Intrinsically safe operation method for dismantling rotating polar plate of electric dust remover

Abstract

The invention discloses an intrinsically safe operation method for dismounting a rotating polar plate of an electric dust remover, and belongs to the technical field of safe operation. According to the method, through full-process systematic reconstruction of quantitative risk pre-diagnosis, logic hard isolation authorization and data-guided bearing hoisting, traditional high-risk operation depending on personal experience is converted into a data-driven and logic-forced standardized process, core risks such as electric shock, dust explosion and mechanical overturning are eliminated from the source, and the safety of operation is improved. Intrinsic safety, process intelligence and management traceability of the electric dust remover rotating pole plate dismantling operation are achieved.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of safe operation, and particularly relates to an intrinsically safe operation method for removing a rotating electrode plate of an electric dust collector. BACKGROUND

[0002] The rotating electrode plate of an electric dust collector needs to be overhauled or replaced after long-term operation, and its removal operation is a high-risk operation recognized by the industry. The existing removal process mainly relies on manual experience, and has the following essential defects: Risk is unknown: there is no quantitative evaluation of the dust accumulation condition of the electrode plate before operation, and only experience is used for judgment, so that incomplete dust cleaning or improper method can easily cause explosion or suffocation of personnel.

[0003] Isolation is not complete: energy isolation relies on personnel operation, and there is a possibility of misoperation or accidental power supply, so that the electrical safety cannot be fundamentally guaranteed.

[0004] Process is uncontrollable: the hoisting process relies on the experience of the command personnel and the driver, and in the narrow space inside the dust collector, the electrode plate is easy to swing and collide, and there is a risk of mechanical injury and high-altitude falling.

[0005] Lack of system: each link is independent of each other, and there is a lack of unified and intelligent safety interlocking and monitoring, so that it is difficult to achieve true "intrinsic safety".

[0006] Therefore, there is an urgent need for a rotating electrode plate removal method and system that can systematically evaluate risks, intelligently control processes, and ensure safety throughout the operation. SUMMARY

[0007] Therefore, the present application aims to provide an intrinsically safe operation method for removing a rotating electrode plate of an electric dust collector.

[0008] In order to achieve the above-mentioned purpose, the present application provides the following technical solutions: In the first aspect, the present application provides an intrinsically safe operation method for removing a rotating electrode plate of an electric dust collector, characterized in that it comprises the following steps: S1, pre-diagnosis and operation planning: Without entering the electric field, a high-definition camera and a dust concentration sensor fixedly installed in the electric field are remotely started to scan the surface of the rotating electrode plate, and obtain dust accumulation image and spatial dust concentration data; the data are processed by an analysis software to generate a dust accumulation risk heat map marked with dust accumulation thickness and risk level, and a pre-treatment operation guidance card is automatically output according to the map; S2, entering authorized control: All related power supply circuits are remotely disconnected, and it is confirmed that the voltage and current have been reduced below the safety threshold by reading the verification sensor signal of the load side of each circuit; Then the rotating plate drive coupling is physically disengaged on site and locked using a mechanical lock with a status sensor, which sends a locked signal. The safety interlock controller makes a logical judgment and activates the authorization function of the electromagnetic lock controller only when it simultaneously receives safety confirmation signals from all power circuits and the mechanical lock signal. The person in charge of the operation can only open the designated maintenance door after the person in charge has verified their identity and dynamic password. S3. Intrinsic safety treatment of dust: After entering the electric field, the operators treat the dust accumulation on the electrode plates according to the parameters in the pretreatment operation instruction card. During the treatment process, the dust concentration is monitored in real time until the reading is stable below the preset safety target value and remains so for a specified time. The control room then confirms that the process is qualified. S4. Programmed support-based dismantling and hoisting: Disassemble the electrode plate connectors in sequence, and the system records each step of the operation. Before disassembling the key load-bearing connecting parts, a special lifting balance beam integrating multiple pressure sensors and attitude sensors is installed at the pole plate lifting point, and the balance beam is operated to make the hook initially bear the force. Based on the real-time tension and tilt angle data displayed on the handheld terminal, the crane and the balance beam are adjusted in a coordinated manner until the preset balance conditions are met. After disconnecting the final load-bearing connection, the pole plate, which was fully supported by the balance beam, was smoothly lifted off and transported under real-time data monitoring.

