System and method for automatically calculating starting and stopping operation time of chemical device

Abstract

The invention provides an automatic calculation system and method for starting and stopping operation time of a chemical device, and the method comprises the steps: solidifying device design parameters through a standard reference data storage module, and providing a reference for operation analysis; the data acquisition module compulsively unifies a timestamp format, and eliminates the risk of format confusion in manual recording; the dynamic calculation engine adopts a spreadsheet and an algorithm to process complex scenes, parking time deficiency and cross-cycle operation scenes; the analysis and comparison module carries out instant verification on the design parameters of the device and actual operation data, and identifies an abnormal working condition that the start-stop frequency and the operation duration deviate from a design threshold value; and the suggestion output module outputs a specific maintenance strategy based on the analysis conclusion, and promotes the operation and maintenance mode to change from post-processing to pre-warning. According to the automatic calculation system for the starting and stopping operation time of the chemical device, the technical problems that in the prior art, data are obtained and input manually, the statistical efficiency is low, the calculation error rate is high, and a dynamic early warning mechanism is lacked are solved.

Description

Technical Field

[0001] This invention belongs to the field of chemical data processing technology, specifically relating to an automatic calculation system and method for start-up and shutdown operation time of chemical plants. Background Technology

[0002] In continuous production industries such as chemical and energy, key equipment (such as compressors, pump sets, and reaction towers) needs to operate 24 hours a day without interruption, and its stability is directly related to the overall production efficiency and safety of the plant. Due to the frequent occurrence of complex operating conditions such as regular equipment switching, planned maintenance shutdowns, and sudden abnormal trips, equipment start-up and shutdown operations have become the norm, which in turn creates a rigid demand for accurate statistics on operating time.

[0003] Currently, the industry generally adopts a statistical method that combines manual recording with spreadsheets. That is, maintenance personnel manually copy the driving and parking times scattered in the DCS system or paper ledgers every day, enter them into the spreadsheet, and then use the spreadsheet to calculate the duration of a single run.

[0004] In existing technologies, data acquisition and entry rely on manual methods, which are subject to various factors, such as format changes leading to calculation errors. Furthermore, manual operations make it difficult to compare actual operating data with design standards in a timely manner. As a result, existing technologies suffer from low statistical efficiency, high calculation error rates, and a lack of dynamic early warning mechanisms. Summary of the Invention

[0005] To address the technical problems of low statistical efficiency, high calculation error rate, and lack of dynamic early warning mechanism in the prior art, which relies on manual data acquisition and input, this invention provides an automatic calculation system and method for start-up and shutdown operation time of chemical plants.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: In a first aspect, the present invention provides an automatic calculation system for start-up and shutdown operation time of a chemical plant, the automatic calculation system for start-up and shutdown operation time of a chemical plant comprising: The standard reference data storage module is used to store the corresponding standard reference data according to the number of the chemical equipment; the standard reference data is derived from the instruction manual of the chemical equipment. The data acquisition module is used to automatically collect the start-up and shutdown timestamps of the chemical plant, in the format YYYY year MM month DD day hh hour mm minute; it also records the number of times the plant is shut down. The dynamic calculation engine calculates the single run time and the cumulative time per unit time based on the timestamps collected by the data acquisition module; the single run time is calculated monthly: if the parking timestamp for the current month exists, then the current run time = parking time - driving time; otherwise, the current run time = the first day of the next month at 00:00 - driving time. Cumulative time calculation: Monthly cumulative running time = the cumulative value obtained by successively adding the single running time within the current month; Annual cumulative running time = the cumulative value of the cumulative running time of all months. The analysis and comparison module is used to compare the actual number of parking times and cumulative running time with standard reference data to generate judgment conclusions. The suggestion output module is used to push maintenance and upkeep recommendations based on the judgment conclusions.

[0007] Optionally, the standard reference data includes: At least one of the following: the maximum number of permissible shutdowns, the minimum continuous operating time, and the maintenance cycle of a chemical plant.

