A hydrogen production and hydrogenation station real-time safety monitoring system

Abstract

The application discloses a hydrogen production and hydrogenation site real-time safety monitoring system, comprising a hydrogen micro-leakage monitoring and early warning module, a hydrogen detection and alarm module, a combustible gas detection and alarm module and an upper computer, the hydrogen micro-leakage monitoring and early warning module adopts a hydrogen-sensitive color change sensing patch to detect the micro-leakage of a hydrogen pipeline flange, a valve and an interface, the patch comprises a detection area and a contrast area, the leakage is judged by comparing the color difference of the two areas, the hydrogen detection and alarm module and the combustible gas detection and alarm module detect medium and large leakage respectively, the upper computer receives the data of each module and performs hierarchical control, a linkage control module executes corresponding response measures according to the leakage degree, the hydrogen-sensitive color change sensing patch is a passive device and has intrinsic safety characteristics, and the application realizes multi-level and all-round real-time safety monitoring of a hydrogen production and hydrogenation site.

Description

Technical Field

[0001] This invention relates to the field of safety monitoring technology for hydrogen production and refueling sites, specifically a real-time safety monitoring system for hydrogen production and refueling sites. Background Technology

[0002] With the rapid development of the hydrogen energy industry, the safe operation of integrated hydrogen production and refueling stations is of paramount importance as an important infrastructure for hydrogen energy supply. Hydrogen, as a flammable and explosive gas, has the characteristics of a wide explosion limit range, low ignition energy, and fast diffusion speed. Once a leak occurs, it can easily cause fire or explosion accidents, resulting in serious casualties and property losses.

[0003] Existing hydrogen leak detection technologies mainly rely on electrochemical, catalytic combustion, or thermal conductivity hydrogen sensors. While these sensors can detect high concentrations of hydrogen leaks, they have the following limitations:

[0004] First, the sensitivity of detecting minute leaks at easily leaking points such as flanges, valves, and pipe joints in hydrogen pipelines is insufficient, making it difficult to detect potential hazards in the early stages of a leak.

[0005] Second, electronic sensors require external power, which poses certain safety risks in a hydrogen environment and do not possess inherent safety characteristics.

[0006] Third, existing detection systems typically employ a single detection method and lack tiered monitoring and response mechanisms for different levels of leakage, thus failing to achieve precise safety control.

[0007] Therefore, there is an urgent need to develop a real-time safety monitoring system for hydrogen production and refueling sites that can achieve multi-level, all-round hydrogen leakage monitoring and has inherent safety characteristics. Summary of the Invention

[0008] The purpose of this invention is to provide a real-time safety monitoring system for hydrogen production and refueling sites.

[0009] To achieve the above objectives, the present invention provides the following technical solution: a real-time safety monitoring system for hydrogen production and refueling sites, wherein the detection system includes a hydrogen micro-leakage monitoring and early warning module, a hydrogen detection alarm module, a combustible gas detection alarm module, and a host computer;

[0010] The hydrogen micro-leakage monitoring and early warning module includes a hydrogen-sensitive color-changing sensor patch, a light source, and an image acquisition device. The hydrogen-sensitive color-changing sensor patch is installed on flanges, valves, and pipe interfaces on the hydrogen pipeline to detect hydrogen on the surface of the hydrogen pipeline and change the displayed color according to the change in hydrogen concentration. The light source is used to provide illumination for the hydrogen-sensitive color-changing sensor patch. The image acquisition device is used to acquire images of the hydrogen-sensitive color-changing sensor patch and transmit them to a host computer. The host computer determines whether a hydrogen micro-leakage has occurred based on the color change of the hydrogen-sensitive color-changing sensor patch in the image.

[0011] The hydrogen detection alarm module includes a hydrogen detector, which is used to detect the hydrogen concentration at hydrogen production and refueling stations.

[0012] The combustible gas detection and alarm module includes a group of fixed combustible gas detectors for detecting the concentration of combustible gas at hydrogen production and refueling stations.

