Instrument automatic control system in caustic soda production process

Abstract

The application discloses an instrument automatic control system in caustic soda production process, and relates to the technical field of instrument automatic control, in order to solve the problem of inaccurate control of different instrument equipment in the caustic soda production process. The application subdivides process, control and detection equipment types, implements multi-dimensional detection such as appearance inspection and mechanical function verification, ensures the reliability of equipment cooperation, dynamically adjusts and maintains the production stable by DCS for non-safety parameters, and triggers the stop of safety parameters through SIS to realize forced action; the production environment and liquid level control are classified according to the risk response, the state of power equipment is monitored in real time, the interlocking logic modification and verification process is standardized, the data is integrated to generate multi-dimensional reports, and early warning of equipment failure is realized.

Description

Technical Field

[0001] This invention relates to the field of instrument automation control technology, specifically to an instrument automation control system in the caustic soda production process. Background Technology

[0002] The existing instrumentation and control systems for caustic soda production processes have many shortcomings: the equipment function detection is incomplete, failing to cover all types of equipment and their linkage performance, making production fluctuations easily caused by hidden equipment failures; the acquisition of key parameters lacks standardized equipment matching and calibration procedures, resulting in high data distortion rates and control deviations; the control of non-safe and safe parameters is confused, with delayed response; the gas monitoring and early warning classification is ambiguous; and the liquid level control logic is simple, making it difficult to balance production continuity and safety, thus requiring systemic optimization. Summary of the Invention

[0003] The purpose of this invention is to provide an automated control system for the instrumentation in the caustic soda production process. By subdividing the types of process, control, and detection equipment, and implementing multi-dimensional detection such as visual inspection and mechanical function verification, the system ensures reliable equipment coordination. Non-safety parameters are dynamically adjusted by the DCS to maintain stable production, while safety parameters are quickly triggered by the SIS to perform mandatory actions such as shutdown. The production environment and liquid level control respond according to risk levels, monitor the status of power equipment in real time, standardize the modification and verification process of interlock logic, and integrate data to generate multi-dimensional reports, thereby achieving early warning of equipment failures and solving the problems in the prior art.

[0004] To achieve the above objectives, the present invention provides the following technical solution:

[0005] The instrumentation automation control system in the caustic soda production process includes:

[0006] The equipment control and management unit is used to verify and test the functionality of the equipment involved in the caustic soda production process;

[0007] The key parameter data acquisition unit is used to collect key parameters in the caustic soda production process in real time based on the equipment involved.

[0008] A conventional control unit is used to automatically adjust non-safety interlock parameters in the real-time collected key parameter data;

[0009] The safety interlock control unit is used to automatically adjust the safety interlock parameters in the key parameter data collected in real time;

[0010] The production environment monitoring unit is used to monitor the concentration of combustible and toxic gases in the production environment during the caustic soda production process, and to issue graded alarms based on the concentration.

[0011] The liquid level control unit is used to dynamically control the liquid level in storage tanks and reaction vessels during the caustic soda production process.

[0012] The equipment operation monitoring unit is used to monitor the operating status of the power equipment involved in the caustic soda production process;

[0013] The interlocking logic management unit is used to modify the logical configuration of the interlocking relationships between each process in the caustic soda production process using logic configuration tools.

[0014] The remote monitoring and diagnostic unit is used to process and generate reports on remote monitoring data and equipment fault diagnosis data of the caustic soda production process.

[0015] Preferably, the device control and management unit includes:

[0016] The equipment involved in the caustic soda production process includes process equipment, control equipment, and testing equipment;

[0017] The process equipment includes electrolysis and chlor-alkali treatment equipment, chlorine treatment equipment, hydrogen treatment equipment, hydrogen chloride synthesis equipment, liquid chlorine liquefaction and packaging equipment, and acid and alkali tank area equipment;

[0018] The control equipment includes a DCS control system, a SIS safety instrumented system, and a GDS combustible and toxic gas detection system;

[0019] The detection equipment includes sensors and gas detectors; the sensors include pressure sensors, flow sensors, liquid level sensors, temperature sensors, pH sensors, vibration sensors, and displacement sensors; the gas detectors include combustible gas detectors and toxic gas detectors.

[0020] The equipment involved in the caustic soda production process undergoes functional testing in sequence. The functional testing includes appearance and basic inspection, mechanical component functional testing, electrical and control system connection testing, functional parameter verification, and equipment linkage function testing.

[0021] After all equipment has been tested and qualified, the next process step will be carried out.

[0022] Preferably, the key parameter data acquisition unit includes:

[0023] Based on the operational requirements of the process equipment, the parameter types collected for each process equipment are confirmed, and the operational requirements of the process equipment are retrieved from the database.

[0024] Identify the corresponding testing equipment based on the parameter type, then install the testing equipment on the monitoring point of the process equipment and calibrate the testing equipment.

[0025] The detection equipment monitors parameter changes at the equipment monitoring points of the process equipment and converts the measured values ​​into electrical or digital signals according to a preset frequency.

[0026] The converted electrical or digital signal is transmitted to the corresponding control device;

[0027] The control equipment performs data preprocessing on the received data;

[0028] After data preprocessing, key parameter data are obtained.

[0029] Preferably, the conventional control unit includes:

[0030] The non-safety interlock parameters in the key parameter data are: parameters in the process equipment that are displayed, alarmed, and automatically adjusted by the DCS system and do not trigger SIS safety interlocks;

[0031] The DCS control system is used to automatically adjust non-safety interlock parameters. The automatic adjustment steps include:

[0032] S1: According to process requirements, preset the normal operating range and adjustment threshold of each non-safety interlock parameter in the DCS control system;

[0033] S2: The DCS control system receives non-safety interlock parameters collected in real time and compares the received data with preset normal operation data;

[0034] S3: Based on the comparison results, confirm the direction of deviation between the received data and the normal operating data, and automatically generate the corresponding adjustment command;

[0035] The adjustment indicators include flow parameter adjustment instructions, pressure parameter adjustment instructions, liquid level parameter adjustment instructions, temperature parameter adjustment instructions, and storage tank liquid level adjustment instructions.

[0036] S4: The DCS control system sends the generated adjustment commands to the corresponding process equipment;

[0037] S5: After the process equipment executes the adjustment command, the DCS control system continuously monitors the parameter changes.

[0038] Preferably, the safety interlock control unit includes:

[0039] The safety interlock parameters in the key parameter data are those that are monitored by the SIS safety instrumented system and trigger emergency safety actions when the parameters reach the interlock value.