[0008] Optionally, the data acquisition module supports manual revision and has data import / export interfaces.

[0009] Optionally, the analysis and comparison module performs: If the actual number of parking attempts is less than the standard allowed number of parking attempts, conclusion 1 is triggered. If the actual number of parking attempts is greater than or equal to the standard allowed number of parking attempts, conclusion 2 is triggered. If the cumulative running time is less than the standard minimum running time, conclusion 3 is triggered; If the cumulative running time is greater than or equal to the standard minimum running time, conclusion 4 is triggered.

[0010] Optionally, the suggested output module responds to conclusion 2 by outputting suggestions for replacing parts or maintenance; and responds to conclusion 4 by outputting suggestions for equipment rerouting, filter cleaning, or periodic maintenance.

[0011] Optionally, the automatic calculation system for start-up and shutdown operation time of the chemical plant further includes: a closed-loop feedback module that provides fields for manual input of processing results and supports data synchronization to the cloud.

[0012] Secondly, the present invention provides an automatic calculation method for start-up and shutdown operation time of a chemical plant, used in the aforementioned automatic calculation system for start-up and shutdown operation time of a chemical plant, comprising: S1: Input the standard reference data of the device into the system; S2: Automatically collects driving / parking timestamps; S3: Calculates single run time, monthly cumulative time, and annual cumulative time using dynamic formulas; S4: Compare the actual number of parking times and cumulative running time with standard data thresholds; S5: Generate maintenance suggestions based on the comparison results and provide feedback on the processing records.

[0013] The beneficial effects of this invention are: This invention provides an automatic calculation system for start-up and shutdown operation times of chemical plants. A standard reference data storage module solidifies plant design parameters, providing a benchmark for operational analysis. A data acquisition module enforces a unified timestamp format, eliminating the risk of format inconsistencies inherent in manual recording and ensuring data source reliability. A dynamic calculation engine uses spreadsheets and algorithms to handle complex scenarios, including missing shutdown times and cross-cycle operation scenarios, transforming the traditional manual calculation process into real-time automatic calculation, avoiding splitting errors and accumulated errors. An analysis and comparison module verifies the plant's design parameters against actual operating data in real time, identifying abnormal operating conditions where start-up and shutdown frequencies and operating durations deviate from design thresholds. A suggestion output module outputs specific maintenance strategies based on the analysis conclusions, shifting the operation and maintenance model from reactive to proactive warning. The automatic calculation system for start-up and shutdown operation times of chemical plants provided in this invention solves the technical problems of existing technologies that rely on manual data acquisition and entry, resulting in low statistical efficiency, high calculation error rates, and a lack of dynamic early warning mechanisms. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the automatic calculation system for start-up and shutdown operation time of chemical plants in this invention; Figure 2 This is a schematic diagram of the automatic calculation method for start-up and shutdown operation time of chemical plants in this invention. Detailed Implementation

[0015] To provide a detailed explanation of the automatic calculation system and method for start-up and shutdown time of chemical plants in this invention, the following description is provided in conjunction with embodiments.

[0016] In continuous production industries such as chemical and energy, key equipment (such as compressors, pump sets, and reaction towers) needs to operate 24 hours a day without interruption, and its stability is directly related to the overall production efficiency and safety of the plant. Due to the frequent occurrence of complex operating conditions such as periodic equipment switching, planned maintenance shutdowns, and sudden abnormal trips, accurate recording and analysis of the start-up and shutdown times of the equipment is a rigid requirement in industrial development.

[0017] In existing technologies, the statistical method of combining manual recording with spreadsheets is commonly used, which has the following problems: 1. Manual statistics are inefficient. The collection, entry, and calculation of running time rely on manual recording in spreadsheets, and the start / stop timestamps need to be repeatedly sorted every month, resulting in low efficiency; 2. The error rate is high. Manual statistical collection and entry are affected by personnel quality, habits, and other uncertain factors, often resulting in inconsistent formats, omissions, or miscalculations; 3. There is a lack of dynamic early warning mechanisms. It is difficult for maintenance personnel to compare actual operating data with design standards in a timely manner, and they cannot proactively trigger maintenance reminders, increasing the risk of unplanned downtime.