[0013] The host computer is communicatively connected to the hydrogen micro-leakage monitoring and early warning module, the hydrogen detection and alarm module, and the combustible gas detection and alarm module, respectively, and is used to receive the detection data from each module and perform hierarchical management and control.

[0014] As a further aspect of the present invention: the hydrogen-sensitive color change sensor patch includes a detection area and a control area;

[0015] The detection area changes color when exposed to hydrogen gas, while the control area does not change color when exposed to hydrogen gas.

[0016] The host computer determines whether a hydrogen leak has occurred by comparing the color difference between the detection area and the control area.

[0017] As a further aspect of the present invention: the detection area includes an encapsulation layer, a color-changing layer, a hydrogen-sensitive catalyst layer, and a substrate layer; the control area includes an encapsulation layer, a color-changing layer, an inert layer, a substrate layer, and a barrier layer;

[0018] The encapsulation layer is transparent, serving to protect the internal functional layers while allowing light to pass through;

[0019] The color-changing layer uses color-changing nanomaterials to change color under the action of hydrogen gas;

[0020] The hydrogen-sensitive catalytic layer is used to catalyze the reaction between hydrogen gas and the color-changing layer;

[0021] The inert layer is used to prevent hydrogen from reacting with the color-changing layer;

[0022] The base layer is breathable to allow hydrogen molecules to pass through;

[0023] The barrier layer is used to prevent gas penetration.

[0024] As a further aspect of the present invention: when the host computer processes the images acquired by the image acquisition device, it includes the following steps:

[0025] The image is preprocessed to extract the image regions of the detection area and the control area;

[0026] Convert the images of the detection area and the control area from the RGB color space to the CIELab color space;

[0027] Calculate the average color values ​​of the detection area and the control area separately;

[0028] Calculate the color difference between the detection area and the control area;

[0029] The color difference value is compared with a preset threshold. If the color difference value is greater than the preset threshold, it is determined that a hydrogen leak has occurred.

[0030] As a further aspect of the present invention: the hydrogen micro-leakage monitoring and early warning module is used to detect hydrogen micro-leakage with a leakage rate of less than 100 ml / min;

[0031] The hydrogen detection alarm module is used to detect hydrogen leaks with a leakage rate in the range of 100 ml / min to 1000 ml / min.

[0032] The combustible gas detection alarm module is used to detect hydrogen leaks with a leakage rate greater than 1000 ml / min.

[0033] As a further embodiment of the present invention: the hydrogen detector is installed at the connection of the hydrogen pipeline, and detects the hydrogen concentration at a fixed frequency and uploads the hydrogen concentration, location and time information to the host computer;

[0034] When the detected hydrogen concentration exceeds the preset concentration, an audible and visual alarm will be triggered to indicate a hydrogen leak.

[0035] As a further aspect of the present invention: the combustible gas detector group is distributed at various gas monitoring points in the hydrogen production and refueling station, and detects the concentration of combustible gas at a preset frequency and uploads monitoring information including gas type, gas concentration, time, and gas monitoring point to the host computer.

[0036] As a further aspect of the present invention: the detection system further includes a linkage control module, which is connected to a host computer;

[0037] When a micro-leak is identified as a Level 1 leak, the linkage control module controls the host computer to record the leak information and generate a maintenance work order.

[0038] When a level 2 leak is detected, the linkage control module activates the audible and visual alarm, turns on the local ventilation equipment, and notifies the on-duty personnel.

[0039] When a Level III major leak is identified, the linkage control module triggers an emergency shutdown, cuts off the hydrogen supply, starts emergency ventilation, and issues an evacuation alarm.

[0040] As a further aspect of the present invention: the hydrogen-sensitive color-changing sensor patch is a passive device, which does not require circuit connection and power supply, and has intrinsic safety characteristics.