[0040] The SIS safety instrumented system is used to automatically adjust safety interlock parameters. The automatic adjustment steps include:

[0041] S1: According to safety regulations, the interlock values ​​and corresponding safety action logic of safety interlock parameters in the SIS safety instrumented system;

[0042] S2: The SIS safety instrumented system receives real-time collected safety interlock parameters and compares the values ​​of the safety interlock parameters with preset interlock values;

[0043] S3: Based on the comparison results, the SIS safety instrumented system sends and executes mandatory commands to the process equipment corresponding to the interlocking logic;

[0044] Among these, mandatory commands include shutdown, material cut-off, and isolation;

[0045] S4: After the process equipment executes the command according to the mandatory command, it reports the execution status to the SIS safety instrumented system. The SIS safety instrumented system confirms that the mandatory command has been completed and synchronizes the interlock information.

[0046] S5: Staff conduct on-site troubleshooting and manually perform interlock reset on the SIS safety instrumented system.

[0047] Preferably, the production environment monitoring unit includes:

[0048] First, identify the monitoring areas for combustible and toxic gases in the production environment. The combustible gas is hydrogen, and the toxic gas is chlorine. The monitoring areas include areas with a high incidence of equipment leaks, enclosed or semi-enclosed spaces, and areas with high personnel activity.

[0049] The gas detector monitors the gas in the monitoring area, collecting data every 1-5 seconds. The gas detector converts the concentration values ​​of combustible and toxic gases into 4-20mA electrical or digital signals, which are then transmitted to the GDS combustible and toxic gas detection system via cable.

[0050] The GDS combustible and toxic gas detection system performs graded alarms based on the received data;

[0051] The warning range for combustible gases is: Level 1 alarm and Level 2 alarm, with a Level 1 alarm threshold of 20% LEL and a Level 2 alarm threshold of 40% LEL.

[0052] The warning range for toxic gases is: Level 1 alarm and Level 2 alarm, with a threshold of 1 ppm for Level 1 alarm and 2 ppm for Level 2 alarm.

[0053] After the scope of the graded alarm is confirmed, the alarm is executed. The alarm execution operation for the first-level alarm is as follows: the GDS combustible and toxic gas detection system triggers the workshop's audible and visual alarm, displays the alarm information on the monitoring interface, and automatically pushes the alarm information to the personnel on duty.

[0054] The alarm execution for a Level 2 alarm is as follows: the GDS combustible and toxic gas detection system triggers a high-intensity audible and visual alarm in the workshop, the alarm information is highlighted on the monitoring interface and marked as an emergency event, the emergency event is automatically pushed to the corresponding safety officer, and finally the ventilation system is activated for ventilation.

[0055] Ultimately, the GDS combustible and toxic gas detection system will synchronize alarm events to the DCS control system in real time. Alarm events include gas type, concentration value, occurrence time, area and alarm level, and automatically record and store the entire alarm process data, including concentration change curves, alarm duration and processing record data.

[0056] Preferably, the liquid level control unit includes:

[0057] Based on the process requirements of the storage tanks and reaction vessels, confirm the normal range of liquid level, alarm values, and interlock values ​​of the storage tanks and reaction vessels;

[0058] The liquid level sensor monitors the liquid level of the storage tank and reaction tank in real time, converts the liquid level value into an electrical signal at a preset frequency, and transmits it to the DCS control system. After receiving the data, the DCS control system performs filtering processing and displays the current liquid level value and trend curve of the storage tank and reaction tank in real time on the monitoring interface.

[0059] Configure the control logic for the liquid levels of storage tanks and reaction vessels in the DCS control system, and confirm the corresponding actions for different liquid level ranges;

[0060] The control logic includes normal range, alarm range, and interlock range. The corresponding action of the normal range is to maintain the current feeding or discharging state when the liquid level is in the normal range. The corresponding action of the alarm range is to start the adjustment action when the liquid level reaches the alarm value. The corresponding action of the interlock range is to trigger the emergency action when the liquid level reaches the interlock value.

[0061] Ultimately, dynamic control of the liquid level in the storage tank and reaction vessel is achieved.

[0062] Preferably, the equipment operation monitoring unit includes:

[0063] Power equipment includes pumps, compressors, rectifiers, and motors;

[0064] Based on the type and operating characteristics of the power equipment, the key parameters to be monitored are confirmed;

[0065] Depending on the type of key parameters, corresponding sensors are installed at the monitoring points of the power equipment, including temperature sensors, vibration sensors, displacement sensors, and pressure sensors.

[0066] Each sensor collects the operating data of the power equipment according to a preset frequency, converts the physical quantity of the collected operating data into a 4-20mA electrical signal or digital signal, and transmits the converted information to the DCS control system.

[0067] The DCS control system receives the transmitted data, configures the monitoring threshold for each monitoring data, and associates it with the corresponding alarm logic.

[0068] The DCS control system compares the collected operating data with preset thresholds based on the alarm logic and corresponding results, and adjusts the operating status of the power equipment according to the comparison results. When the staff receives an alarm, they retrieve the historical data and trend charts of the alarm device through the DCS control system, and adjust the operating status of the power equipment in conjunction with the abnormal reasons found during on-site inspections.

[0069] Preferably, the interlocking logic management unit includes:

[0070] First, retrieve the interlocking logic configuration data for each process from the SIS safety instrumented system, and sort out the logical relationships. After sorting out the logical relationships, generate a logic list for each process.

[0071] Start the logic configuration tool in the SIS safety instrumented system, import the logic list into the logic configuration tool to build the interlocking logic diagram;

[0072] Define the mapping relationship between input parameters and output actions in the interlocking logic construction diagram, and set the threshold of interlocking conditions and action delay time.

[0073] Download the interlocking logic diagram with interlocking conditions set to the SIS safety instrumented system;

[0074] After downloading, perform centrifugation verification, which includes static verification, dynamic verification, and environmental verification.

[0075] After the centrifugation verification is completed and passed, the logic configuration is modified.

[0076] Preferably, the remote monitoring and diagnostic unit includes:

[0077] Remote monitoring data includes monitoring data of process equipment, control equipment, and testing equipment, including real-time values ​​and historical trends of various process parameters, equipment operating status data, alarm records, and process interlock action records;

[0078] Equipment fault diagnosis data consists of alarm data from remote monitoring data, including faulty equipment number and type, fault symptoms, associated parameters at the time of the fault, and fault handling process.

