Multi-loop cooperative integrated steam heat tracing system

Abstract

The invention discloses a multi-loop cooperative type integrated steam heat tracing system, which relates to the technical field of steam heat tracing automatic control systems, and comprises a central cooperative control unit which is in communication connection with each module and generates a control instruction; the multi-loop steam supply module comprises a main pipe, a branch regulating valve and a pressure stabilizing assembly, and steam is distributed according to needs; the heat tracing pipeline integration module adopts an integrated heat preservation structure and comprises a heat tracing branch and a temperature sensing cable; the temperature monitoring module is used for collecting and transmitting temperature data; the pressure and flow regulation and control module dynamically adjusts steam parameters; the safety interlocking module is used for executing graded safety protection; and the data storage and analysis module is used for storing data and optimizing a control strategy. Through multi-loop collaborative distribution and dynamic correction, the steam utilization rate and the temperature control precision are improved; the safety and stability of operation are enhanced through integrated design and graded protection, energy conservation and consumption reduction are achieved through energy consumption optimization and remote operation and maintenance, and the system is suitable for complex working conditions and multi-scene application.

Description

Technical Field

[0001] This invention relates to the field of automatic control system technology for steam tracing, and in particular to a multi-loop coordinated integrated steam tracing system. Background Technology

[0002] Steam tracing technology is widely used in industrial fields such as petrochemicals, natural gas transportation, power generation, and municipal engineering. Its core function is to transfer heat through steam to maintain the process temperature of media within pipelines and equipment, preventing transportation obstruction or equipment damage caused by the media solidifying at low temperatures or increasing viscosity. With the increasing scale and complexity of industrial production, single-loop steam tracing systems can no longer meet the tracing needs of multiple areas and media, and multi-loop steam tracing systems are gradually becoming the mainstream application. Currently, most multi-loop steam tracing systems in the industry are simply assembled from multiple independent single-loop systems, lacking a unified and coordinated control mechanism. The steam supply to each loop uses a fixed distribution ratio, making it impossible to dynamically adjust according to the real-time tracing needs of different areas.

[0003] Existing technologies suffer from several significant drawbacks. First, they exhibit poor multi-loop coordination and unreasonable steam distribution. In traditional systems, each loop operates independently, with steam supply allocated according to initial settings, ignoring differences in heating area, ambient temperature, process requirements, and demand fluctuations caused by changes in operating conditions. Some loops may waste energy due to excess steam, while others may fail to meet process requirements due to insufficient steam, impacting production stability. Second, they suffer from low system integration and insufficient operational reliability. Heating pipelines, insulation layers, and temperature monitoring devices are often designed separately, with sparsely arranged temperature sensors, resulting in delayed and inaccurate data acquisition, making it difficult to comprehensively reflect the temperature distribution in different areas. Scaling easily forms on the inner walls of the pipelines, and thermal expansion can lead to pipeline deformation or leakage. Severe heat interference between loops further reduces system operational stability. Third, they suffer from insufficient control accuracy and response speed. Existing systems often employ simple PID control, failing to consider the impact of differences in heating area and environmental interference between loops. Temperature deviation correction is delayed, making it difficult to adapt to scenarios with rapid changes in ambient temperature or adjustments to process requirements. Fourth, the system suffers from weak safety protection and energy consumption optimization capabilities. Its safety interlock function is limited, only triggering shutdown when parameters severely exceed limits. It lacks a tiered protection mechanism and sufficient flexibility in fault handling. Furthermore, the system lacks in-depth analysis of operational data, making it unable to identify inefficient operational processes, hindering energy-saving optimization, and resulting in widespread energy waste.

[0004] With the increasing demands for process stability, energy efficiency, and safe production in industrial production, the shortcomings of existing multi-loop steam tracing systems in terms of collaborative control, integrated design, control accuracy, safety protection, and energy-saving optimization are becoming increasingly apparent, and they can no longer meet the needs of modern industrial production. There is an urgent need for a steam tracing system with multi-loop collaborative distribution, integrated design, high-precision dynamic control, hierarchical safety protection, and energy consumption optimization analysis capabilities to solve many technical pain points of traditional systems and improve the reliability, accuracy, and economy of steam tracing. Summary of the Invention

[0005] The present invention proposes a multi-loop coordinated integrated steam tracing system to solve the problems mentioned in the prior art.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a multi-loop coordinated integrated steam tracing system, comprising the following modules: The central collaborative control unit establishes communication with each module through industrial Ethernet or wireless communication protocol. It has a built-in multi-loop collaborative control algorithm and adaptive learning model, receives monitoring data, analyzes the process temperature range and heat preservation requirements of the heat-traced object, and generates and issues control commands. The multi-loop steam supply module includes a steam header, an electric branch regulating valve, a pressure reducing valve, and a pressure stabilizing component linked with a pressure transmitter. The header receives external steam through a flange interface, and the pressure is stabilized by the pressure stabilizing component. The branch regulating valves independently adjust the steam supply of each loop according to control commands. The integrated heat tracing pipeline module adopts an integrated insulation design, which includes parallel heat tracing branches. Each branch corresponds to an independent heat tracing area and the pipeline diameter is adapted to the heat tracing requirements of the area. The inner wall of the branch is coated with a ceramic-based composite anti-scaling coating and wrapped with a rock wool and polyurethane composite insulation layer on the outside. The temperature monitoring module integrates a fiber optic grating or platinum resistance distributed temperature sensor with a high-speed data acquisition terminal; the sensor collects the ambient temperature, pipe wall temperature and medium temperature of each circuit heating area in real time; the acquisition terminal uses a Kalman filter algorithm to filter and reduce noise in the raw data and transmits it to the central collaborative control unit at a fixed period. The pressure and flow control module includes a pressure sensor, an electromagnetic flow sensor, and an electric ball valve or butterfly valve; it collects steam pressure and instantaneous flow data from each circuit and adjusts the valve opening according to control commands issued by the central control unit. The safety interlock module integrates an over-temperature alarm component, an over-pressure relief valve, and an ultrasonic leak detection component. It monitors key operating parameters of the system and triggers an audible and visual alarm when the temperature exceeds the process threshold, the pressure exceeds the safety limit, or a steam leak is detected. It also cuts off the steam supply to the corresponding circuit and activates the pressure relief valve. The data storage and analysis module uses an industrial database to receive and store system operation data, control commands, and monitoring results; it also uses time series analysis algorithms to uncover patterns in temperature and pressure changes and characteristics of energy consumption fluctuations.

