the running time of the auxiliary motor and dynamic calculation of the remaining time until the next lubrication; triggering a first-level alarm when the remaining time is less than or equal to 20% of the lubrication cycle; triggering a second-level alarm when the remaining time is less than or equal to 10% of the lubrication cycle; and resetting the running time statistics by resetting the system through password verification after the equipment supervisor completes the lubrication.

[0006] As a preferred embodiment of the auxiliary machine refueling management method based on DCS or SIS online monitoring described in this invention, the information displayed in the block includes the equipment name, preset refueling cycle, and real-time remaining time.

[0007] As a preferred embodiment of the auxiliary machine refueling management method based on DCS or SIS online monitoring described in this invention, the first-level alarm is a yellow visual indicator, and the second-level alarm is a red visual indicator.

[0008] As a preferred embodiment of the auxiliary refueling management method based on DCS or SIS online monitoring described in this invention, the system is reset via password verification, wherein the reset operation includes inputting a password to verify identity, and after successful verification, resetting the remaining time to a preset refueling cycle.

[0009] As a preferred embodiment of the auxiliary machine refueling management method based on DCS or SIS online monitoring described in this invention, the method of calculating the running time of the auxiliary machine motor includes determining the equipment operation by the on / off status of the auxiliary machine motor.

[0010] If the switch is in the closed state, the running time is accumulated according to the preset scanning cycle.

[0011] As a preferred embodiment of the auxiliary machine refueling management method based on DCS or SIS online monitoring described in this invention, the calculation of the remaining time until the next refueling includes converting the cumulative running time into hourly units;

[0012] The difference between the refueling cycle and the cumulative running hours is calculated using the subtraction module.

[0013] As a preferred embodiment of the auxiliary machine refueling management method based on DCS or SIS online monitoring described in this invention, when an alarm is triggered, the display color of the corresponding block switches to yellow or red in real time.

[0014] This invention provides an auxiliary refueling management system based on DCS or SIS online monitoring.

[0015] As a preferred embodiment of the DCS or SIS-based online monitoring auxiliary refueling management system described in this invention, it includes: an equipment status acquisition module, a time calculation and statistics module, an alarm control module, and a human-machine interaction module.

[0016] The equipment status acquisition module collects the on / off status signals of the auxiliary motor in real time and scans the periodically to detect the equipment operating status.

[0017] The time calculation and statistics module accumulates the running time and converts it to hourly units through a division unit; it dynamically calculates the difference between the preset refueling cycle and the accumulated running hours, and outputs the remaining time.

[0018] The alarm control module generates a yellow alarm signal when the remaining time is less than or equal to 20% of the refueling cycle and a red alarm signal when the remaining time is less than or equal to 10% of the refueling cycle.

[0019] The human-machine interaction module generates equipment information blocks on the DCS / SIS screen, displaying the name, refueling cycle, remaining time, and alarm status in layers; it receives password verification commands and triggers a reset operation to set the accumulated time to zero and the remaining time to zero.

[0020] The present invention provides a computer device, including a memory and a processor. The memory stores a computer program, and the processor executes the computer program to implement the steps of an auxiliary machine refueling management method based on DCS or SIS online monitoring.

[0021] The present invention provides a computer-readable storage medium having a computer program stored thereon, wherein the computer program, when executed by a processor, implements the steps of a DCS or SIS-based online monitoring auxiliary machine refueling management method.

[0022] The beneficial effects of this invention are as follows: This invention can use a DCS or SIS system to statistically analyze the running time of the generator, accurately calculate the running time of a given device, avoid bearing damage caused by inaccurate manual statistics and untimely lubrication of the generator motor, greatly reduce the labor intensity of personnel, reduce the failure of auxiliary equipment in thermal power plants, thereby ensuring the safe operation of thermal power units and significantly improving economic efficiency. Attached Figure Description

[0023] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1This is a schematic diagram of auxiliary control motor refueling detection provided in an embodiment of the present invention, based on a DCS or SIS online monitoring auxiliary machine refueling management method.

[0025] Figure 2 This is a schematic diagram of the furnace-side rotary motor lubrication detection method based on DCS or SIS online monitoring auxiliary machine lubrication management, provided as an embodiment of the present invention.

[0026] Figure 3 This is a schematic diagram of the engine-side rotary motor refueling detection method based on DCS or SIS online monitoring auxiliary machine refueling management, provided as an embodiment of the present invention.