[0041] Compared with the prior art, the beneficial effects of the present invention by adopting the above technical solution are as follows:

[0042] 1. This invention sets up a hydrogen micro-leakage monitoring and early warning module, and uses a hydrogen-sensitive color-changing sensor patch to monitor leak-prone points such as flanges, valves and pipe interfaces of hydrogen pipelines in real time. It can detect micro-leakage in the early stage of hydrogen leakage, making up for the lack of sensitivity of traditional electronic sensors to detect micro-leakage. The hydrogen-sensitive color-changing sensor patch is a passive device, which does not require circuit connection and power supply. It has intrinsic safety characteristics and can be safely applied in hydrogen environment, avoiding the safety hazards that electronic sensors may cause in hydrogen environment.

[0043] 2. This invention constructs a three-level monitoring system comprising a hydrogen micro-leakage monitoring and early warning module, a hydrogen detection and alarm module, and a combustible gas detection and alarm module. It implements graded control for different levels of leakage, thereby achieving comprehensive and multi-level safety monitoring of hydrogen production and refueling stations.

[0044] 3. This invention uses a detection area and a control area set in a hydrogen-sensitive color-changing sensor patch to determine whether a hydrogen leak has occurred by comparing the color difference between the two areas. This effectively eliminates the interference of environmental factors on the detection results, improves the accuracy and reliability of the detection, and sets up a linkage control module that can automatically execute corresponding emergency response measures according to the degree of leakage, from recording work orders to emergency shutdown and evacuation, realizing intelligent safety management. Attached Figure Description

[0045] Figure 1 This is a schematic diagram of the overall process in an embodiment of the present invention. Detailed Implementation

[0046] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings. It should be noted that the description of these embodiments is for the purpose of helping to understand the present invention, but does not constitute a limitation of the present invention.

[0047] Furthermore, the technical features involved in the various embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0048] Example 1

[0049] like Figure 1As shown in the figure, this embodiment of the invention provides a real-time safety monitoring system for hydrogen production and refueling sites. The system includes a hydrogen micro-leakage monitoring and early warning module, a hydrogen detection alarm module, a combustible gas detection alarm module, and a host computer.

[0050] The hydrogen micro-leakage monitoring and early warning module includes a hydrogen-sensitive color-changing sensor patch, a light source, and an image acquisition unit. The hydrogen-sensitive color-changing sensor patch is installed at flanges, valves, and pipe interfaces on the hydrogen pipeline. These locations are the weakest points in the hydrogen pipeline system most prone to leakage. The hydrogen-sensitive color-changing sensor patch can detect hydrogen on the surface of the hydrogen pipeline and change the displayed color according to the change in hydrogen concentration. The light source is used to provide stable illumination for the hydrogen-sensitive color-changing sensor patch, ensuring that the image acquisition unit can acquire clear images. The image acquisition unit is used to acquire images from the hydrogen-sensitive color-changing sensor patch and transmit the acquired images to the host computer. After receiving the images, the host computer determines whether a hydrogen micro-leakage has occurred based on the color change of the hydrogen-sensitive color-changing sensor patch in the image.

[0051] The hydrogen detection and alarm module includes a hydrogen detector, which is used to detect the hydrogen concentration at the hydrogen production and refueling station. The hydrogen detector is installed at the hydrogen pipeline connection point and detects the hydrogen concentration at a fixed frequency and uploads the hydrogen concentration, location and time information to the host computer. When the detected hydrogen concentration exceeds the preset concentration, the hydrogen detector will issue an audible and visual alarm to indicate a hydrogen leak.

[0052] The combustible gas detection and alarm module includes a fixed combustible gas detector group, which is used to detect the concentration of combustible gas at the hydrogen production and refueling station. The fixed combustible gas detector group is distributed at various gas monitoring points in the hydrogen production and refueling station to form a full-coverage monitoring network. Each detector detects the concentration of combustible gas at a preset frequency and uploads monitoring information including gas type, gas concentration, time, and gas monitoring point to the host computer.