[0079] First, perform data preprocessing on remote monitoring data and equipment fault diagnosis data, including data cleaning, data standardization, and data unification;

[0080] After data preprocessing, data classification is performed, including classification by process step, data type, and equipment.

[0081] Data analysis is performed based on the data classification results, including trend analysis, correlation analysis, and statistical analysis.

[0082] Reports are generated based on the data analysis results. The generated reports include operation reports, fault diagnosis reports, and summary reports.

[0083] The generated report undergoes manual review. Once the review is completed and the report is deemed acceptable, it is converted into visual data and then transmitted to a display terminal for display.

[0084] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0085] 1. The instrument automation control system for caustic soda production provided by this invention, through the subdivision of process, control, and testing equipment types, implements multi-dimensional testing such as visual inspection and mechanical function verification to ensure reliable equipment coordination; it precisely matches testing equipment according to process requirements, and ensures the quality of parameter acquisition through calibration and standardization. This eliminates equipment blind spots and data distortion problems from the source, reduces unplanned downtime by more than 30%, and lays a stable equipment and data foundation for automated control.

[0086] 2. In the caustic soda production process provided by this invention, the instrument automation control system dynamically adjusts non-safety parameters to maintain stable production, while safety parameters are quickly triggered by the SIS to perform forced actions such as shutdown; the production environment and liquid level control respond according to risk level.

[0087] 3. The instrument automation control system in the caustic soda production process provided by this invention monitors the status of power equipment in real time, standardizes the modification and verification process of interlock logic, integrates data to generate multi-dimensional reports, realizes early warning of equipment failure, zero risk of logic modification, and data-driven management decisions, reduces the troubleshooting time by 40%, and provides full-process data support for process optimization. Attached Figure Description

[0088] Figure 1 This is a schematic diagram of the instrument automation control unit of the present invention;

[0089] Figure 2 This is a schematic diagram of the instrument automation control steps of the present invention. Detailed Implementation

[0090] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0091] To address the issues of incomplete functional testing of caustic soda production equipment in existing technologies, and the lack of standardized equipment matching, calibration, and data processing for key parameter acquisition, which lead to low equipment reliability and inaccurate parameter data, please refer to [the relevant documentation]. Figure 1 and Figure 2 This embodiment provides the following technical solution:

[0092] The instrumentation automation control system in the caustic soda production process includes:

[0093] The equipment control and management unit is used to verify and test the functionality of the equipment involved in the caustic soda production process;

[0094] The key parameter data acquisition unit is used to collect key parameters in the caustic soda production process in real time based on the equipment involved.

[0095] A conventional control unit is used to automatically adjust non-safety interlock parameters in the real-time collected key parameter data;

[0096] The safety interlock control unit is used to automatically adjust the safety interlock parameters in the key parameter data collected in real time;

[0097] The production environment monitoring unit is used to monitor the concentration of combustible and toxic gases in the production environment during the caustic soda production process, and to issue graded alarms based on the concentration.

[0098] The liquid level control unit is used to dynamically control the liquid level in storage tanks and reaction vessels during the caustic soda production process.

[0099] The equipment operation monitoring unit is used to monitor the operating status of the power equipment involved in the caustic soda production process;

[0100] The interlocking logic management unit is used to modify the logical configuration of the interlocking relationships between each process in the caustic soda production process using logic configuration tools.

[0101] The remote monitoring and diagnostic unit is used to process and generate reports on remote monitoring data and equipment fault diagnosis data of the caustic soda production process.

[0102] The equipment control and management unit includes:

[0103] The equipment involved in the caustic soda production process includes process equipment, control equipment, and testing equipment;

[0104] The process equipment includes electrolysis and chlor-alkali treatment equipment, chlorine treatment equipment, hydrogen treatment equipment, hydrogen chloride synthesis equipment, liquid chlorine liquefaction and packaging equipment, and acid and alkali tank area equipment;

[0105] The control equipment includes a DCS control system, a SIS safety instrumented system, and a GDS combustible and toxic gas detection system;

[0106] The detection equipment includes sensors and gas detectors; the sensors include pressure sensors, flow sensors, liquid level sensors, temperature sensors, pH sensors, vibration sensors, and displacement sensors; the gas detectors include combustible gas detectors and toxic gas detectors.

[0107] The equipment involved in the caustic soda production process undergoes functional testing in sequence. The functional testing includes appearance and basic inspection, mechanical component functional testing, electrical and control system connection testing, functional parameter verification, and equipment linkage function testing.

[0108] After all equipment has been tested and qualified, the next process step will be carried out.

[0109] Specifically, by clearly defining three main categories—process equipment, control equipment, and testing equipment—and further specifying specific equipment models and functions, this ensures that all equipment directly involved in production, control, and monitoring throughout the caustic soda production process is included in the management scope. This avoids blind spots in control caused by equipment omissions. Functional testing ranges from basic visual inspection to specialized testing of mechanical components and electrical connections, and then to parameter verification and equipment linkage testing, forming a comprehensive testing chain from point to surface, and from single function to system collaboration. This design not only ensures that the performance of individual equipment meets standards but also verifies the collaborative capabilities between equipment, ensuring that the equipment group can operate in a coordinated manner in actual production. All equipment must pass testing before entering the next process, preventing unqualified equipment from being put into production at the source and reducing unplanned downtime, product quality fluctuations, or safety accidents caused by equipment failures. At the same time, specialized tests are designed for different equipment characteristics, improving the targeting and accuracy of testing and providing a reliable equipment foundation for subsequent automated control.

[0110] The key parameter data acquisition unit includes:

[0111] Based on the operational requirements of the process equipment, the parameter types collected for each process equipment are confirmed, and the operational requirements of the process equipment are retrieved from the database.

[0112] Identify the corresponding testing equipment based on the parameter type, then install the testing equipment on the monitoring point of the process equipment and calibrate the testing equipment.

[0113] The detection equipment monitors parameter changes at the equipment monitoring points of the process equipment and converts the measured values ​​into electrical or digital signals according to a preset frequency.

[0114] The converted electrical or digital signal is transmitted to the corresponding control device;

[0115] The control equipment performs data preprocessing on the received data;

[0116] After data preprocessing, key parameter data are obtained.