[0009] Furthermore, the generation of the dust accumulation risk heat map in S1 specifically includes: analyzing the image through a grayscale contrast algorithm, estimating the dust accumulation thickness based on a pre-calibrated "grayscale-thickness" model, and fusing the thickness data with the real-time dust concentration data at the corresponding location, using different colors to indicate the risk level; Specifically: Extract the average gray value G of the pixels in the region to be evaluated from the gray image; Substituting the average gray value G into the pre-calibrated linear relationship model H=a×(G-G0), the estimated ash accumulation thickness H is calculated; where a is the calibration coefficient and G0 is the reference gray value of the clean electrode surface. Obtain the real-time dust concentration data C for the corresponding area; Based on the estimated thickness H and dust concentration C, the risk level of the area is determined according to a preset risk matrix; The risk matrix is: when H>H th And C>C th When H > H, it is classified as a high-risk level; th Or C>C th If the risk level is high, it is classified as medium risk; otherwise, it is classified as low risk. (H)th C is the thickness threshold. th The concentration threshold; Based on the risk level of each region, different colors are used to mark the areas on the image to generate the risk heat map.

[0010] Furthermore, the preprocessing job instruction card in S1 includes: When there are high-risk areas, high-pressure atomized water wetting is used; otherwise, low-pressure atomization is used for dust suppression.

[0011] Furthermore, the safety thresholds in S2 are: the output voltage of the high-voltage power supply circuit is less than 10V; the output voltage of the low-voltage power and lighting circuit is less than 24V; and the output current of all circuits is less than 0.1A.

[0012] Furthermore, the processing method in S3 is high-pressure atomized water wetting, and the key parameters include water pressure, flow rate and spraying time; Furthermore, the preset safety target value in S3 is a dust concentration of less than 5 mg / m³. 3 The duration of stability should be no less than 5 minutes.

[0013] Furthermore, in the S4, a tension sensor is integrated under each hook of the special lifting balance beam, and a dual-axis tilt sensor is integrated in the center of the balance beam.

[0014] Furthermore, the balance condition in S4 is: the difference in tension at each suspension point is ≤ 10% of the average value, and the tilt angle of the electrode plate is < 0.5°. It contains at least the following beneficial technical effects: This invention systematically reconstructs the entire process of lifting and hoisting by pre-diagnosing and quantifying risks, implementing logical hard isolation authorization, and data-guided support. It transforms traditional high-risk operations that rely on personal experience into standardized processes driven by data and enforced by logic, eliminating core risks such as electric shock, dust explosion, and mechanical overturning from the source. This achieves inherent safety, intelligent processes, and traceable management for the removal of rotating plates from electrostatic precipitators. Detailed Implementation

[0015] Various exemplary embodiments of the present invention will now be described in detail. This detailed description should not be considered as a limitation of the present invention, but rather as a more detailed description of certain aspects, features, and embodiments of the present invention.

[0016] It should be understood that the terminology used in this invention is merely for describing particular embodiments and is not intended to limit the invention. Furthermore, with respect to numerical ranges in this invention, it should be understood that each intermediate value between the upper and lower limits of the range is also specifically disclosed. Every smaller range between any stated value or intermediate value within a stated range, and any other stated value or intermediate value within said range, is also included in this invention. The upper and lower limits of these smaller ranges may be independently included or excluded from the range.

[0017] Unless otherwise stated, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. While only preferred methods and materials have been described herein, any methods and materials similar or equivalent to those described herein may be used in the implementation or testing of this invention. All references to this specification are incorporated by way of citation to disclose and describe methods and / or materials associated with those references. In the event of any conflict with any incorporated reference, the content of this specification shall prevail.

[0018] Example This embodiment uses the dismantling operation of the rotating electrode plate module on the east side of the third electric field of the furnace electrostatic precipitator as an example to explain in detail the implementation process of the present invention.

[0019] The system is configured as follows: the high-definition camera is a Hikvision explosion-proof type (DS-2CD3T86WDV3-IS); the dust concentration sensor is a SICKGM700; the safety interlock controller is a Siemens S7-1200PLC; the electromagnetic lock is an ASSAABLOYEL520; and the intelligent hoisting balance beam is a custom-made component, integrating four HBMS9M tension sensors and a Swiss Leica Nivel220 dual-axis inclinometer.

[0020] S1, Pre-diagnosis and work planning After the electrostatic precipitator is shut down, the operator initiates a pre-diagnostic procedure in the central control room. Four high-definition cameras, fixedly installed within the electric field, automatically scan all eight rows of rotating electrode plates. Simultaneously, three dust concentration sensors begin operation.

[0021] The analysis software processes the acquired images. Taking the lower part of the second row of electrodes, where the risk is most prominent, as an example: Image analysis shows that the average gray value of this area is G=180 (clean plate reference gray value G0=120, calibration coefficient a=0.05mm / gray value).

[0022] Substituting into the pre-calibration model, the estimated thickness is: H = 0.05 × (180 - 120) = 3.0 mm.