[0053] The host computer is connected to the hydrogen micro-leakage monitoring and early warning module, the hydrogen detection and alarm module, and the combustible gas detection and alarm module to receive detection data from each module and perform hierarchical management and control. As the control center of the entire monitoring system, the host computer is responsible for summarizing and analyzing data from each monitoring module and taking corresponding control measures according to the degree of leakage.

[0054] Example 2

[0055] The hydrogen-sensitive color-changing sensor patch includes a detection area and a control area. The detection area changes color when exposed to hydrogen gas, while the control area does not change color. The host computer determines whether a hydrogen leak has occurred by comparing the color difference between the detection area and the control area. The purpose of setting up the control area is to eliminate the interference of factors such as changes in ambient light and temperature on the detection results and improve the accuracy of the detection.

[0056] Example 3

[0057] The detection area comprises, from the outside in, an encapsulation layer, a color-changing layer, a hydrogen-sensitive catalyst layer, and a substrate layer. The encapsulation layer, located on the outermost layer, is transparent and protects the internal functional layers while allowing light to pass through, enabling light emitted from the light source to illuminate the color-changing layer. Simultaneously, the image acquisition device can capture the color information of the color-changing layer. The color-changing layer utilizes color-changing nanomaterials that change color upon contact with hydrogen gas. Commonly used color-changing nanomaterials include metal oxide nanomaterials such as tungsten oxide and molybdenum oxide. These materials undergo a reduction reaction upon contact with hydrogen gas, causing their color to change. The optical properties change, resulting in a color change. The hydrogen-sensitive catalyst layer is located between the color-changing layer and the base layer. It is used to catalyze the reaction between hydrogen and the color-changing layer. The hydrogen-sensitive catalyst layer usually uses noble metal nanoparticles such as palladium and platinum. These materials have good adsorption and catalytic effects on hydrogen, and can decompose hydrogen molecules into hydrogen atoms, promoting the reaction between hydrogen and the color-changing layer material. The base layer is located in the innermost layer and is permeable to allow hydrogen molecules to pass through. The base layer is made of porous material so that hydrogen molecules in the environment can pass through the base layer to reach the hydrogen-sensitive catalyst layer and the color-changing layer.

[0058] Example 4

[0059] The control area comprises, from the outside in, an encapsulation layer, a color-changing layer, an inert layer, a substrate layer, and a barrier layer. The encapsulation layer and color-changing layer of the control area are the same as those of the detection area. The inert layer is placed between the color-changing layer and the substrate layer to prevent hydrogen from reacting with the color-changing layer. The inert layer is made of a material that is inert to hydrogen and does not have the ability to catalyze the hydrogen reaction. The substrate layer is also permeable to air. The barrier layer is placed on the outside of the substrate layer to prevent gas permeation and further ensure that hydrogen does not reach the color-changing layer. Through this design, the control area maintains its color under any environmental conditions, providing a stable reference standard for the color change of the detection area.

[0060] Example 5

[0061] When the bit machine processes the image acquired by the image acquisition device, it performs the following operations:

[0062] First, the image is preprocessed to extract the image regions of the detection area and the control area. The preprocessing operations include image denoising, brightness correction, and region segmentation, with the aim of obtaining clear images of the detection area and the control area.

[0063] Then, the images of the detection area and the control area are converted from the RGB color space to the CIELab color space. The CIELab color space is a device-independent color model, where L represents luminance, a represents the chromaticity components from green to red, and b represents the chromaticity components from blue to yellow. The reason for choosing the CIELab color space is that it better conforms to the human eye's perception of color differences and can more accurately quantify color differences.

[0064] Next, the average color values ​​of the detection area and the control area are calculated separately. Specifically, the average value of the detection area image in the three channels L, a, and b is calculated to obtain the average color value of the detection area. Similarly, the average value of the control area image in the three channels L, a, and b is calculated to obtain the average color value of the control area.

[0065] Next, the color difference value between the detection area and the control area is calculated;

[0066] Finally, the color difference value is compared with a preset threshold. If the color difference value is greater than the preset threshold, it is determined that a hydrogen leak has occurred. The preset threshold is set according to the actual application scenario and the characteristics of the hydrogen-sensitive color change sensor patch.