[0117] Specifically, parameter types are determined based on the operational requirements of the process equipment, and these requirements are retrieved from the database, ensuring a high degree of matching between parameter acquisition and actual production. The core parameters of different process equipment vary significantly; customized parameter confirmation avoids redundant acquisition of irrelevant data, reducing the load on data transmission and processing while preserving the core value of the acquired data. This provides precise, targeted information for subsequent control and adjustment, with dual protection achieved through equipment calibration and signal standardization. The calibration process before equipment installation eliminates issues such as sensor drift and detector sensitivity deviation, ensuring the accuracy of the original measurements. Converting measured values ​​into electrical or digital signals standardizes the data format, reducing compatibility issues between different equipment. This design lays a reliable foundation for data preprocessing in control equipment, avoiding control decision deviations caused by distorted raw data. The preset frequency signal conversion mechanism ensures real-time data acquisition, enabling dynamic capture of parameter changes. The data preprocessing stage in control equipment further purifies the data, ensuring the usability of the final key parameter data. This systematic design not only meets the timeliness requirements of automated control, but also improves data quality through multi-layer verification, providing high-quality data input for subsequent routine control, safety interlock and other units, thus ensuring the stable operation of the entire automated system from the source.

[0118] To address the issues in existing technologies, such as non-automatic adjustment of non-safety interlock parameters, untimely safety interlock control, unclear gas monitoring and early warning classifications, and imperfect liquid level control logic, which affect production stability and safety, please refer to [the relevant documentation / reference]. Figure 1 and Figure 2 This embodiment provides the following technical solution:

[0119] A conventional control unit includes:

[0120] The non-safety interlock parameters in the key parameter data are: parameters in the process equipment that are displayed, alarmed, and automatically adjusted by the DCS system and do not trigger SIS safety interlocks;

[0121] The DCS control system is used to automatically adjust non-safety interlock parameters. The automatic adjustment steps include:

[0122] S1: According to process requirements, preset the normal operating range and adjustment threshold of each non-safety interlock parameter in the DCS control system;

[0123] S2: The DCS control system receives non-safety interlock parameters collected in real time and compares the received data with preset normal operation data;

[0124] S3: Based on the comparison results, confirm the direction of deviation between the received data and the normal operating data, and automatically generate the corresponding adjustment command;

[0125] The adjustment indicators include flow parameter adjustment instructions, pressure parameter adjustment instructions, liquid level parameter adjustment instructions, temperature parameter adjustment instructions, and storage tank liquid level adjustment instructions.

[0126] S4: The DCS control system sends the generated adjustment commands to the corresponding process equipment;

[0127] S5: After the process equipment executes the adjustment command, the DCS control system continuously monitors the parameter changes.

[0128] Specifically, the definition of non-safety interlock parameters is clearly defined, avoiding confusion with the control of safety parameters; preset normal operating ranges and adjustment thresholds provide clear intervention standards for parameter fluctuations. Adjustment commands are subdivided into specific types such as flow rate, pressure, and level, enabling process equipment to receive targeted instructions. For example, flow rate adjustment commands can precisely control material ratios, and temperature adjustment commands can stabilize the reaction environment, significantly improving the accuracy of parameter control. The DCS control system continuously receives parameter data and compares it with preset ranges. Once a deviation is detected, an adjustment command is immediately generated to ensure that parameters are always maintained within the required process range. This dynamic adjustment capability effectively avoids production fluctuations caused by abnormal non-safety parameters. Furthermore, because it does not involve SIS interlock actions, smooth adjustment can be achieved while ensuring safety, reducing interference with production continuity and providing reliable support for stable capacity and product quality. From an operational efficiency perspective, automated adjustment reduces the need for manual intervention, lowering the lag and error rate of human operation. Subdivided adjustment commands make equipment responses more targeted, improving adjustment efficiency; the continuous monitoring mechanism can promptly detect potential deviations and intervene in advance, preventing small fluctuations from escalating into major malfunctions. This efficient control mode not only reduces operation and maintenance costs, but also enhances the production line's ability to adapt to subtle changes in process parameters, creating conditions for optimizing production processes and improving overall operational efficiency.

[0129] The safety interlock control unit includes:

[0130] The safety interlock parameters in the key parameter data are those that are monitored by the SIS safety instrumented system and trigger emergency safety actions when the parameters reach the interlock value.

[0131] The SIS safety instrumented system is used to automatically adjust safety interlock parameters. The automatic adjustment steps include:

[0132] S1: According to safety regulations, the interlock values ​​and corresponding safety action logic of safety interlock parameters in the SIS safety instrumented system;

[0133] S2: The SIS safety instrumented system receives real-time collected safety interlock parameters and compares the values ​​of the safety interlock parameters with preset interlock values;

[0134] S3: Based on the comparison results, the SIS safety instrumented system sends and executes mandatory commands to the process equipment corresponding to the interlocking logic;

[0135] Among these, mandatory commands include shutdown, material cut-off, and isolation;

[0136] S4: After the process equipment executes the command according to the mandatory command, it reports the execution status to the SIS safety instrumented system. The SIS safety instrumented system confirms that the mandatory command has been completed and synchronizes the interlock information.

[0137] S5: Staff conduct on-site troubleshooting and manually perform interlock reset on the SIS safety instrumented system.

[0138] Specifically, a rigid safety barrier is constructed through an independent system and clear logic. Safety interlock parameters are exclusively monitored by the SIS (Safety Instrumented System), functionally isolated from the conventional DCS (Distributed Control System), avoiding the risk of inter-system interference. Interlock values ​​and corresponding safety action logic are preset according to safety specifications, ensuring that emergency measures after parameter exceedances are systematic and followable. This design addresses high-risk scenarios in caustic soda production, such as high-temperature, high-pressure, and toxic media. In extreme situations like chlorine leaks or excessive hydrogen levels, it can quickly interrupt the danger chain through mandatory commands, preventing the escalation of safety accidents. The SIS receives and compares safety interlock parameters in real time, immediately triggering mandatory commands once interlock values ​​are reached, eliminating manual judgment and reducing response time to milliseconds. Simultaneously, process equipment must report its status to the SIS after executing commands, ensuring that safety actions are effectively implemented and avoiding risk exposure due to command failures. This closed-loop mechanism of "monitoring-judgment-execution-feedback" buys crucial time to curb the spread of danger, significantly improving the efficiency of emergency response. Interlock reset requires manual execution by staff after on-site troubleshooting, avoiding secondary risks that might arise from automatic reset and ensuring the root cause of the fault is completely eliminated. The interlock information synchronization mechanism enables full traceability of safety events, providing data support for post-event analysis and process optimization. Furthermore, customized interlock logic for different safety parameters makes safety control more targeted, further enhancing the system's reliability and applicability. The automatic adjustment table is shown below:

[0139]

[0140]

[0141]

[0142] The production environment monitoring unit includes:

[0143] First, identify the monitoring areas for combustible and toxic gases in the production environment. The combustible gas is hydrogen, and the toxic gas is chlorine. The monitoring areas include areas with a high incidence of equipment leaks, enclosed or semi-enclosed spaces, and areas with high personnel activity.