[0018] Example 1 See Figure 1 A schematic diagram of the automatic calculation system for start-up and shutdown operation time of a chemical plant provided in this invention is shown, including: The standard reference data storage module is used to store the corresponding standard reference data according to the number of the chemical equipment; the standard reference data is derived from the instruction manual of the chemical equipment. The data acquisition module is used to automatically collect the start-up and shutdown timestamps of the chemical plant, in the format YYYY year MM month DD day hh hour mm minute; it also records the number of times the plant is shut down. The dynamic calculation engine calculates the single run time and the cumulative time per unit time based on the timestamps collected by the data acquisition module; the single run time is calculated monthly: if the parking timestamp for the current month exists, then the current run time = parking time - driving time; otherwise, the current run time = the first day of the next month at 00:00 - driving time. Cumulative time calculation: Monthly cumulative running time = the cumulative value obtained by successively adding the single running time within the current month; Annual cumulative running time = the cumulative value of the cumulative running time of all months. The analysis and comparison module is used to compare the actual number of parking times and cumulative running time with standard reference data to generate judgment conclusions. The suggestion output module is used to push maintenance and upkeep suggestions based on the judgment conclusion.

[0019] In this embodiment, the standard reference data storage module solidifies the device design parameters, providing a benchmark for operational analysis; the data acquisition module enforces a unified timestamp format, eliminating the risk of format confusion in manual recording and ensuring data source reliability; the dynamic calculation engine uses spreadsheets and algorithms to handle complex scenarios, including missing shutdown times and cross-cycle operation scenarios, transforming the traditional calculation process that relies on manual breakdown into real-time automatic completion, avoiding breakdown errors and cumulative errors; the analysis and comparison module verifies the device's design parameters with actual operating data in real time, identifying abnormal operating conditions where the start-up and shutdown frequency and operating duration deviate from the design threshold; the suggestion output module outputs specific maintenance strategies based on the analysis conclusions, promoting the shift of operation and maintenance mode from post-event handling to pre-event early warning. The automatic calculation system for start-up and shutdown operating times of chemical plants provided in this invention solves the technical problems of existing technologies that rely on manual data acquisition and entry, resulting in low statistical efficiency, high calculation error rates, and a lack of dynamic early warning mechanisms.

[0020] Furthermore, the spreadsheet in this embodiment is an Excel spreadsheet.

[0021] Optionally, the standard reference data in this invention includes at least one of the following: the maximum number of permissible shutdowns of a chemical plant, the minimum continuous operating time, and the maintenance cycle.

[0022] In this embodiment, by clearly defining standard reference data including core parameters such as the maximum allowable number of shutdowns, minimum continuous operating time, and maintenance cycle, an indicator system covering the safety, efficiency, and maintenance dimensions of the device is constructed. This design enables the system to match differentiated control thresholds based on device characteristics (such as the fatigue resistance of the reactor and the mechanical life of the compressor), ensuring deep coupling between the early warning logic of the analysis and comparison module and the physical characteristics of the equipment. The minimum continuous operating time threshold provides a criterion for identifying abnormally frequent start-ups and shutdowns, the maximum allowable number of shutdowns adds a defense against unplanned shutdowns, and the maintenance cycle parameter drives the suggestion output module to generate preventive maintenance strategies that conform to the equipment wear and tear patterns, thereby improving the scientific nature and adaptability of device management.

[0023] Optionally, the data acquisition module in this invention supports manual revision and has data import / export interfaces.