[0067] Example 6

[0068] The monitoring system of this invention is equipped with a three-level monitoring mechanism for different leakage levels. The hydrogen micro-leakage monitoring and early warning module is used to detect hydrogen micro-leakage with a leakage rate of less than 100 ml / min. These micro-leakages usually occur at flange sealing surfaces, valve packings, and other locations, which are difficult to detect with traditional electronic sensors. The hydrogen detection and alarm module is used to detect hydrogen leaks with a leakage rate in the range of 100 ml / min to 1000 ml / min. These leaks have already formed a certain concentration accumulation and need to be dealt with in a timely manner. The combustible gas detection and alarm module is used to detect hydrogen leaks with a leakage rate of more than 1000 ml / min. These large leaks may quickly form an explosive gas mixture and require immediate emergency measures.

[0069] The monitoring system of the present invention also includes a linkage control module, which is connected to a host computer and performs corresponding linkage control operations according to the degree of leakage.

[0070] When a micro-leak is identified as a Level 1 leak, meaning the hydrogen micro-leakage monitoring and early warning module detects a color change in the hydrogen-sensitive color-changing sensor patch, the linkage control module controls the host computer to record the leak information and generate a maintenance work order, arranging for maintenance personnel to handle the leak point during planned maintenance.

[0071] When a level 2 leak is detected, meaning the hydrogen detection alarm module detects that the hydrogen concentration exceeds the preset concentration, the linkage control module activates the audible and visual alarm to issue an on-site alarm, simultaneously turns on the local ventilation equipment to accelerate the diffusion of hydrogen, and notifies the on-duty personnel to handle the situation on-site via SMS, telephone, etc.

[0072] When a Level III major leak is identified, the combustible gas detection and alarm module detects that the concentration of combustible gas has reached a dangerous level. The linkage control module triggers the emergency shutdown procedure, cuts off the hydrogen supply valve, starts the emergency ventilation system for forced ventilation, and issues an evacuation alarm to notify personnel in the station to evacuate immediately.

[0073] The hydrogen-sensitive color-changing sensor patch of the present invention is a passive device that does not require circuit connection or power supply and has intrinsic safety characteristics. Since the hydrogen-sensitive color-changing sensor patch does not involve any electrical components and does not generate electric sparks, it can be safely and directly pasted onto the surface of equipment such as hydrogen pipelines and valves without considering explosion-proof requirements, which greatly simplifies the installation and use process.

[0074] While the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the invention. Any variations and modifications can be made by those skilled in the art without departing from the spirit and scope of the invention. Therefore, any modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention, without departing from the scope of the invention, fall within the protection scope defined by the claims of the present invention.

Claims

1. A real-time safety monitoring system for hydrogen production and refueling stations, characterized in that: The detection system includes a hydrogen micro-leakage monitoring and early warning module, a hydrogen detection and alarm module, a combustible gas detection and alarm module, and a host computer; The hydrogen micro-leakage monitoring and early warning module includes a hydrogen-sensitive color-changing sensor patch, a light source, and an image acquisition device. The hydrogen-sensitive color-changing sensor patch is installed on flanges, valves, and pipe interfaces on the hydrogen pipeline to detect hydrogen on the surface of the hydrogen pipeline and change the displayed color according to the change in hydrogen concentration. The light source is used to provide illumination for the hydrogen-sensitive color-changing sensor patch. The image acquisition device is used to acquire images of the hydrogen-sensitive color-changing sensor patch and transmit them to a host computer. The host computer determines whether a hydrogen micro-leakage has occurred based on the color change of the hydrogen-sensitive color-changing sensor patch in the image. The hydrogen detection alarm module includes a hydrogen detector, which is used to detect the hydrogen concentration at hydrogen production and refueling stations. The combustible gas detection and alarm module includes a group of fixed combustible gas detectors for detecting the concentration of combustible gas at hydrogen production and refueling stations. The host computer is communicatively connected to the hydrogen micro-leakage monitoring and early warning module, the hydrogen detection and alarm module, and the combustible gas detection and alarm module, respectively, and is used to receive the detection data from each module and perform hierarchical management and control.