[0007] Furthermore, it also includes a multi-loop steam distribution optimization unit. The central coordination control unit uses this unit to collect the heat tracing demand parameters of each loop in real time and substitute them into the optimization formula to calculate and realize the distribution of steam flow in each loop. The optimization formula is as follows: ,in For the first Steam distribution flow rate of the loop This represents the total steam supply flow rate of the system. For the first The heat tracing coefficient of a single circuit is determined by the thermal conductivity of the heat tracing medium. For the first The heat tracing area of ​​the circuit, For the first The process setting temperature for the strip loop, For the first Real-time ambient temperature of the loop This represents the total number of system loops.

[0008] Furthermore, it also includes a dynamic temperature deviation correction unit. The central coordination control unit collects temperature deviation data once per second through this unit and performs real-time correction. The correction formula is as follows: ,in For the first The control output correction amount of the loop. This is the proportionality coefficient. The integral coefficient is... These are the differential coefficients. This is the area compensation coefficient. For the first The temperature deviation of a circuit is the difference between the process set temperature and the real-time actual temperature. To correct the time, This represents the average heat tracing area for all circuits.

[0009] Furthermore, the integrated heat tracing pipeline module also includes a heat compensation component. Each heat tracing branch is connected to a corrugated compensator at both ends via a flange. The compensator's pressure rating is consistent with the pipeline system. Aluminum silicate fiber insulation baffles are installed between the branches. The thickness of the baffles is adapted to the loop spacing to block heat conduction between loops.

[0010] Furthermore, the pressure and flow control module also includes a dynamic adaptive adjustment unit with built-in flow and pressure coupling control logic. When the rate of change of steam pressure in a certain loop exceeds the set value, it automatically adjusts the response speed and adjustment range of the flow control valve to suppress parameter fluctuations caused by mutual interference between pressure and flow, while monitoring the steam source pressure change trend in real time.

[0011] Furthermore, the safety interlock module also includes a graded protection unit, which is divided into three levels according to the severity of the fault: early warning, alarm, and emergency shutdown. When the temperature or pressure exceeds the threshold by less than 5%, an early warning is triggered and the operator is notified on the monitoring interface. When the exceedance is between 5% and 10%, an alarm is triggered and the control parameters are automatically adjusted. When steam leakage occurs or the exceedance exceeds 10%, an emergency shutdown is immediately executed, the total steam supply is cut off, and the pressure relief valve is activated to minimize safety risks.

[0012] Furthermore, the data storage and analysis module also includes an energy consumption optimization analysis unit. By comparing the steam consumption and heat tracing temperature compliance rate of each circuit under different operating conditions, a multiple linear regression energy consumption-effect correlation model is established to identify inefficient operating circuits and analyze the causes, generating targeted optimization suggestions.

[0013] Furthermore, it also includes a remote monitoring and maintenance module, which establishes encrypted communication with the central collaborative control unit through MQTT or HTTP communication protocols, supports remote access via computers and mobile phones, displays the system's operating status, temperature, pressure, and flow parameters of each loop, and fault information in real time, provides remote control command issuance, process parameter modification, and intelligent fault diagnosis functions, and automatically generates operating data reports and maintenance cycle reminders.

[0014] Furthermore, the adaptive learning model of the central collaborative control unit optimizes control parameters based on the gradient descent algorithm and autonomously adjusts the control logic according to historical operating data and environmental change trends. When the process requirements of the heat tracing object change or the ambient temperature changes periodically, the model automatically optimizes the steam supply strategy and temperature control parameters.

[0015] Furthermore, the multi-loop steam supply module also includes a steam purification unit with a built-in stainless steel sintered filter element and an adsorption dryer. The filter element removes solid impurities and water droplets from the steam, and the dryer element reduces the steam humidity to below 5% to prevent impurities from accumulating and causing pipe blockage or internal wall corrosion.

[0016] Compared with existing technologies, the beneficial effects of this invention are: The central collaborative control unit, based on multi-dimensional parameters such as the heating area of ​​each loop, process temperature, and ambient temperature, uses optimization algorithms to achieve precise allocation of steam flow. This dynamically matches the steam supply with the actual heating demand of each loop, completely changing the traditional system's fixed allocation model and effectively reducing the problems of steam surplus or shortage, thus achieving efficient energy utilization. Simultaneously, the adaptive learning model can autonomously optimize the control strategy based on historical operating data and trends in operating conditions. It can quickly adapt to changes in process requirements or periodic changes in ambient temperature without manual intervention, improving the system's adaptability to complex operating conditions.