[0024] In this embodiment, the data acquisition module supports manual revision and data import / export functions, greatly enhancing the system's compatibility with complex operating conditions. The manual revision mechanism allows operators to manually correct timestamps when DCS signals are interrupted or sensors malfunction, preventing the calculation chain from breaking due to data source failure. The data import interface can connect to heterogeneous data sources such as DCS historical databases and MES work order systems, enabling automatic integration of cross-platform operation records. The export function supports sending standardized timestamps and calculation results to the ERP maintenance plan module, breaking down data silos in operation and maintenance. This not only ensures the robustness of core automated processes but also provides a technical link for multi-system collaborative management, achieving an organic unity of rigid automation and flexible human-machine interaction.

[0025] Optionally, the dynamic calculation engine in this invention is implemented using a spreadsheet, the structure of which includes: Merge the header rows (A1-E1) and label them "Equipment Start-up and Shutdown Records"; The date base cell (C2) should be formatted as yyyy year mm month; Timestamp column (Column A: Driving time, Column B: Parking time); Calculated columns (Column C: Current run time, Column D: Monthly cumulative time, Column E: Yearly cumulative time).

[0026] Optionally, the calculation logic in the calculated column in this invention includes: Single run time (column C) calculation rules: If the driving time and parking time are in the same month: Total operating time = Parking time - Driving time; If the driving time is before 00:00 on the first day of the month and the parking time is within the month: This operation time = parking time - driving time; If the vehicle was driven and did not stop this month: the operating time for this run = 00:00 on the first day of next month - the driving time; If the driving time is before 00:00 on the first day of the month and there is no parking during the month: the running time for this operation = 00:00 on the first day of the next month - driving time.

[0027] Rules for calculating single run time in the current month: If the driving time and parking time are in the same month: Single trip time in the month = Parking time - Driving time; If the driving time is before 00:00 on the first day of the month and the parking time is within the month: Single running time in the month = Parking time - 00:00 on the first day of the month; If the vehicle was driven and not stopped this month: Single run time for the month = 00:00 on the first day of the following month - Drive time; If the driving time is before 00:00 on the first day of the month and there is no parking during the month: the single running time in the current month = 00:00 on the first day of the next month - 00:00 on the first day of the current month.

[0028] Monthly cumulative time (column D) calculation rules: First row of each month: Retrieves the single run time value of the current row for the current month; Starting from the next row: the value in column D of the previous row + the value in column C of the current row.

[0029] Rules for calculating cumulative annual time (column E): The first row of each January: retrieves the cumulative time value for the current month; Starting from the next row: the value in column E of the previous row + the value in column C of the current row; For the first row of any month other than January: take the cumulative time value of the current row plus the value in column E of the last row of the previous month; Starting from the next row: the value in column E of the previous row + the value in column C of the current row.

[0030] In this embodiment, the dynamic calculation engine is implemented using a structured spreadsheet. By merging header rows to clearly define the data scope, anchoring the calculation period to date-based cells, and separating the timestamp column from the calculated column, the data logic is ensured to be layered. This architecture creates a clear progressive calculation hierarchy for single run time, monthly cumulative time, and yearly cumulative time. The monthly cumulative value is dynamically updated using a row-by-row accumulation mechanism, and the yearly cumulative value directly references the monthly cumulative result to avoid duplicate calculations. The spreadsheet approach reduces system deployment costs (eliminating the need for a dedicated computing platform), while the explicit association between cell position and formulas enhances algorithm traceability, providing maintenance personnel with an intuitive data verification window and significantly reducing system maintenance complexity.

[0031] Optionally, the logic for generating 00:00 on the first day of the next month in this invention includes: If the current month is December, then the first day of the next month will be January 1st, (current year + 1) at 00:00. Otherwise, the first day of the next month will be (current year) / (current month + 1) / 01 day 00:00.