2. The real-time safety monitoring system for hydrogen production and refueling stations according to claim 1, characterized in that: The hydrogen-sensitive color-changing sensor patch includes a detection area and a control area; The detection area changes color when exposed to hydrogen gas, while the control area does not change color when exposed to hydrogen gas. The host computer determines whether a hydrogen leak has occurred by comparing the color difference between the detection area and the control area.

3. The real-time safety monitoring system for hydrogen production and refueling stations according to claim 2, characterized in that: The detection area includes an encapsulation layer, a color-changing layer, a hydrogen-sensitive catalyst layer, and a substrate layer; the control area includes an encapsulation layer, a color-changing layer, an inert layer, a substrate layer, and a barrier layer. The encapsulation layer is transparent, serving to protect the internal functional layers while allowing light to pass through; The color-changing layer uses color-changing nanomaterials to change color under the action of hydrogen gas; The hydrogen-sensitive catalytic layer is used to catalyze the reaction between hydrogen gas and the color-changing layer; The inert layer is used to prevent hydrogen from reacting with the color-changing layer; The base layer is breathable to allow hydrogen molecules to pass through; The barrier layer is used to prevent gas penetration.

4. The real-time safety monitoring system for hydrogen production and refueling stations according to claim 2, characterized in that: When the host computer processes the images acquired by the image acquisition device, it includes the following steps: The image is preprocessed to extract the image regions of the detection area and the control area; Convert the images of the detection area and the control area from the RGB color space to the CIELab color space; Calculate the average color values ​​of the detection area and the control area separately; Calculate the color difference between the detection area and the control area; The color difference value is compared with a preset threshold. If the color difference value is greater than the preset threshold, it is determined that a hydrogen leak has occurred.

5. The real-time safety monitoring system for hydrogen production and refueling stations according to claim 1, characterized in that: The hydrogen micro-leakage monitoring and early warning module is used to detect hydrogen micro-leakage with a leakage rate of less than 100 ml / min. The hydrogen detection alarm module is used to detect hydrogen leaks with a leakage rate in the range of 100 ml / min to 1000 ml / min. The combustible gas detection alarm module is used to detect hydrogen leaks with a leakage rate greater than 1000 ml / min.

6. The real-time safety monitoring system for hydrogen production and refueling stations according to claim 1, characterized in that: The hydrogen detector is installed at the hydrogen pipeline connection point to detect the hydrogen concentration at a fixed frequency and upload hydrogen concentration, location and time information to the host computer. When the detected hydrogen concentration exceeds the preset concentration, an audible and visual alarm will be triggered to indicate a hydrogen leak.

7. The real-time safety monitoring system for hydrogen production and refueling stations according to claim 1, characterized in that: The combustible gas detector group is distributed at various gas monitoring points in the hydrogen production and refueling station. It detects the concentration of combustible gas at a preset frequency and uploads monitoring information, including gas type, gas concentration, time, and gas monitoring point, to the host computer.

8. The real-time safety monitoring system for hydrogen production and refueling stations according to claim 1, characterized in that: The detection system also includes a linkage control module, which is connected to a host computer. When a micro-leak is identified as a Level 1 leak, the linkage control module controls the host computer to record the leak information and generate a maintenance work order. When a level 2 leak is detected, the linkage control module activates the audible and visual alarm, turns on the local ventilation equipment, and notifies the on-duty personnel. When a Level III major leak is identified, the linkage control module triggers an emergency shutdown, cuts off the hydrogen supply, starts emergency ventilation, and issues an evacuation alarm.

9. The real-time safety monitoring system for hydrogen production and refueling stations according to claim 1, characterized in that: The hydrogen-sensitive color-changing sensor patch is a passive device that does not require circuit connections or power supply, and has intrinsic safety characteristics.

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