[0017] This invention employs an integrated design and a high-precision monitoring and control mechanism, significantly improving the operational stability and temperature control accuracy of the heat tracing system. The integrated heat tracing pipeline module combines heat tracing branches, anti-scaling coating, composite insulation layer, and temperature sensing cables into a single unit, reducing component connection points and lowering the risk of leakage. Insulation baffles are installed between loops to block heat interference and ensure the temperature independence of each loop. The temperature monitoring module uses a densely distributed array of sensors, combined with filtering and noise reduction algorithms, to ensure the accuracy and real-time performance of temperature data acquisition. The dynamic adaptive adjustment unit of the pressure and flow control module suppresses parameter fluctuations, and the dynamic temperature deviation correction unit further improves the temperature control consistency of different heat tracing area loops through multi-parameter collaborative correction, ensuring that the system temperature remains stable within the allowable process range.

[0018] The hierarchical safety protection mechanism and steam purification design of this invention significantly improve the safety and service life of the system. The hierarchical protection unit of the safety interlock module executes different actions such as early warning, alarm, and emergency shutdown according to the severity of the fault. This avoids excessive shutdowns caused by minor faults and can quickly cut off the risk source in the event of a serious fault, minimizing safety hazards. The steam purification unit removes impurities and moisture from the steam, preventing pipe blockage and corrosion. The heat compensation component absorbs the thermal expansion of the pipes, alleviating thermal stress. These designs collectively extend the service life of system components and reduce maintenance frequency and costs.

[0019] This invention achieves continuous system optimization and simplified operation and maintenance through data storage analysis and remote operation and maintenance functions. The energy consumption optimization analysis unit of the data storage and analysis module establishes an energy consumption-effect correlation model, accurately identifies inefficient operating links, and generates targeted optimization suggestions to help the system continuously save energy. The remote monitoring and operation and maintenance module supports remote access from multiple terminals, displays the system's operating status, parameter data, and fault information in real time, provides remote control and fault diagnosis functions, and automatically generates operation reports and maintenance reminders, significantly reducing on-site operation and maintenance workload and improving operation and maintenance efficiency and timeliness. Attached Figure Description

[0020] Figure 1This is a schematic block diagram of the multi-loop coordinated integrated steam tracing system proposed in this invention; Figure 2 A bar chart comparing steam utilization rates with different numbers of loops; Figure 3 A line graph showing the temperature control accuracy under ambient temperature fluctuations; Figure 4 Grouped bar charts comparing response times under different fault types. Detailed Implementation

[0021] 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.

[0022] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0023] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of the stated features. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified. Furthermore, the terms "installed," "connected," and "linked" should be interpreted broadly; for example, they may refer to a fixed connection, a detachable connection, or an integral connection; they may refer to a mechanical connection or an electrical connection; they may refer to a direct connection or an indirect connection through an intermediate medium; and they may refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances. The invention will now be described in further detail with reference to the accompanying drawings.

[0024] Reference Figures 1 to 4 A multi-loop coordinated integrated steam tracing system includes the following modules: The central collaborative control unit, as the core of the system, establishes stable communication with each module through industrial Ethernet or wireless communication protocol. It has built-in multi-loop collaborative control algorithm and adaptive learning model based on machine learning, receives monitoring data such as temperature, pressure and flow in real time, accurately analyzes the core parameters such as process temperature range and insulation requirements of the heat-traced object, generates and issues targeted control commands, and dynamically coordinates the steam supply and operation rhythm of each loop. The multi-loop steam supply module is interconnected with the central coordination control unit. It includes a steam header, electric branch regulating valves, pressure reducing valves, and a pressure stabilizing component linked with a pressure transmitter. The header receives external steam through a flange interface and the pressure stabilizing component stabilizes the pressure within a set range. The branch regulating valves independently adjust the steam supply of each loop according to control commands, realizing on-demand distribution and dynamic balance of multi-loop steam. The integrated heat tracing pipeline module adopts an integrated insulation design, which includes multiple parallel heat tracing branches. Each branch corresponds to an independent heat tracing area and the pipeline diameter is adapted to the heat tracing requirements of that area. The inner wall of the branch is coated with a ceramic-based composite anti-scaling coating, and the outer layer is wrapped with a rock wool and polyurethane composite insulation layer. The insulation layer has a built-in distributed temperature sensing cable, forming an integrated structure of heat tracing, insulation and monitoring. The temperature monitoring module integrates a distributed temperature sensor of fiber optic grating or platinum resistance with a high-speed data acquisition terminal. The sensor is evenly arranged every meter along the heat tracing pipeline to collect the ambient temperature, pipeline wall temperature and medium temperature of each circuit's heat tracing area in real time. The acquisition terminal uses a Kalman filter algorithm to filter and reduce noise in the raw data and then transmits it to the central collaborative control unit at a fixed period. The pressure and flow control module is bidirectionally linked with the multi-loop steam supply module and the central coordination control unit. It includes a high-precision pressure sensor, an electromagnetic flow sensor, and an electric ball valve or butterfly valve. It collects steam pressure and instantaneous flow data of each loop in real time and dynamically adjusts the valve opening according to the control commands issued by the central coordination control unit, so that the steam parameters of each loop are always stable within the process allowable range. The safety interlock module integrates an over-temperature alarm component, an over-pressure relief valve, and an ultrasonic leak detection component. It monitors key operating parameters of the system in real time. When it detects that the temperature exceeds the process threshold, the pressure exceeds the safety limit, or there is a steam leak, it immediately triggers an audible and visual alarm and executes safety actions such as cutting off the steam supply to the corresponding circuit and starting the pressure relief valve. The data storage and analysis module uses an industrial database to receive and store system operation data, control commands, and monitoring results. It uses time series analysis algorithms to mine the patterns of temperature and pressure changes and energy consumption fluctuations, providing data support for the central collaborative control unit to optimize control strategies and promoting continuous improvement in heat tracing efficiency and energy-saving effects.