[0027] Figure 4 This is a schematic diagram of a condensate pump based on an online monitoring auxiliary refueling management method using DCS or SIS, as provided in one embodiment of the present invention.

[0028] Figure 5 This is a schematic diagram of a condensate pump based on an online monitoring auxiliary refueling management method using DCS or SIS, provided as an embodiment of the present invention. Detailed Implementation

[0029] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of the present invention.

[0030] Example 1, the first embodiment of the present invention, provides a method for auxiliary machine refueling management based on DCS or SIS online monitoring, including:

[0031] S1: Displays information about auxiliary equipment requiring grease lubrication in the form of squares on the DCS or SIS monitoring screen.

[0032] S2: Real-time statistics of the auxiliary motor's running time and dynamic calculation of the remaining time until the next refueling.

[0033] S3: When the remaining time is less than or equal to 20% of the refueling cycle, the first-level alarm is triggered; when the remaining time is less than or equal to 10% of the refueling cycle, the second-level alarm is triggered.

[0034] S4: After the person in charge of the equipment completes the refueling, they reset the runtime statistics by verifying the password in the reset system.

[0035] Furthermore, all rotating motor bearings that require grease are displayed in the form of squares. The squares show the motor name, grease cycle, remaining hours of the rotating motor that need grease, and an alarm is triggered when 20% of the time is left before grease is added, and another alarm is triggered when 10% is left, reminding maintenance personnel to add grease in time. After grease is added, the equipment supervisor can reset the machine by entering a password and recalculate the operating hours.

[0036] In one feasible embodiment, the reset control process can be implemented through two-factor authentication. Specifically, after the person in charge enters the password, the system generates a dynamic verification code and sends it to their secure mobile phone. The person then enters the received verification code on the DCS screen, triggering the following actions: the accumulated running time is reset to zero; the remaining time is reset to the refueling cycle; and the system records the reset operator's employee number and timestamp.

[0037] In another feasible embodiment, the reset control process can also be implemented through operation log association. Specifically, after the person in charge enters the password, the system requires the association of the work order number (such as preventive maintenance work order PM001), retrieves the refueling record (oil type, refueling amount) of the equipment in the work order system, and automatically executes the following when the work order status is "completed": reset the cumulative running time; update the remaining time to the new cycle value.

[0038] The condensate pump motor bearing has a lubrication cycle of 1500 hours. After lubrication, the remaining operating hours displayed in the box are 1500 hours. As the equipment runs, these 1500 hours decrease with each condensate pump operation. When the condensate pump has run for 1200 hours, the internal display shows 300 hours remaining, triggering a yellow alarm indicating 20% ​​remaining lubrication time, reminding staff to schedule lubrication. When the condensate pump has run for 1350 hours, the internal display shows 150 hours remaining, triggering a red alarm indicating 10% remaining lubrication time, requiring lubrication. After lubrication, the shift leader or technician resets the display with a password, restoring the 1500-hour count to begin the next cycle. The rotating motor's operating hours are counted automatically by the DCS or SIS system. The corresponding display box decreases as the rotating motor runs. This precise counting completely prevents bearing damage caused by missed or excessive lubrication.

[0039] In one feasible embodiment, the alarm triggering mechanism can be implemented through a composite prompt alarm. Specifically, when the remaining time is ≤20%, a yellow flashing icon (such as an exclamation mark) is generated in the display square, and the DCS / SIS system voice broadcast is triggered simultaneously: "Equipment [Name] needs planned refueling".

[0040] When the remaining time is ≤10%, the background of the square will be switched to red and will continue to flash, and an emergency work order (including the equipment name and remaining time) will be pushed to the mobile terminal of the person in charge of the equipment.

[0041] In another feasible embodiment, the alarm triggering mechanism can also be implemented through a progressive alarm, specifically, when the remaining time is ≤30%, the square border turns into a thin yellow line (without flashing);

[0042] When the remaining time is ≤20%, the entire block switches to a yellow background and flashes once per second;

[0043] When the remaining time is ≤10%, the block switches to a red background and flashes 3 times per second, automatically popping up a forced confirmation dialog box (you need to manually click "I understand").

[0044] Example 2, refer to Figures 1-5 As an embodiment of the present invention, an auxiliary machine refueling management method based on DCS or SIS online monitoring is provided. In order to verify the beneficial effects of the present invention, scientific demonstration is carried out through experiments.