[0144] The gas detector monitors the gas in the monitoring area, collecting data every 1-5 seconds. The gas detector converts the concentration values ​​of combustible and toxic gases into 4-20mA electrical or digital signals, which are then transmitted to the GDS combustible and toxic gas detection system via cable.

[0145] The GDS combustible and toxic gas detection system performs graded alarms based on the received data;

[0146] The warning range for combustible gases is: Level 1 alarm and Level 2 alarm, with a Level 1 alarm threshold of 20% LEL and a Level 2 alarm threshold of 40% LEL.

[0147] The warning range for toxic gases is: Level 1 alarm and Level 2 alarm, with a threshold of 1 ppm for Level 1 alarm and 2 ppm for Level 2 alarm.

[0148] After the scope of the graded alarm is confirmed, the alarm is executed. The alarm execution operation for the first-level alarm is as follows: the GDS combustible and toxic gas detection system triggers the workshop's audible and visual alarm, displays the alarm information on the monitoring interface, and automatically pushes the alarm information to the personnel on duty.

[0149] The alarm execution for a Level 2 alarm is as follows: the GDS combustible and toxic gas detection system triggers a high-intensity audible and visual alarm in the workshop, the alarm information is highlighted on the monitoring interface and marked as an emergency event, the emergency event is automatically pushed to the corresponding safety officer, and finally the ventilation system is activated for ventilation.

[0150] Ultimately, the GDS combustible and toxic gas detection system will synchronize alarm events to the DCS control system in real time. Alarm events include gas type, concentration value, occurrence time, area and alarm level, and automatically record and store the entire alarm process data, including concentration change curves, alarm duration and processing record data.

[0151] Specifically, the system clearly focuses on two core hazardous sources in caustic soda production: hydrogen (flammable) and chlorine (toxic). It also identifies high-risk areas such as equipment leakage hotspots, enclosed spaces, and densely populated areas, ensuring monitoring resources are concentrated on the most critical scenarios. A high-frequency data acquisition interval of 1-5 seconds, combined with stable transmission of 4-20mA electrical or digital signals, captures subtle changes in gas concentration. The specialized processing by the GDS flammable and toxic gas detection system avoids interference from irrelevant gases or areas, providing high-quality raw data for subsequent alarms. Multiple threshold levels are set for each type of gas, corresponding to differentiated alarm execution strategies: Level 1 alarms trigger audible and visual alerts in the workshop and push information to on-duty personnel for early warning; Level 2 alarms escalate to high-intensity audible and visual alarms, emergency event labeling, and direct push notifications to safety supervisors, while simultaneously linking with the ventilation system to form a closed loop from early warning to initial response. This tiered response avoids excessive disruption to production caused by low-risk alarms while ensuring emergency handling of high-risk situations, thus improving emergency response efficiency. The GDS combustible and toxic gas detection system synchronizes alarm events to the DCS in real time, covering key information such as gas type, concentration, time, area, and level, and automatically records concentration change curves, duration, and handling records, providing complete data support for post-event analysis, accountability, and process optimization. This end-to-end data retention mechanism not only meets the compliance requirements of safety management but also provides historical data references for risk prediction. Regarding the effectiveness of emergency linkage, the design of the two-level alarm linkage ventilation system achieves seamless connection between alarm and response. By actively activating ventilation to reduce gas concentration, initial control can be carried out before the safety officer intervenes, delaying the escalation of risks. At the same time, alarm information is accurately pushed to the corresponding personnel according to level, avoiding redundancy or omissions in information transmission, ensuring clear response responsibilities and efficient action, and significantly improving the ability to control environmental risks.

[0152] The liquid level control unit includes:

[0153] Based on the process requirements of the storage tanks and reaction vessels, confirm the normal range of liquid level, alarm values, and interlock values ​​of the storage tanks and reaction vessels;

[0154] The liquid level sensor monitors the liquid level of the storage tank and reaction tank in real time, converts the liquid level value into an electrical signal at a preset frequency, and transmits it to the DCS control system. After receiving the data, the DCS control system performs filtering processing and displays the current liquid level value and trend curve of the storage tank and reaction tank in real time on the monitoring interface.

[0155] Configure the control logic for the liquid levels of storage tanks and reaction vessels in the DCS control system, and confirm the corresponding actions for different liquid level ranges;

[0156] The control logic includes normal range, alarm range, and interlock range. The corresponding action of the normal range is to maintain the current feeding or discharging state when the liquid level is in the normal range. The corresponding action of the alarm range is to start the adjustment action when the liquid level reaches the alarm value. The corresponding action of the interlock range is to trigger the emergency action when the liquid level reaches the interlock value.

[0157] Ultimately, dynamic control of the liquid level in the storage tank and reaction vessel is achieved.

[0158] Specifically, the normal range, alarm value, and interlock value of the liquid levels in storage tanks and reaction vessels are clearly defined, providing clear thresholds for control. Liquid level sensors collect data at a preset frequency and convert it into electrical signals. After filtering by the DCS control system, the current value and trend curve are displayed in real time on the monitoring interface. This not only filters out signal noise to ensure data accuracy but also helps operators predict liquid level changes through trend visualization, laying the foundation for precise adjustment. Within the normal range, the current state is maintained, avoiding unnecessary adjustments that disrupt production stability. In the alarm range, adjustment actions are initiated, actively intervening to bring the liquid level back to the normal range. In the interlock range, emergency actions are triggered to prevent overflow due to excessively high liquid levels or idling of equipment due to excessively low liquid levels. This tiered response ensures stable routine production while allowing for escalated handling in case of anomalies, balancing production continuity and safety. The liquid level sensors continuously collect data, and the DCS control system automatically matches corresponding actions according to preset control logic, dynamically maintaining liquid level stability without frequent manual intervention. For example, when the liquid level in the reaction tank approaches the alarm value due to feed fluctuations, the system can automatically adjust the discharge rate to avoid triggering the alarm. Real-time updates of the trend curve provide operators with a basis for adjusting control strategies, allowing the control logic to be flexibly optimized according to changes in process conditions. Liquid level data is connected to the DCS monitoring platform in real time, forming a linkage reference with other process parameters. Standardized configuration of the control logic ensures a unified liquid level control mode for different storage tanks and reaction tanks, facilitating centralized management. This synergy enhances the overall integrity of the production system and provides complete liquid level data support for subsequent data analysis and process optimization, helping to improve the overall operational efficiency.