[0025] This invention also includes a multi-loop steam distribution optimization unit. The central coordination control unit uses this unit to collect real-time heat tracing demand parameters for each loop and substitutes them into the optimization formula to calculate and achieve precise distribution of steam flow in each loop. The optimization formula is as follows: ,in For the first Steam distribution flow rate of the loop This represents the total steam supply flow rate of the system. For the first The heat tracing coefficient of a single circuit is determined by the thermal conductivity of the heat tracing medium. For the first The heat tracing area of ​​the circuit, For the first The process setting temperature for the strip loop, For the first Real-time ambient temperature of the loop Given the total number of system loops, this allocation logic ensures a precise match between the steam supply and the heat tracing needs of each loop, reducing energy waste.

[0026] This invention also includes a dynamic temperature deviation correction unit. The central coordination control unit collects temperature deviation data once per second through this unit and performs real-time correction. The correction formula is as follows: ,in For the first The control output correction amount of the loop. This is the proportionality coefficient. The integral coefficient is... These are the differential coefficients. This is the area compensation coefficient. The temperature deviation of the i-th loop is the difference between the process set temperature and the real-time actual temperature. To correct the time, The average heating area of ​​all loops is used as the basis for multi-parameter collaborative correction, which simultaneously improves the temperature control accuracy of loops with different heating areas.

[0027] In this invention, the integrated heat tracing pipeline module also includes a heat compensation component. Each heat tracing branch is connected to a corrugated compensator at both ends via a flange. The compensator has the same pressure rating as the pipeline system and can fully absorb the thermal expansion generated by the pipeline during the steam heating process, thereby alleviating the thermal stress of the pipeline. Aluminum silicate fiber heat insulation baffles are installed between the branches. The thickness of the baffles is adapted to the distance between the circuits to block the heat conduction between the circuits and ensure the independence of temperature control for each circuit.

[0028] In this invention, the pressure and flow control module also includes a dynamic adaptive adjustment unit with built-in flow and pressure coupling control logic. When the rate of change of steam pressure in a certain loop exceeds the set value, the response speed and adjustment range of the flow control valve are automatically adjusted to suppress parameter fluctuations caused by mutual interference between pressure and flow. At the same time, the steam source pressure change trend is monitored in real time, and pre-adjustment is performed in advance to maintain the stability of steam parameters in each loop.

[0029] In this invention, the safety interlock module also includes a graded protection unit, which is divided into three levels according to the severity of the fault: early warning, alarm, and emergency shutdown. When the temperature or pressure exceeds the threshold by less than 5%, an early warning is triggered and the operator is notified on the monitoring interface. When the exceedance is between 5% and 10%, an alarm is triggered and the control parameters are automatically adjusted. When steam leakage occurs or the exceedance exceeds 10%, an emergency shutdown is immediately executed, the total steam supply is cut off, and the pressure relief valve is activated to minimize safety risks.

[0030] In this invention, the data storage and analysis module also includes an energy consumption optimization analysis unit. By comparing the steam consumption and heat tracing temperature compliance rate of each circuit under different operating conditions, a multivariate linear regression energy consumption-effect correlation model is established to accurately identify inefficient operating circuits and analyze the reasons for inefficient operation in terms of pipeline insulation, steam distribution, etc., and generate targeted optimization suggestions such as adjusting the set temperature and optimizing the steam distribution ratio to help the system achieve energy-saving operation.

[0031] This invention also includes a remote monitoring and maintenance module, which establishes encrypted communication with the central collaborative control unit through MQTT or HTTP communication protocols, supports remote access from multiple terminals such as computers and mobile phones, displays the system's operating status, temperature, pressure, and flow parameters of each loop, and fault information in real time, provides functions such as remote control command issuance, process parameter modification, and intelligent fault diagnosis, and automatically generates operating data reports and maintenance cycle reminders, thereby reducing on-site maintenance workload and costs.

[0032] In this invention, the adaptive learning model of the central collaborative control unit optimizes control parameters based on the gradient descent algorithm. It can autonomously adjust the control logic according to historical operating data and environmental change trends. When the process requirements of the heat tracing object change or the ambient temperature undergoes seasonal or periodic changes, the model automatically optimizes the steam supply strategy and temperature control parameters. It can quickly adapt to new operating conditions without manual intervention, thereby improving the system's adaptability to operating conditions.

[0033] In this invention, the multi-loop steam supply module also includes a steam purification unit with a built-in stainless steel sintered filter element and an adsorption dryer. The filter element removes solid impurities and water droplets from the steam, and the drying element reduces the steam humidity to below 5%, avoiding impurity deposition that could cause pipe blockage or inner wall corrosion, reducing the impact of condensate in the steam on the heat tracing effect, extending the system's service life and ensuring heat tracing stability.

[0034] The following two examples further illustrate specific embodiments of the present invention: Example 1: Multi-pipeline coordinated steam tracing system for petrochemical industry This embodiment is applied to a petrochemical industrial park, where heat tracing is implemented on five parallel pipelines that transport different media. Each pipeline is 1000 meters long, and the heat tracing requirements cover different process requirements such as viscosity control and anti-condensation. A multi-loop collaborative integrated steam heat tracing system is used to achieve precise heat tracing.

[0035] I. System Deployment and Parameter Configuration 1. Deployment of the Central Coordination and Control Unit The central control unit communicates with each module via industrial Ethernet. It has a built-in adaptive learning model optimized based on gradient descent algorithm and pre-stores parameters such as the process temperature range of the medium in each pipeline (30℃ to 80℃) and insulation requirements. The data reception cycle is set to 1 second, and the control command issuance delay does not exceed 50 milliseconds, coordinating the operation status of the five heat tracing circuits in real time.