[0032] In this embodiment, the logic for generating the first day of the next month is designed with specific processing rules for year-end scenarios: in December scenarios, it automatically switches to January 1st of the following year; in non-December scenarios, it increments the month and locks the first day. This algorithm completely avoids the cumulative breakage problem caused by year changes in traditional manual statistics, ensuring the continuity of annual cumulative time when transitioning to the next year; the virtual endpoint 00:00 is set in strict accordance with the "whole month segmentation" business rule (e.g., December's running time is counted in the current year, and January's running time is counted in the following year), so that the monthly / annual cumulative value is fully matched with the equipment management accounting cycle, providing accurate data benchmarks for time-based performance analysis (such as monthly energy efficiency benchmarking and annual reliability assessment).

[0033] Optionally, the analysis and comparison module in this invention performs: If the actual number of parking attempts is less than the standard allowed number of parking attempts, conclusion 1 is triggered. If the actual number of parking attempts is greater than or equal to the standard allowed number of parking attempts, conclusion 2 is triggered. If the cumulative running time is less than the standard minimum running time, conclusion 3 is triggered; If the cumulative running time is greater than or equal to the standard minimum running time, conclusion 4 is triggered.

[0034] Optionally, the suggested output module in this invention responds to conclusion 2 by outputting suggestions for replacing parts or maintenance; and responds to conclusion 4 by outputting suggestions for equipment rerouting, filter cleaning, or periodic maintenance.

[0035] In this embodiment, the analysis and comparison module constructs a four-quadrant judgment logic based on standard parameters (maximum number of shutdowns, minimum running time): Conclusion 1 / 3 indicates that the operating status is better than the design lower limit, and Conclusion 2 / 4 warns of approaching or exceeding the design threshold. This design transforms discrete operating data (number of start-stops, cumulative duration) into a qualitative judgment of equipment health status, shifting the focus of operation and maintenance from data recording to risk management; the threshold triggering mechanism matches differentiated response strategies to different levels of risk, realizing multi-level classification and early warning of device status, significantly improving the granularity of risk identification and the targeting of management.

[0036] Furthermore, based on the judgment conclusions, maintenance instructions corresponding to the failure modes are generated: Conclusion 2 triggers replacement of parts or emergency maintenance recommendations (such as seal wear, bearing overheating prevention); Conclusion 4 triggers reverse switching or preventive maintenance recommendations (such as filter cleaning to prevent clogging, periodic maintenance to avoid fatigue). This design transforms abstract risk levels into specific executable work orders, and the maintenance strategy is deeply coupled with the equipment failure mechanism (frequent start-stop cycles cause mechanical shock requiring parts replacement, long-term operation causes scaling requiring filter cleaning), forming a decision-making closed loop of "risk identification - failure attribution - measure matching," effectively shortening the response link from diagnosis to execution.

[0037] Optionally, the automatic calculation system for start-up and shutdown operation time of chemical plants in this invention further includes: a closed-loop feedback module, which provides fields for manual input of processing results and supports data synchronization to the cloud.

[0038] In this embodiment, the closed-loop feedback module records maintenance execution results (such as "bearing replaced" and "filter cleaning completed") through manually input fields and achieves multi-terminal status sharing through cloud synchronization. This module transforms the system's output suggestions into a traceable work order lifecycle. After the maintenance results are fed back to the standard reference data storage module, the threshold settings can be iteratively optimized (e.g., if the actual lifespan of the parts is extended, the maintenance cycle parameters are adjusted), forming a continuous improvement loop of "early warning-handling-feedback-optimization," driving the evolution of device management from static standards to dynamic self-adaptation.

[0039] Example 2 Secondly, referring to Figure 2 The present invention also provides an automatic calculation method for start-up and shutdown operation time of a chemical plant, used in the automatic calculation system for start-up and shutdown operation time of the chemical plant in Embodiment 1, comprising: S1: Input the standard reference data of the device into the system; S2: Automatically collects driving / parking timestamps; S3: Calculates single run time, monthly cumulative time, and annual cumulative time using dynamic formulas; S4: Compare the actual number of parking times and cumulative running time with standard data thresholds; S5: Generate maintenance suggestions based on the comparison results and provide feedback on the processing records.