[0159] To address the problems in existing technologies, such as unsystematic monitoring of key parameters of power equipment, non-standardized interlocking logic management, and weak remote monitoring data processing and diagnostic capabilities, which lead to low equipment operational safety and reliability, and poor fault handling efficiency, please refer to [the relevant documentation / reference]. Figure 1 and Figure 2 This embodiment provides the following technical solution:

[0160] The equipment operation monitoring unit includes:

[0161] Power equipment includes pumps, compressors, rectifiers, and motors;

[0162] Based on the type and operating characteristics of the power equipment, the key parameters to be monitored are confirmed;

[0163] Depending on the type of key parameters, corresponding sensors are installed at the monitoring points of the power equipment, including temperature sensors, vibration sensors, displacement sensors, and pressure sensors.

[0164] Each sensor collects the operating data of the power equipment according to a preset frequency, converts the physical quantity of the collected operating data into a 4-20mA electrical signal or digital signal, and transmits the converted information to the DCS control system.

[0165] The DCS control system receives the transmitted data, configures the monitoring threshold for each monitoring data, and associates it with the corresponding alarm logic.

[0166] The DCS control system compares the collected operating data with preset thresholds based on the alarm logic and corresponding results, and adjusts the operating status of the power equipment according to the comparison results. When the staff receives an alarm, they retrieve the historical data and trend charts of the alarm device through the DCS control system, and adjust the operating status of the power equipment in conjunction with the abnormal reasons found during on-site inspections.

[0167] Specifically, the system explicitly includes core power equipment such as pumps, compressors, rectifiers, and motors within its monitoring scope. Key parameters are customized based on equipment type and operating characteristics, and targeted sensors are installed to ensure that core operating indicators of each device are captured in real time, preventing missed fault detection due to monitoring blind spots. Sensors convert physical quantities into 4-20mA electrical or digital signals, which are stably transmitted to the DCS control system, reducing signal attenuation and interference while standardizing data formats. The monitoring thresholds and alarm logic configured in the DCS control system provide clear standards for automated data analysis, ensuring that raw data can be quickly transformed into information with decision-making value. The solution achieves early risk detection and handling through a "real-time monitoring - threshold comparison - alarm linkage" mechanism. When operating data exceeds preset thresholds, the DCS control system immediately triggers an alarm and simultaneously pushes information to staff. Staff can access historical data and trend charts through the system, combined with on-site inspections, to quickly locate the cause of anomalies, shortening troubleshooting time. This design shifts from reactive maintenance to proactive prevention, significantly reducing unplanned downtime. The DCS control system can automatically adjust equipment operating status based on comparison results, while retaining room for manual intervention. This ensures rapid response under complex operating conditions and avoids operational errors through professional judgment. Standardized monitoring logic and data traceability functions also provide data support for optimizing equipment maintenance plans and extending service life, improving the overall scientific and economical nature of power equipment management.

[0168] The interlocking logic management unit includes:

[0169] First, retrieve the interlocking logic configuration data for each process from the SIS safety instrumented system, and sort out the logical relationships. After sorting out the logical relationships, generate a logic list for each process.

[0170] Start the logic configuration tool in the SIS safety instrumented system, import the logic list into the logic configuration tool to build the interlocking logic diagram;

[0171] Define the mapping relationship between input parameters and output actions in the interlocking logic construction diagram, and set the threshold of interlocking conditions and action delay time.

[0172] Download the interlocking logic diagram with interlocking conditions set to the SIS safety instrumented system;

[0173] After downloading, perform centrifugation verification, which includes static verification, dynamic verification, and environmental verification.

[0174] After the centrifugation verification is completed and passed, the logic configuration is modified.

[0175] Specifically, by retrieving configuration data from the SIS safety instrumented system, clarifying logical relationships, and generating a list, it is ensured that the interlocking logic of each process is included in the standardized management scope, avoiding logical fragmentation or omissions. The application of logic configuration tools realizes the transformation from the list to a visual logic diagram, making complex interlocking relationships clearly identifiable. This facilitates managers' overall control of the connections between various processes, laying a systematic foundation for subsequent modifications and verifications. It clarifies the mapping relationship between input parameters and output actions, while setting thresholds and action delay times to ensure that the interlocking logic not only meets process safety requirements but also avoids malfunctions caused by instantaneous fluctuations. This refined configuration enables the SIS safety instrumented system to accurately assess risks under complex operating conditions, improving the reliability and relevance of safety interlocks. Static verification ensures that the configuration data is free of formal errors; dynamic verification verifies the effectiveness of the logic under operating conditions; and environmental verification simulates extreme conditions such as high temperature and electromagnetic interference to ensure stable operation of the logic in complex environments. The three-tiered verification process eliminates logical vulnerabilities at the source, significantly reducing safety risks caused by interlock failures. Visual editing via logic configuration tools makes logic adjustments during process optimization or equipment modification more efficient. Once verified, the logic can be downloaded to the SIS (Safety Instrumented System), shortening the cycle from logic update to practical application. This flexibility allows production lines to quickly adapt to process upgrades and capacity adjustments, enhancing the long-term applicability of the safety control system and providing reliable logical support for the continuous optimization of caustic soda production.

[0176] The remote monitoring and diagnostic unit includes:

[0177] Remote monitoring data includes monitoring data of process equipment, control equipment, and testing equipment, including real-time values ​​and historical trends of various process parameters, equipment operating status data, alarm records, and process interlock action records;

[0178] Equipment fault diagnosis data consists of alarm data from remote monitoring data, including faulty equipment number and type, fault symptoms, associated parameters at the time of the fault, and fault handling process.

[0179] First, perform data preprocessing on remote monitoring data and equipment fault diagnosis data, including data cleaning, data standardization, and data unification;

[0180] After data preprocessing, data classification is performed, including classification by process step, data type, and equipment.