[0036] 2. Multi-loop steam supply module setup The multi-loop steam supply module includes a DN200 steam header, five DN50 electrically operated branch control valves, and a pressure stabilizing assembly that links the pressure reducing valve and pressure transmitter. The header connects to the park's steam source via a flange interface, and the pressure stabilizing assembly maintains the steam pressure between 0.8MPa and 1.0MPa. The module has a built-in steam purification unit, employing a 304 stainless steel sintered filter element and an adsorption dryer to reduce the steam humidity to below 5%, removing solid impurities and water droplets.

[0037] 3. Structure of Integrated Heat Tracing Pipeline Module The integrated heat tracing pipeline module comprises five parallel heat tracing branches, with branch diameters ranging from DN32 to DN40 to accommodate the heat tracing requirements of various pipelines. The inner wall of each branch is coated with a 0.5mm thick ceramic-based composite anti-scaling coating, and the outer layer is wrapped with a 50mm thick rock wool and polyurethane composite insulation layer, which incorporates fiber optic distributed temperature sensing cables. Each branch is connected to a corrugated compensator at both ends via flanges. The compensator has a pressure resistance rating of 1.6MPa, and the branches are spaced 1 meter apart, with a 20mm thick aluminum silicate fiber insulation partition in between.

[0038] 4. Monitoring and Control Module Configuration The temperature monitoring module employs 5000 fiber optic sensors, one per meter along the heat tracing pipeline, to collect real-time data on ambient temperature, pipeline wall temperature, and medium temperature. The high-speed data acquisition terminal uses a Kalman filter algorithm for noise reduction before data transmission. The pressure and flow control module is equipped with a high-precision pressure sensor (0-2MPa range), an electromagnetic flow sensor (±0.5% accuracy), and an electric ball valve, and is bidirectionally linked with the central control unit.

[0039] 5. Safety Interlock and Auxiliary Module Settings The safety interlock module integrates an audible and visual over-temperature alarm component, a DN80 overpressure relief valve, and an ultrasonic leak detection component. It sets tiered protection thresholds: exceeding the threshold by less than 5% triggers a warning; 5% to 10% triggers an alarm; and exceeding 10% or a leak triggers an emergency shutdown. The remote monitoring and maintenance module communicates encrypted with the central collaborative control unit via the MQTT protocol, supporting access from computers and mobile terminals, and automatically generates daily operation reports. The data storage and analysis module uses an industrial database with a one-year storage period and includes a built-in energy consumption optimization analysis unit.

[0040] II. System Operation and Cooperative Control Process 1. Precise steam distribution After the system starts up, the central coordination control unit collects parameters of each loop through the multi-loop steam distribution optimization unit: - The values ​​are 0.9, 1.1, 1.0, 0.8, and 1.2 respectively. - The corresponding unit sizes are 314㎡, 377㎡, 345.4㎡, 282.6㎡, and 408.2㎡. - The real-time ambient temperatures were 40℃, 60℃, 50℃, 30℃, and 80℃, respectively. Both are at 15℃, and the total steam supply flow rate of the system is... =5000 kg / h. Substitute into the optimization formula: The total sum of the denominators is calculated as follows: 0.9×314×(40-15)+1.1×377×(60-15)+1.0×345.4×(50-15)+0.8×282.6×(30-15)+1.2×408.2×(80-15)=0.9×314×25+1.1×377×45+1.0×345.4×35+0.8×282.6×15+1.2×408. 2 × 65 = 7065 + 18766.5 + 12089 + 3391.2 + 31839.6 = 73151.3; the numerators of each loop are 0.9 × 314 × 25 = 7065, 1.1 × 377 × 45 = 18766.5, 1.0 × 345.4 × 35 = 12089, 0.8 × 282.6 × 15 = 3391.2, and 1.2 × 408.2 × 65 = 31839.6; therefore =5000×7065 / 73151.3≈483kg / h, =5000×18766.5 / 73151.3≈1289kg / h、 =5000×12089 / 73151.3≈832kg / h, =5000×3391.2 / 73151.3≈233kg / h, =5000×31839.6 / 73151.3≈2163kg / h. The branch regulating valve adjusts its opening according to the calculation result to achieve steam distribution on demand.

[0041] 2. Dynamic temperature correction and parameter control During operation, the temperature monitoring module collected data in real time and found that the actual temperature of loop 3 was 48℃, which was a temperature deviation. =50℃-48℃=2℃. The central coordination control unit sets the temperature deviation dynamic correction unit. =2.0、 =0.5、 =0.3、 =1.2, average heat tracing area =344.64㎡, substituting into the correction formula: Calculated =4 + 0.5 × 2 × 1 + 0.3 × 0 + 1.2 × 1.002 ≈ 4 + 1 + 0 + 1.202 ≈ 6.202. The pressure and flow control module increases the opening of the electric ball valve in loop 3 by 6.2%, and the temperature in loop 3 stabilizes at 50℃ after 10 seconds. The dynamic adaptive adjustment unit monitors the steam source pressure in real time. When the pressure fluctuation rate exceeds 0.05 MPa / s, it automatically adjusts the valve response speed to suppress parameter fluctuations.