[0023] The real-time reading of the dust concentration sensor in this area is C=25mg / m³. 3 .

[0024] Preset threshold H th =2.0mm, C th =20mg / m 3 Because H > H th (3.0>2.0) and C>C th (25>20), the software determines that the area is high-risk and marks it in red on the heat map.

[0025] After the software traverses all areas, it generates an overall risk heat map, showing that the lower part of the second column is the only high-risk area.

[0026] Automatically generate pre-processing work instruction cards: Due to the existence of high-risk areas, the cards are confirmed as follows: Pretreatment method: High-pressure atomized water wetting.

[0027] Key parameters: Based on the maximum thickness H_max=3.0mm in the high-risk area, refer to the table (thickness 2.0-4.0mm corresponds to a flow rate of 15L / min) to get Q=15L / min; based on its average concentration C_avg=25mg / m³, take k=0.5 to calculate T=0.5×25=12.5 minutes, round up to get T=15 minutes; pressure P=0.8MPa.

[0028] Key area: The section marked in the diagram, from the bottom to the top 6 meters of the second column of plates.

[0029] Safety target: The dust concentration after treatment must remain stable below 5 mg / m³ for 5 consecutive minutes. 3 .

[0030] S2, Enter Authorization Control Electrical isolation and verification: The operator remotely disconnects the third electric field high-voltage power supply cabinet (72kV), the rotating plate drive motor (380V) power supply cabinet, and the electric field lighting box.

[0031] The system reads and verifies the sensor signals: auxiliary contact of the high-voltage switch grounding switch (closed), voltage output voltage detector signal (voltage < 5V); zero-voltage relay signal of the motor circuit (voltage < 10V); current transmitter signal of the lighting circuit (current 0.02A).

[0032] All signals meet the safety thresholds (high voltage <10V, low voltage <24V, current <0.1A), and the central control interface displays electrical isolation confirmation.

[0033] On-site personnel used a hydraulic wrench to disengage the drive coupling, installed and locked the mechanical lock with a micro switch. The wireless transmitter inside the lock sent a locked signal to the PLC.

[0034] Logical authorization and access: The safety interlock controller (PLC) detected that all input signals (electrical safety signals and mechanical interlocking signals) were "true".

[0035] When the PLC output point is connected, a 24V authorization signal is sent to the electromagnetic lock controller of the A2 inspection door.

[0036] The person in charge of the operation swipes their card at the access control card reader and enters a dynamic password.

[0037] Password verification successful, electromagnetic lock de-energizes and releases. After personnel open the door, door magnetic signal is received, and the system records entry.

[0038] S3. Dust-based safety treatment The workers entered the electric field and located the preset water supply valve and spray gun according to the instruction card.

[0039] The valve was opened, and the operator remotely started the high-pressure pump, stabilizing the pressure at 0.8 MPa. Workers then conducted a focused atomized spraying on the lower red-marked area of ​​the second column for 15 minutes.

[0040] The control room operator monitors the dust concentration curve. After spraying, the concentration dropped from 25 mg / m³. 3 Reduced to 3 mg / m 3 It then stabilized at 2-4 mg / m² within 5 minutes. 3 Between (consistently below 5 mg / m²) 3 (Target value).

[0041] The control room operator confirmed that the dust pretreatment was qualified and the concentration had reached the standard, and dismantling could begin.

[0042] S4. Programmed support-based dismantling and hoisting Programmed disassembly: Operators use a smart torque wrench to disassemble bolts according to the bolt disassembly sequence diagram displayed on a handheld terminal. After each bolt is disassembled, the operator confirms the process on the terminal, and the system records the bolt ID and torque value.

[0043] Installation and intelligent leveling: When only the bottom four M30 load-bearing bolts remain, hoist the intelligent lifting balance beam in and hook the four hooks onto the top lifting lugs of the electrode plate.

[0044] Operate the balance beam controller to tension the four chains synchronously until each tension sensor displays the initial force.

[0045] The terminal displays real-time data: F1=1.1t, F2=1.9t, F3=0.9t, F4=1.7t, tilt angle α=+2.8°, β=-1.5°. The system indicates an imbalance.

[0046] Based on the data, the commander directed the crane and adjusted the balance beam. The final stable values ​​were: F1=1.48t, F2=1.52t, F3=1.50t, F4=1.50t (maximum deviation 2.7% < 10%), α=+0.2°, β=-0.1° (all < 0.5°).

[0047] Final separation and controlled hoisting: Workers removed the last four load-bearing bolts. During the removal process, the tensile force remained stable without any sudden changes.

[0048] After the bolts were removed, the tension at the four lifting points rose synchronously and steadily to approximately 5.0t, while the tilt angle remained stable.