[0181] Data analysis is performed based on the data classification results, including trend analysis, correlation analysis, and statistical analysis.

[0182] Reports are generated based on the data analysis results. The generated reports include operation reports, fault diagnosis reports, and summary reports.

[0183] The generated report undergoes manual review. Once the review is completed and the report is deemed acceptable, it is converted into visual data and then transmitted to a display terminal for display.

[0184] Specifically, remote monitoring and fault diagnosis data undergo cleaning, standardization, and unification to eliminate data redundancy and formatting issues. Classifying data by process stage, data type, and equipment transforms scattered monitoring data into structured datasets, facilitating efficient retrieval and providing a consistent data foundation for subsequent analysis. This avoids analytical biases caused by data clutter. Trend analysis tracks parameter changes, aiding in the prediction of potential faults. Correlation analysis reveals the intrinsic relationships between parameters, providing clues for fault tracing. Statistical analysis quantifies equipment operating indicators, supporting performance evaluation. This multi-level analysis overcomes the limitations of single-data sources, achieving a deep transformation from data to information. Operation reports present real-time production status, providing a basis for daily management; fault diagnosis reports focus on fault details and handling processes, facilitating rapid reproduction and problem resolution; and summary reports extract phased operational patterns, providing a reference for process optimization. Manual review ensures report accuracy, while visualization, using charts and graphs, presents data intuitively, lowering the barrier to understanding and enabling managers to quickly grasp core information. Centralized integration of system-wide data breaks down geographical limitations, allowing managers to remotely monitor the entire production process. Correlation analysis and report summaries of fault diagnosis data provide data-driven decision-making for equipment maintenance and process adjustments, reducing the subjectivity of experience-based judgments. This remote, data-driven management model improves management efficiency and enhances the accuracy of problem-solving, providing strong support for the stable operation and continuous improvement of caustic soda production.

[0185] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0186] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention.

Claims

1. An automated control system for the caustic soda production process, characterized in that, include: The equipment control and management unit is used to verify and test the functionality of the equipment involved in the caustic soda production process; The key parameter data acquisition unit is used to collect key parameters in the caustic soda production process in real time based on the equipment involved. A conventional control unit is used to automatically adjust non-safety interlock parameters in the real-time collected key parameter data; The safety interlock control unit is used to automatically adjust the safety interlock parameters in the key parameter data collected in real time; The production environment monitoring unit is used to monitor the concentration of combustible and toxic gases in the production environment during the caustic soda production process, and to issue graded alarms based on the concentration. The liquid level control unit is used to dynamically control the liquid level in storage tanks and reaction vessels during the caustic soda production process. The equipment operation monitoring unit is used to monitor the operating status of the power equipment involved in the caustic soda production process; The interlocking logic management unit is used to modify the logical configuration of the interlocking relationships between each process in the caustic soda production process using logic configuration tools. The remote monitoring and diagnostic unit is used to process and generate reports on remote monitoring data and equipment fault diagnosis data of the caustic soda production process. The interlocking logic management unit includes: First, retrieve the interlocking logic configuration data for each process from the SIS safety instrumented system, and sort out the logical relationships. After sorting out the logical relationships, generate a logic list for each process. Start the logic configuration tool in the SIS safety instrumented system, import the logic list into the logic configuration tool to build the interlocking logic diagram; Define the mapping relationship between input parameters and output actions in the interlocking logic construction diagram, and set the threshold of interlocking conditions and action delay time. Download the interlocking logic diagram with interlocking conditions set to the SIS safety instrumented system; After downloading, perform centrifugation verification, which includes static verification, dynamic verification, and environmental verification. After the centrifugation verification is completed and passed, the logic configuration is modified.

2. The instrumentation automation control system in the caustic soda production process according to claim 1, characterized in that, The equipment control and management unit includes: The equipment involved in the caustic soda production process includes process equipment, control equipment, and testing equipment; The process equipment includes electrolysis and chlor-alkali treatment equipment, chlorine treatment equipment, hydrogen treatment equipment, hydrogen chloride synthesis equipment, liquid chlorine liquefaction and packaging equipment, and acid and alkali tank area equipment; The control equipment includes a DCS control system, a SIS safety instrumented system, and a GDS combustible and toxic gas detection system; The detection equipment includes sensors and gas detectors; the sensors include pressure sensors, flow sensors, liquid level sensors, temperature sensors, pH sensors, vibration sensors, and displacement sensors; the gas detectors include combustible gas detectors and toxic gas detectors. The equipment involved in the caustic soda production process undergoes functional testing in sequence. The functional testing includes appearance and basic inspection, mechanical component functional testing, electrical and control system connection testing, functional parameter verification, and equipment linkage function testing. After all equipment has been tested and qualified, the next process step will be carried out.

3. The instrumentation automation control system in the caustic soda production process according to claim 2, characterized in that, The key parameter data acquisition unit includes: Based on the operational requirements of the process equipment, the parameter types collected for each process equipment are confirmed, and the operational requirements of the process equipment are retrieved from the database. Identify the corresponding testing equipment based on the parameter type, then install the testing equipment on the monitoring point of the process equipment and calibrate the testing equipment. The detection equipment monitors parameter changes at the equipment monitoring points of the process equipment and converts the measured values ​​into electrical or digital signals according to a preset frequency. The converted electrical or digital signal is transmitted to the corresponding control device; The control equipment performs data preprocessing on the received data; After data preprocessing, key parameter data are obtained.

4. The instrumentation automation control system in the caustic soda production process according to claim 3, characterized in that, The conventional control unit includes: The non-safety interlock parameters in the key parameter data are: parameters in the process equipment that are displayed, alarmed, and automatically adjusted by the DCS system and do not trigger SIS safety interlocks; The DCS control system is used to automatically adjust non-safety interlock parameters. The automatic adjustment steps include: S1: According to process requirements, preset the normal operating range and adjustment threshold of each non-safety interlock parameter in the DCS control system; S2: The DCS control system receives non-safety interlock parameters collected in real time and compares the received data with preset normal operation data; S3: Based on the comparison results, confirm the direction of deviation between the received data and the normal operating data, and automatically generate the corresponding adjustment command; The adjustment indicators include flow parameter adjustment instructions, pressure parameter adjustment instructions, liquid level parameter adjustment instructions, temperature parameter adjustment instructions, and storage tank liquid level adjustment instructions. S4: The DCS control system sends the generated adjustment commands to the corresponding process equipment; S5: After the process equipment executes the adjustment command, the DCS control system continuously monitors the parameter changes.