[0045] like Figure 4 As shown in the diagram, the first row displays the name of the monitored equipment, the second row displays the manufacturer's recommended refueling cycle, the third row displays the remaining time until the next refueling, and the fourth row shows the 20% mark. When the remaining time is less than or equal to 20%, a Level II alarm signal is triggered, displayed in yellow, reminding staff to schedule refueling. When the remaining time is less than or equal to 10%, a Level I alarm is triggered, with the 10% mark lit in red, reminding staff that refueling is necessary to prevent equipment damage. Taking the #1 unit A condensate pump as an example, when the #1 unit A condensate pump starts running, the running time begins to be recorded. If it has run for 1200 hours, the remaining hours are displayed as 300 hours, triggering the 20% Level II alarm signal. When the cumulative running time reaches 1350 hours, the remaining hours are displayed as 150 hours, triggering a Level I alarm, with the 10% mark lit in red, reminding staff that refueling is necessary to prevent equipment damage. After refueling, the equipment supervisor resets the count by entering a password, recalculating the running hours. The reset button requires a password to prevent accidental activation by other personnel, which could lead to inaccurate statistics.

[0046] like Figure 5As shown, the operation of the equipment is determined by the switch of the auxiliary motor. When the control switch of the auxiliary motor is in the closed position, the operation of the equipment is determined by the analog scan cycle (once every 0.25 seconds) and the switching fast, and the cumulative timer starts. The cumulative duration (seconds) is divided by 3600 seconds (1 hour = 3600 seconds) using a division block to convert the cumulative seconds to cumulative hours. The remaining time is calculated using a subtraction block between the refueling cycle and the cumulative duration (hours). The remaining 20% ​​of the refueling cycle is calculated using a multiplication block and compared with the remaining time. If the remaining refueling cycle is greater than 20%, no alarm is triggered. If it is less than or equal to 20%, a Level II alarm for 20% is activated and turns yellow, reminding staff to plan refueling earlier. Similarly, the remaining 10% of the refueling cycle is calculated using a multiplication block and compared with the remaining time. If the remaining 10% of the refueling cycle is greater than 10%, only a Level II alarm for 20% is triggered; a Level I alarm for 10% is not triggered. If it is less than or equal to 10%, a Level I alarm for 10% is activated and turns red, reminding staff that refueling is necessary. After refueling, staff can reset the cycle by pressing the reset button and entering a password to enter the next statistical cycle. If the equipment motor switch is in the off position, no statistics are collected, and equipment operation is not displayed. This allows for accurate tracking of equipment uptime according to the manufacturer's recommended refueling schedule, preventing equipment damage caused by exceeding the refueling interval.

[0047] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

[0048] Example 3 is the third embodiment of the present invention, which differs from the previous two embodiments in that:

[0049] If the aforementioned functions are implemented as software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0050] The logic and / or steps represented in the flowchart or otherwise described herein, for example, can be considered as a sequenced list of executable instructions for implementing logical functions, and can be embodied in any computer-readable medium for use by, or in conjunction with, an instruction execution system, apparatus, or device (such as a computer-based system, a processor-included system, or other system that can fetch and execute instructions from, an instruction execution system, apparatus, or device). For the purposes of this specification, "computer-readable medium" can be any means that can contain, store, communicate, propagate, or transmit programs for use by, or in conjunction with, an instruction execution system, apparatus, or device.

[0051] More specific examples of computer-readable media (a non-exhaustive list) include: electrical connections (electronic devices) having one or more wires, portable computer disk drives (magnetic devices), random access memory (RAM), read-only memory (ROM), erasable and editable read-only memory (EPROM or flash memory), fiber optic devices, and portable optical disc read-only memory (CDROM). Furthermore, computer-readable media can even be paper or other suitable media on which the program can be printed, because the program can be obtained electronically, for example, by optically scanning the paper or other medium, followed by editing, interpreting, or otherwise processing as necessary, and then stored in computer memory.

[0052] It should be understood that various parts of the present invention can be implemented in hardware, software, firmware, or a combination thereof. In the above embodiments, multiple steps or methods can be implemented in software or firmware stored in memory and executed by a suitable instruction execution system. For example, if implemented in hardware, as in another embodiment, it can be implemented using any one or a combination of the following techniques known in the art: discrete logic circuits having logic gates for implementing logical functions on data signals, application-specific integrated circuits (ASICs) having suitable combinational logic gates, programmable gate arrays (PGAs), field-programmable gate arrays (FPGAs), etc.