[0042] 3. Security Protection and Data Processing At a certain moment during operation, the temperature of loop 2 exceeded the threshold by 8°C (13.3%) due to partial damage to the insulation layer. The safety interlock module immediately triggered an emergency shutdown, cutting off the steam supply to loop 2 and activating the pressure relief valve, while simultaneously sending an alarm message to the maintenance personnel's terminal. The data storage and analysis module recorded the fault data, and the energy consumption optimization analysis unit compared the energy consumption and temperature compliance rates of each loop, generating suggestions for adjusting the insulation layer of loop 2 and optimizing the steam distribution ratio.

[0043] II. Data Representation and Interpretation Table 1: Comparison of the operating performance of the traditional system and the system of the present invention

[0044] Table 1 shows that traditional multi-loop systems, employing a fixed steam distribution mode, have a steam utilization rate of only 65%, an annual energy consumption of 12,000 tons, and a temperature control accuracy of ±3℃, making it difficult to meet the requirements of fine chemical processes. The system experiences 8 failures per year, with maintenance costs reaching 150,000 yuan, primarily due to pipeline leaks, scaling, and parameter fluctuations. The system of this invention, through precise steam distribution and dynamic correction, increases steam utilization to 92%, reduces annual energy consumption to 7,800 tons, and achieves a temperature control accuracy of ±0.5℃, significantly improving process stability. Steam purification and integrated design reduce pipeline failures to only 1 failure per year. Remote maintenance and energy consumption optimization analysis lower maintenance costs to 60,000 yuan, making it comprehensively superior to traditional systems.

[0045] Example 2: Heat Tracing System for Natural Gas Station Equipment Cluster This embodiment is applied to a natural gas station, where heat tracing is implemented for four key pieces of equipment: separator, heat exchanger, storage tank, and transfer pump. The heat tracing area of ​​the equipment varies greatly, and the ambient temperature fluctuates from -20℃ to 15℃. It is necessary to cope with different operating conditions such as low-temperature start-up and steady-state operation. A multi-loop coordinated integrated steam heat tracing system is adopted to ensure the normal operation of the equipment.

[0046] I. System Deployment and Parameter Configuration 1. Deployment of the Central Coordination and Control Unit The central collaborative control unit communicates with each module via a wireless communication protocol and has a built-in adaptive learning model. It pre-stores the process temperature requirements for the equipment: 45℃ for the separator, 60℃ for the heat exchanger, 35℃ for the storage tank, and 50℃ for the transfer pump. The model optimizes control parameters based on nearly one year of historical operating data and can automatically adapt to seasonal fluctuations in ambient temperature.

[0047] 2. Multi-loop steam supply module setup The multi-loop steam supply module includes a DN150 steam header, four DN40 electrically operated branch regulating valves, and a pressure stabilizing component to maintain the steam pressure between 0.6MPa and 0.9MPa. The steam purification unit uses a stainless steel sintered filter element and an adsorption dryer to ensure that the steam impurity particle size is less than 5μm and the humidity is less than 5%.

[0048] 3. Structure of Integrated Heat Tracing Pipeline Module The integrated heat tracing pipeline module comprises four heat tracing branches, with heat tracing areas of 80㎡ for the separator, 120㎡ for the heat exchanger, 200㎡ for the storage tank, and 60㎡ for the transfer pump. The inner walls of each branch are coated with a 0.5mm ceramic-based anti-scaling coating and wrapped with a 60mm composite insulation layer. Built-in platinum resistance distributed temperature sensing cables are incorporated. Corrugated compensators are connected at both ends of each branch, and 25mm thick thermal insulation baffles are installed between loops to prevent heat interference.

[0049] 4. Monitoring and Control Module Configuration The temperature monitoring module uses 650 platinum resistance sensors spaced 0.8 meters apart. The data acquisition terminal employs a Kalman filter algorithm for noise reduction, with a transmission cycle of 1 second. The pressure and flow control module is equipped with a high-precision pressure sensor, an electromagnetic flow sensor, and an electric butterfly valve. The dynamic adaptive adjustment unit incorporates flow and pressure coupling control logic.

[0050] 5. Safety Interlock and Auxiliary Module Settings The safety interlock module sets tiered protection thresholds: warning within 5% exceeding the threshold, alarm for 5% to 10%, and emergency shutdown for exceeding 10% or a leak. The remote monitoring and maintenance module supports multi-terminal access, allowing remote modification of process parameters and fault diagnosis. The data storage and analysis module uses an industrial database, and the energy consumption optimization analysis unit establishes a multiple linear regression model.

[0051] II. System Operation and Cooperative Control Process 1. Precise steam distribution During the low-temperature start-up phase, the ambient temperature =-10℃, total steam supply flow rate of the system =3000kg / h, heat tracing coefficient of each circuit - The values ​​are 1.0, 1.2, 0.9, and 1.1 respectively. Substituting these values ​​into the steam distribution optimization formula: The total sum of the denominators is calculated as 1.0×80×(45+10)+1.2×120×(60+10)+0.9×200×(35+10)+1.1×60×(50+10)=1.0×80×55+1.2×120×70+0.9×200×45+1.1×60×60=4400+10080+8100+3960=26540; the numerators of each loop are 1.0×80×55=4400, 1.2×120×70=10080, 0.9×200×45=8100, and 1.1×60×60=3960 respectively; therefore... =3000×4400 / 26540≈497kg / h, =3000×10080 / 26540≈1150kg / h、 =3000×8100 / 26540≈916kg / h、 =3000×3960 / 26540≈437kg / h, the branch regulating valve is adjusted according to the calculated value to achieve precise steam supply during the start-up phase.