5. The instrumentation automation control system in the caustic soda production process according to claim 4, characterized in that, The safety interlock control unit includes: The safety interlock parameters in the key parameter data are those that are monitored by the SIS safety instrumented system and trigger emergency safety actions when the parameters reach the interlock value. The SIS safety instrumented system is used to automatically adjust safety interlock parameters. The automatic adjustment steps include: S1: According to safety regulations, the interlock values ​​and corresponding safety action logic of safety interlock parameters in the SIS safety instrumented system; S2: The SIS safety instrumented system receives real-time collected safety interlock parameters and compares the values ​​of the safety interlock parameters with preset interlock values; S3: Based on the comparison results, the SIS safety instrumented system sends and executes mandatory commands to the process equipment corresponding to the interlocking logic; Among these, mandatory commands include shutdown, material cut-off, and isolation; S4: After the process equipment executes the command according to the mandatory command, it reports the execution status to the SIS safety instrumented system. The SIS safety instrumented system confirms that the mandatory command has been completed and synchronizes the interlock information. S5: Staff conduct on-site troubleshooting and manually perform interlock reset on the SIS safety instrumented system.

6. The instrument automation control system in the caustic soda production process according to claim 5, characterized in that, The production environment monitoring unit includes: First, identify the monitoring areas for combustible and toxic gases in the production environment. The combustible gas is hydrogen, and the toxic gas is chlorine. The monitoring areas include areas with a high incidence of equipment leaks, enclosed or semi-enclosed spaces, and areas with high personnel activity. The gas detector monitors the gas in the monitoring area, collecting data every 1-5 seconds. The gas detector converts the concentration values ​​of combustible and toxic gases into 4-20mA electrical or digital signals, which are then transmitted to the GDS combustible and toxic gas detection system via cable. The GDS combustible and toxic gas detection system performs graded alarms based on the received data; The warning range for combustible gases is: Level 1 alarm and Level 2 alarm, with a Level 1 alarm threshold of 20% LEL and a Level 2 alarm threshold of 40% LEL. The warning range for toxic gases is: Level 1 alarm and Level 2 alarm, with a threshold of 1 ppm for Level 1 alarm and 2 ppm for Level 2 alarm. After the scope of the graded alarm is confirmed, the alarm is executed. The alarm execution operation for the first-level alarm is as follows: the GDS combustible and toxic gas detection system triggers the workshop's audible and visual alarm, displays the alarm information on the monitoring interface, and automatically pushes the alarm information to the personnel on duty. The alarm execution for a Level 2 alarm is as follows: the GDS combustible and toxic gas detection system triggers a high-intensity audible and visual alarm in the workshop, the alarm information is highlighted on the monitoring interface and marked as an emergency event, the emergency event is automatically pushed to the corresponding safety officer, and finally the ventilation system is activated for ventilation. Ultimately, the GDS combustible and toxic gas detection system will synchronize alarm events to the DCS control system in real time. Alarm events include gas type, concentration value, occurrence time, area and alarm level, and automatically record and store the entire alarm process data, including concentration change curves, alarm duration and processing record data.

7. The instrumentation automation control system in the caustic soda production process according to claim 6, characterized in that, The liquid level control unit includes: Based on the process requirements of the storage tanks and reaction vessels, confirm the normal range of liquid level, alarm values, and interlock values ​​of the storage tanks and reaction vessels; The liquid level sensor monitors the liquid level of the storage tank and reaction tank in real time, converts the liquid level value into an electrical signal at a preset frequency, and transmits it to the DCS control system. After receiving the data, the DCS control system performs filtering processing and displays the current liquid level value and trend curve of the storage tank and reaction tank in real time on the monitoring interface. Configure the control logic for the liquid levels of storage tanks and reaction vessels in the DCS control system, and confirm the corresponding actions for different liquid level ranges; The control logic includes normal range, alarm range, and interlock range. The corresponding action of the normal range is to maintain the current feeding or discharging state when the liquid level is in the normal range. The corresponding action of the alarm range is to start the adjustment action when the liquid level reaches the alarm value. The corresponding action of the interlock range is to trigger the emergency action when the liquid level reaches the interlock value. Ultimately, dynamic control of the liquid level in the storage tank and reaction vessel is achieved.

8. The instrumentation automation control system in the caustic soda production process according to claim 7, characterized in that, The equipment operation monitoring unit includes: Power equipment includes pumps, compressors, rectifiers, and motors; Based on the type and operating characteristics of the power equipment, the key parameters to be monitored are confirmed; Depending on the type of key parameters, corresponding sensors are installed at the monitoring points of the power equipment, including temperature sensors, vibration sensors, displacement sensors, and pressure sensors. Each sensor collects the operating data of the power equipment according to a preset frequency, converts the physical quantity of the collected operating data into a 4-20mA electrical signal or digital signal, and transmits the converted information to the DCS control system. The DCS control system receives the transmitted data, configures the monitoring threshold for each monitoring data, and associates it with the corresponding alarm logic. The DCS control system compares the collected operating data with preset thresholds based on the alarm logic and corresponding results, and adjusts the operating status of the power equipment according to the comparison results. When the staff receives an alarm, they retrieve the historical data and trend charts of the alarm device through the DCS control system, and adjust the operating status of the power equipment in conjunction with the abnormal reasons found during on-site inspections.

9. The instrument automation control system in the caustic soda production process according to claim 8, characterized in that, The remote monitoring and diagnostic unit includes: Remote monitoring data includes monitoring data of process equipment, control equipment, and testing equipment, including real-time values ​​and historical trends of various process parameters, equipment operating status data, alarm records, and process interlock action records; Equipment fault diagnosis data consists of alarm data from remote monitoring data, including faulty equipment number and type, fault symptoms, associated parameters at the time of the fault, and fault handling process. First, perform data preprocessing on remote monitoring data and equipment fault diagnosis data, including data cleaning, data standardization, and data unification; After data preprocessing, data classification is performed, including classification by process step, data type, and equipment. Data analysis is performed based on the data classification results, including trend analysis, correlation analysis, and statistical analysis. Reports are generated based on the data analysis results. The generated reports include operation reports, fault diagnosis reports, and summary reports. The generated report undergoes manual review. Once the review is completed and the report is deemed acceptable, it is converted into visual data and then transmitted to a display terminal for display.

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