[0053] Example 4, an embodiment of the present invention, provides an online monitoring auxiliary refueling management system based on DCS or SIS, including an equipment status acquisition module, a time calculation and statistics module, an alarm control module, and a human-machine interaction module.

[0054] The equipment status acquisition module collects the on / off status signals of the auxiliary motors in real time and scans the periodically to detect the equipment's operating status.

[0055] The time calculation and statistics module accumulates the running time and converts it to hours using a division unit; it dynamically calculates the difference between the preset refueling cycle and the accumulated running hours and outputs the remaining time.

[0056] The alarm control module generates a yellow alarm signal when the remaining time is less than or equal to 20% of the refueling cycle and a red alarm signal when the remaining time is less than or equal to 10% of the refueling cycle.

[0057] The human-machine interaction module generates equipment information blocks on the DCS / SIS screen, displaying the name, refueling cycle, remaining time, and alarm status in layers; it receives password verification commands and triggers a reset operation to set the accumulated time to zero and the remaining time to zero.

[0058] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A method for managing auxiliary equipment refueling based on DCS or SIS online monitoring, characterized in that: include, Information on auxiliary equipment requiring grease lubrication is displayed in the form of squares on the DCS or SIS monitoring screen; The running time of the auxiliary motor is counted in real time, and the remaining time before the next refueling is dynamically calculated. The first-level alarm is triggered when the remaining time is less than or equal to 20% of the refueling cycle. A second-level alarm is triggered when the remaining time is less than or equal to 10% of the refueling cycle. After the person in charge of the equipment completes refueling, they reset the runtime statistics by using a password verification system.

2. The auxiliary machine refueling management method based on DCS or SIS online monitoring as described in claim 1, characterized in that: The information displayed in the box includes the equipment name, preset refueling cycle, and real-time remaining time.

3. The auxiliary machine refueling management method based on DCS or SIS online monitoring as described in claim 2, characterized in that: The first-level alarm is indicated by a yellow visual cue, and the second-level alarm is indicated by a red visual cue.

4. The auxiliary machine refueling management method based on DCS or SIS online monitoring as described in claim 3, characterized in that: The password-verified reset system includes a reset operation that involves entering a password to verify identity. Once the verification is successful, the remaining time is reset to a preset refueling cycle.

5. The auxiliary machine refueling management method based on DCS or SIS online monitoring as described in claim 4, characterized in that: The statistical auxiliary motor running time includes determining equipment operation by the on / off status of the auxiliary motor; If the switch is in the closed state, the running time is accumulated according to the preset scanning cycle.

6. The auxiliary machine refueling management method based on DCS or SIS online monitoring as described in claim 5, characterized in that: The calculation of the remaining time until the next refueling includes converting the cumulative running time into hours. The difference between the refueling cycle and the cumulative running hours is calculated using the subtraction module.

7. The auxiliary machine refueling management method based on DCS or SIS online monitoring as described in claim 6, characterized in that: When an alarm is triggered, the display color of the corresponding block changes to yellow or red in real time.

8. A system for auxiliary equipment refueling management based on DCS or SIS online monitoring, employing the method for auxiliary equipment refueling management based on DCS or SIS online monitoring as described in any one of claims 1 to 7, characterized in that, Includes: equipment status acquisition module, time calculation and statistics module, alarm control module, and human-machine interaction module. The equipment status acquisition module collects the on / off status signals of the auxiliary motor in real time and scans the periodically to detect the equipment operating status. The time calculation and statistics module accumulates the running time and converts it to hourly units through a division unit; it dynamically calculates the difference between the preset refueling cycle and the accumulated running hours, and outputs the remaining time. The alarm control module generates a yellow alarm signal when the remaining time is less than or equal to 20% of the refueling cycle and a red alarm signal when the remaining time is less than or equal to 10% of the refueling cycle. The human-machine interaction module generates equipment information blocks on the DCS / SIS screen, displaying the name, refueling cycle, remaining time, and alarm status in layers; it receives password verification commands and triggers a reset operation to set the accumulated time to zero and the remaining time to zero.

9. A computer device comprising a memory and a processor, wherein the memory stores a computer program, characterized in that, When the processor executes the computer program, it implements the steps of any one of claims 1 to 7 of the auxiliary machine refueling management method based on DCS or SIS online monitoring.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the computer program is executed by the processor, it implements the steps of any one of the DCS or SIS online monitoring auxiliary machine refueling management methods according to claims 1 to 7.

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