[0052] 2. Dynamic temperature correction and operating condition adaptation During steady-state operation, when the ambient temperature rises to 10℃, the actual temperature of the storage tank is 33℃, resulting in a temperature deviation e3 = 2℃. Substituting this into the dynamic temperature deviation correction formula: set up =1.8、 =0.4、 =0.2、 =1.1, =(80+120+200+60) / 4=115㎡, calculated to =1.8×2+0.4×2×1+0.2×0+1.1×200 / 115≈3.6+0.8+0+1.913≈6.313, controlling the increase of the tank circuit valve opening by 6.3%, the temperature stabilizes at 35℃ after 5 seconds. The adaptive learning model autonomously optimizes the steam distribution ratio in winter and summer according to seasonal temperature changes, adapting to environmental fluctuations.

[0053] 3. Security Protection and Operation and Maintenance Management During operation, the heat exchanger loop pressure suddenly rose to 1.0 MPa, exceeding the standard by 11.1%. The safety interlock module immediately executed an emergency shutdown, cutting off the steam supply to the loop and activating the pressure relief valve. Maintenance personnel viewed the fault data through the remote monitoring module, determining it to be valve jamming, and remotely issued a maintenance reminder. The data storage and analysis module recorded parameter changes before and after the fault, and the energy consumption optimization analysis unit suggested adjusting the steam distribution ratio of the heat exchanger loop to further reduce energy consumption.

[0054] II. Data Representation and Interpretation Table 2: Comparison of the operating performance of the traditional system and the system of the present invention under fluctuating operating conditions

[0055] Table 2 data illustrates that, under conditions of large ambient temperature fluctuations, the traditional system requires up to 30 minutes for temperature stabilization, consumes 800 kg / h of energy for low-temperature startup, and has a temperature fluctuation range of ±4℃, making it unable to quickly adapt to changes in operating conditions. Fault response relies on manual on-site troubleshooting, taking 15 minutes and requiring 12 maintenance visits per year, impacting continuous equipment operation. The system of this invention, through dynamic correction and adaptive learning, shortens the temperature stabilization time to 5 minutes, reduces low-temperature startup energy consumption to 500 kg / h, and controls the temperature fluctuation range to ±0.8℃, significantly improving its ability to adapt to environmental fluctuations. The safety interlock module responds to faults within 30 seconds, remote operation and maintenance reduce on-site intervention, and the number of maintenance visits per year is only 2, ensuring continuous and stable equipment operation and meeting the high reliability requirements of natural gas stations.

[0056] refer to Figure 2This bar chart visually illustrates the impact of changes in the number of loops on steam utilization and the core advantages of this invention. Traditional systems show only a slight increase in steam utilization with increasing loop count, reaching a maximum of only 66%. The core reason is that the fixed allocation mode cannot adapt to the differentiated needs of multiple loops; the more loops there are, the more pronounced the allocation imbalance becomes. This invention accurately calculates the demand of each loop through a steam allocation optimization formula. Even with six loops, the utilization rate remains above 91%, an average improvement of over 25 percentage points compared to traditional systems. This advantage stems from the dynamic adaptation of multi-dimensional parameters, completely solving the energy waste caused by the "one-size-fits-all" allocation of traditional systems. The energy-saving effect is particularly significant in multi-loop industrial scenarios, also demonstrating the system's stability across different application scales.

[0057] refer to Figure 3 The line graph clearly reflects the impact of ambient temperature changes on temperature control accuracy. Traditional systems show only a slight decrease in temperature deviation as ambient temperature rises, but the deviation remains above 3°C, failing to meet high-precision process requirements. The core issue is the lack of a dynamic correction mechanism, making it difficult to adapt to ambient temperature fluctuations. The system of this invention uses a dynamic temperature deviation correction formula combined with an adaptive learning model to adjust control parameters in real time. As the ambient temperature rises from -20°C to 20°C, the temperature deviation decreases only from 0.9°C to 0.4°C, remaining within 1°C throughout. This demonstrates the system's strong environmental adaptability; even under extreme low-temperature conditions, it can ensure temperature stability through multi-parameter collaborative correction, making it suitable for complex application scenarios such as petrochemical plants and natural gas stations.

[0058] refer to Figure 4 The bar chart highlights the absolute advantage of this invention in fault response efficiency. Traditional systems rely on manual troubleshooting, with response times for various faults exceeding 10 minutes, and even reaching 20 minutes for pipe scaling faults, easily leading to escalation of the fault. The safety interlock module of this invention incorporates hierarchical protection logic, combined with real-time data monitoring, controlling the response time for all types of faults to within 40 seconds, with steam leak faults triggering protective actions in just 20 seconds. This rapid response reduces the impact of faults on production and lowers safety risks, especially for high-risk faults like steam leaks, where the second-level response minimizes the risk of accidents. Simultaneously, the system records fault response data, providing a basis for subsequent optimization of protection strategies and further enhancing safety assurance capabilities.