[0049] Under data monitoring, the crane operator lifted the electrode plate vertically and smoothly out of the electric field at a minimum speed and safely placed it onto the transfer vehicle. At this point, the rotating electrode plate module was safely removed.

[0050] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. An intrinsically safe operation method for removing rotating plates of an electrostatic precipitator, characterized in that, Includes the following steps: S1. Pre-diagnosis and work planning: Without personnel entering the electric field, a high-definition camera and dust concentration sensor fixedly installed in the electric field are remotely activated to scan the surface of the rotating electrode and obtain images of accumulated dust and spatial dust concentration data. The analysis software processes the data to generate a heat map of ash accumulation risk, which is marked with the thickness of ash accumulation and the risk level. Based on the map, a pretreatment operation instruction card is automatically generated. S2, Access Authorization Control: Remotely disconnect all relevant power circuits and confirm that the voltage and current have dropped below the safe threshold by reading the verification sensor signals on the load side of each circuit; Then the rotating plate drive coupling is physically disengaged on site and locked using a mechanical lock with a status sensor, which sends a locked signal. The safety interlock controller makes a logical judgment and activates the authorization function of the electromagnetic lock controller only when it simultaneously receives safety confirmation signals from all power circuits and the mechanical lock signal. The person in charge of the operation can only open the designated maintenance door after the person in charge has verified their identity and dynamic password. S3. Intrinsic safety treatment of dust: After entering the electric field, the operators treat the dust accumulation on the electrode plates according to the parameters in the pretreatment operation instruction card. During the treatment process, the dust concentration is monitored in real time until the reading is stable below the preset safety target value and remains so for a specified time. The control room then confirms that the process is qualified. S4. Programmed support-based dismantling and hoisting: Disassemble the electrode plate connectors in sequence, and the system records each step of the operation. Before disassembling the key load-bearing connecting parts, a special lifting balance beam integrating multiple pressure sensors and attitude sensors is installed at the pole plate lifting point, and the balance beam is operated to make the hook initially bear the force. Based on the real-time tension and tilt angle data displayed on the handheld terminal, the crane and the balance beam are adjusted in a coordinated manner until the preset balance conditions are met. After disconnecting the final load-bearing connection, the pole plate, which was fully supported by the balance beam, was smoothly lifted off and transported under real-time data monitoring.

2. The intrinsically safe operation method according to claim 1, characterized in that, The generation of the dust accumulation risk heat map in S1 specifically includes: analyzing the image through a grayscale contrast algorithm, estimating the dust accumulation thickness based on a pre-calibrated "grayscale-thickness" model, and fusing the thickness data with the real-time dust concentration data at the corresponding location, using different colors to indicate the risk level; Specifically: Extract the average gray value G of the pixels in the region to be evaluated from the gray image; Substituting the average gray value G into the pre-calibrated linear relationship model H=a×(G-G0), the estimated ash accumulation thickness H is calculated; where a is the calibration coefficient and G0 is the reference gray value of the clean electrode surface. Obtain the real-time dust concentration data C for the corresponding area; Based on the estimated thickness H and dust concentration C, the risk level of the area is determined according to a preset risk matrix; The risk matrix is: when H>H th And C>C th When H > H, it is classified as a high-risk level; th Or C>C th If the risk level is high, it is classified as medium risk; otherwise, it is classified as low risk. (H) th C is the thickness threshold. th The concentration threshold; Based on the risk level of each region, different colors are used to mark the areas on the image to generate the risk heat map.

3. The intrinsically safe operation method according to claim 1, characterized in that, The preprocessing operation instruction card in S1 includes: When there are high-risk areas, high-pressure atomized water wetting is used; otherwise, low-pressure atomization is used for dust suppression.

4. The intrinsically safe operation method according to claim 1, characterized in that, The safety thresholds in S2 are: the output voltage of the high-voltage power supply circuit is less than 10V; the output voltage of the low-voltage power and lighting circuit is less than 24V; and the output current of all circuits is less than 0.1A.

5. The intrinsically safe operation method according to claim 1, characterized in that, The processing method in S3 is high-pressure atomized water wetting.

6. The intrinsically safe operation method according to claim 1, characterized in that, The preset safety target value in S3 is a dust concentration of less than 5 mg / m³. 3 The duration of stability should be no less than 5 minutes.

7. The intrinsically safe operation method according to claim 1, characterized in that, The S4 special lifting balance beam has a tension sensor integrated under each hook, and a dual-axis tilt sensor integrated in the center of the balance beam.

8. The intrinsically safe operation method according to claim 1, characterized in that, The balance conditions in S4 are: the difference in tension at each suspension point is ≤ 10% of the average value, and the tilt angle of the electrode plate is < 0.5°.