[0040] In this embodiment, an automatic calculation method for the start-up and shutdown operation time of a chemical plant is provided, which is used in the automatic calculation system for the start-up and shutdown operation time of the chemical plant in Embodiment 1. It should be noted that the automatic calculation method for the start-up and shutdown operation time of the chemical plant in this embodiment is based on the automatic calculation system for the start-up and shutdown operation time of the chemical plant in Embodiment 1. Its usage process and beneficial effects are the same as those of the automatic calculation system for the start-up and shutdown operation time of the chemical plant in Embodiment 1, and will not be described in detail here.

Claims

1. An automatic calculation system for start-up and shutdown operation time of a chemical plant, characterized in that, include: The standard reference data storage module is used to store the corresponding standard reference data according to the number of the chemical plant. The reference data for the standard is derived from the instruction manual of the chemical equipment. The data acquisition module is used to automatically collect the start-up and shutdown timestamps of the chemical plant, in the format YYYY year MM month DD day hh hour mm minute; it also records the number of times the plant is shut down. The dynamic calculation engine calculates the single run time and the cumulative time per unit time based on the timestamps collected by the data acquisition module. Monthly calculation of single run time: If a parking timestamp exists for the current month, then the run time = parking time - driving time; Otherwise, the running time for this operation will be calculated as follows: 00:00 on the first day of the following month - departure time. Cumulative time calculation: Monthly cumulative running time = the cumulative value obtained by successively adding the single running time within the current month; Annual cumulative running time = the cumulative value of the cumulative running time of all months. The analysis and comparison module is used to compare the actual number of parking times and cumulative running time with standard reference data to generate judgment conclusions. The suggestion output module is used to push maintenance and upkeep suggestions based on the judgment conclusion.

2. The automatic calculation system for start-up and shutdown operation time of a chemical plant according to claim 1, characterized in that, The standard reference data includes: At least one of the following: the maximum number of permissible shutdowns, the minimum continuous operating time, and the maintenance cycle of a chemical plant.

3. The automatic calculation system for start-up and shutdown operation time of a chemical plant according to claim 1, characterized in that, The data acquisition module supports manual revision and has data import / export interfaces.

4. The automatic calculation system for start-up and shutdown operation time of a chemical plant according to claim 2, characterized in that, The analysis and comparison module performs the following: If the actual number of parking attempts is less than the standard allowed number of parking attempts, conclusion 1 is triggered. If the actual number of parking attempts is greater than or equal to the standard allowed number of parking attempts, conclusion 2 is triggered. If the cumulative running time is less than the standard minimum running time, conclusion 3 is triggered; If the cumulative running time is greater than or equal to the standard minimum running time, conclusion 4 is triggered.

5. The automatic calculation system for start-up and shutdown operation time of a chemical plant according to claim 4, characterized in that, The suggested output module responds to conclusion 2 by outputting suggestions for replacing parts or maintenance; and responds to conclusion 4 by outputting suggestions for equipment relocation, filter cleaning, or periodic maintenance.

6. The automatic calculation system for start-up and shutdown operation time of a chemical plant according to claim 1, characterized in that, Also includes: The closed-loop feedback module provides a field for manual input of processing results and supports data synchronization to the cloud.

7. A method for automatically calculating the start-up and shutdown operating time of a chemical plant, used in the automatic calculation system for the start-up and shutdown operating time of a chemical plant as described in claim 1, characterized in that, include: S1: Input the standard reference data of the device into the system; S2: Automatically collects driving / parking timestamps; S3: Calculates single run time, monthly cumulative time, and annual cumulative time using dynamic formulas; S4: Compare the actual number of parking times and cumulative running time with standard data thresholds; S5: Generate maintenance suggestions based on the comparison results and provide feedback on the processing records.

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