[0059] The above are merely preferred embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A multi-loop coordinated integrated steam tracing system, characterized in that, The system comprises the following modules: A central cooperative control unit, which establishes communication with each module through industrial Ethernet or wireless communication protocol, has a built-in multi-loop cooperative control algorithm and adaptive learning model, receives monitoring data, analyzes the process temperature range of the heat tracing object and the heat preservation requirement, generates and issues control instructions; A multi-loop steam supply module, which includes a steam main pipe, electric shunt regulating valves, and a pressure stabilizing assembly linked with pressure reducing valves and pressure transmitters; the main pipe receives external steam through flange interfaces, stabilizes the pressure through the pressure stabilizing assembly, and independently adjusts the steam supply amount of each loop according to the control instructions; A heat tracing pipe integrated module, which adopts an integrated heat preservation design and includes parallelly arranged heat tracing branches, each branch corresponding to an independent heat tracing area and the pipe diameter being adapted to the heat tracing demand of the area; the inner wall of each branch is coated with a ceramic-based anti-fouling coating, and the outer layer is wrapped with a rock wool and polyurethane composite heat preservation layer; A temperature monitoring module, which integrates distributed temperature sensors such as fiber Bragg grating or platinum resistance and a high-speed data acquisition terminal; the sensors collect real-time environmental temperature, pipe wall temperature, and medium temperature of each heat tracing area; the acquisition terminal uses Kalman filtering algorithm to filter and denoise the original data and transmits them to the central cooperative control unit at a fixed cycle; A pressure and flow regulation module, which includes pressure sensors, electromagnetic flow sensors, and electric ball valves or butterfly valves; it collects steam pressure and instantaneous flow data of each loop and adjusts the valve opening degree according to the control instructions issued by the central cooperative control unit; A safety interlocking module, which integrates an over-temperature alarm assembly, an over-pressure relief valve, and an ultrasonic leak detection assembly; it monitors key operating parameters of the system and triggers audible and visual alarms, cuts off the steam supply to the corresponding loop, and starts the relief valve when it detects that the temperature exceeds the process threshold, the pressure exceeds the safety upper limit, or steam leaks; A data storage and analysis module, which uses an industrial database to receive and store system operating data, control instructions, and monitoring results; it uses time series analysis algorithm to mine temperature and pressure change rules and energy consumption fluctuation characteristics.

2. A multi-circuit coordinated integrated steam tracing system according to claim 1, wherein, Also includes a multi-loop steam distribution optimization unit, the central cooperative control unit through the unit real-time acquisition of each loop heat tracing demand parameters and into the optimization formula calculation, the realization of each loop steam flow distribution, the optimization formula is Wherein is the steam distribution flow of the first loop, is the total steam supply flow of the system, is the heat tracing coefficient of the first loop determined by the heat conduction characteristics of the heat tracing medium, is the heat tracing area of the first loop, is the process set temperature of the first loop, is the real-time ambient temperature of the first loop, is the total number of system loops.

3. A multi-circuit coordinated integrated steam tracing system according to claim 1, wherein, It also comprises a temperature deviation dynamic correction unit, through which the central cooperative control unit collects temperature deviation data once per second and makes real-time correction, with the correction formula being Wherein is the control output correction amount of the first loop, is a proportional coefficient, is an integral coefficient, is a differential coefficient, is an area compensation coefficient, is the temperature deviation of the first loop, i.e. the difference between the process set temperature and the real-time actual temperature, is the correction time, is the average heat tracing area of all loops.

4. A multi-circuit coordinated integrated steam tracing system in accordance with claim 1, wherein, The heat tracing pipe integrated module further comprises a thermal compensation assembly, each heat tracing branch is connected with a corrugated compensator at both ends through flanges, the compensator has the same pressure rating as the pipe system, and an aluminum silicate fiber heat insulation partition is arranged between the branches to block heat conduction between the loops.

5. A multi-circuit coordinated integrated steam tracing system in accordance with claim 1, wherein, The pressure and flow regulation module further comprises a dynamic adaptive adjustment unit, which has a built-in flow and pressure coupling control logic; when it detects that the steam pressure change rate of a certain loop exceeds the set value, it automatically adjusts the response speed and adjustment range of the flow regulating valve to suppress parameter fluctuations caused by mutual interference between pressure and flow, and simultaneously monitors the steam source pressure change trend in real time.

6. A multi-loop coordinated integrated steam tracing system according to claim 1, wherein, The safety interlocking module further comprises a hierarchical protection unit, which divides the fault severity into three levels of pre-warning, warning, and emergency shutdown; when the temperature or pressure exceeds the threshold by less than 5%, it triggers a pre-warning and prompts the operator on the monitoring interface; when the exceeding range is between 5% and 10%, it triggers a warning and automatically adjusts the control parameters; when steam leakage or exceeding is more than 10%, it immediately executes emergency shutdown, cuts off the total steam supply, and starts the relief valve to minimize safety risks.

7. A multi-circuit coordinated integrated steam tracing system in accordance with claim 1, wherein, The data storage and analysis module further comprises an energy consumption optimization analysis unit, which establishes a multiple linear regression energy consumption-effect correlation model by comparing the steam consumption and heat tracing temperature compliance rate of each circuit under different working conditions, identifies low-efficiency operation circuits and analyzes the reasons, and generates targeted optimization suggestions.

8. A multi-circuit coordinated integrated steam tracing system in accordance with claim 1, wherein, It also includes a remote monitoring and operation module, which establishes encrypted communication with the central collaborative control unit through MQTT or HTTP communication protocol, supports remote access by computer and mobile phone, real-time displays system running status, circuit temperature, pressure, flow parameters and fault information, provides remote control instruction issuing, process parameter modification, fault intelligent diagnosis functions, automatically generates operation data report and maintenance period reminder.

9. A multi-loop coordinated integrated steam tracing system as set forth in claim 1, wherein, The adaptive learning model of the central collaborative control unit optimizes control parameters based on gradient descent algorithm, adjusts control logic according to historical operation data and environmental change trend, automatically optimizes steam supply strategy and temperature control parameters when the process requirements of heat tracing objects change or the environmental temperature changes periodically.

10. A multi-loop coordinated integrated steam tracing system as set forth in claim 1, wherein, The multi-circuit steam supply module further comprises a steam purification unit, which is internally provided with a stainless steel sintered filter element and an adsorption dryer. The filter element removes solid impurities and water droplets in the steam, and the drying assembly reduces the steam humidity to below 5%, avoiding pipeline blockage or internal wall corrosion caused by impurity deposition.

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