Second-level monitoring DCS interlocking multi-state system and method

Abstract

The application relates to the technical field of operation and maintenance management, and particularly discloses a second-level monitoring system for DCS interlocking multi-state systems. The system comprises a data acquisition module, a data correlation module, a data storage module, a data processing module and a monitoring display module. The data acquisition module communicates with the DCS system through an industrial communication protocol and acquires real-time interlocking signal data. The data correlation module generates correlation data by online correlation of real-time data and interlocking logic according to the correlation rules in the pre-established interlocking account. The data storage module transmits and stores the correlation data to a relational database through a subscription service. The data processing module judges whether the interlocking is triggered and the commissioning state of the interlocking condition end and the execution end based on the correlation data. The monitoring display module displays the judgment result in real time at a second-level refresh frequency. The application also provides a method based on the above system.

Description

Technical Field

[0001] This invention relates to the field of operation and maintenance management technology, specifically to a second-level monitoring DCS interlocking multi-state system and method. Background Technology

[0002] In the field of industrial automation control, distributed control systems (DCS) are widely used in process industries such as power, petrochemical, and metallurgy to achieve centralized monitoring and decentralized control of production processes. Among them, interlocking systems, as an important means of ensuring the safe operation of equipment, automatically trigger protective actions under abnormal or dangerous conditions by comprehensively judging key process parameters, equipment status, and logical relationships, thereby preventing accidents from escalating.

[0003] Currently, most process control systems in chemical enterprises are DCS (Distributed Control System) systems. Various process and equipment safety interlocks are built based on DCS systems to ensure safe production in chemical enterprises. However, in the management of interlocks in chemical enterprises, it is impossible to effectively control thousands or tens of thousands of interlocks. Among them, there are safety hazards such as incorrect or missed interlock activation, and even a very small number of interlock logics have deviations from the design data, which greatly increases the difficulty of discovering these interlock problems. Summary of the Invention

[0004] The technical objective of this invention is to provide a second-level monitoring system and method for DCS interlocking multi-state operation, so as to improve the visualization level and safety and reliability of interlocking operation.

[0005] To achieve the above-mentioned technical objectives, the present invention provides the following technical solution: This invention provides a second-level monitoring DCS interlocking multi-state system, comprising a data acquisition module, a data association module, a data storage module, a data processing module, and a monitoring and display module. The data acquisition module communicates with the DCS system through an industrial communication protocol to collect and store real-time data of various interlocking signals in the DCS system. The data association module is connected to the data acquisition module. Based on the association rules in the pre-established interlocking ledger, it associates the collected real-time data with the interlocking logic online in real time to generate associated data. The data storage module is connected to the data association module, and transmits and stores the associated data to the relational database in real time through a subscription service; The data processing module is connected to the data storage module, and performs real-time processing on each interlock signal based on the associated data, determines whether the interlock is triggered and the commissioning status of each instrument or valve at the interlock condition end and the execution end, and stores the output judgment result; The monitoring and display module is connected to the data processing module and is used to display the judgment result on the monitoring page in real time at a refresh rate of seconds, thereby enabling second-level monitoring of the DCS interlock activation status, deactivation status and trigger status.

[0006] Furthermore, the system also includes a ledger management module, which is configured as follows: Receive interlocking basic information ledger A, which includes interlocking description, interlocking instrument, interlocking instrument description, interlocking category, interlocking level, interlocking logic, interlocking value, interlocking relationship and interlocking signal ASSETS address; The interlocking basic information ledger A is converted into interlocking ledger B according to preset logic. Interlocking ledger B is used to establish the association rules between interlocking signal addresses and interlocking logic, and to set the interlocking activation standard value. The interlocking ledger B is converted into an interlocking logic ledger C, which is used to display the interlocking logic on the monitoring and display module according to the structure of condition end, logic end and execution end.

[0007] Furthermore, the data processing module is configured to determine the activation status of the interlocking condition terminal in the following manner: The system collects the real-time set values ​​of the signals from each instrument at the interlocking condition terminal, compares the real-time set values ​​with the corresponding interlocking activation standard values, and determines that the corresponding instrument is in an inactive state if the real-time set values ​​are inconsistent with the standard values. The system then marks the determination result, stores it, and displays it.

[0008] Preferably, the interlocking logic of the DCS system has a pre-set conditional bypass function, and the interlocking release and activation operations are both performed in a standardized manner through the conditional bypass function. The data acquisition module also acquires the real-time bypass status of the condition terminal bypass. The data processing module compares the condition terminal bypass status with the corresponding standard status and, together with the interlock setting value comparison result, jointly determines the activation or deactivation status of each instrument at the interlock condition terminal.

[0009] More preferably, the data processing module is further configured to determine the activation status of the interlocking execution end in the following manner: The bypass status of each valve or device at the interlocking execution end is collected, and the bypass status is compared with the corresponding standard status. If the bypass status is inconsistent with the standard status, the corresponding valve or device is determined to be in an unused state, and the judgment result is marked, stored, and displayed.

[0010] Furthermore, the data processing module is also configured to jointly screen for anomalies and trigger interlocks: When an interlock trigger signal is acquired, and at least one valve or device at the interlock execution end is in a bypass state, the corresponding interlock is marked as an abnormally triggered interlock and an alarm is issued. An abnormally triggered interlock refers to an interlock in which the execution end cannot perform the interlock action due to bypass after the interlock is triggered.

[0011] Based on the above, the monitoring and display module is also configured as follows: Record the start time and duration of interlock release, and issue a timeout alarm when the interlock release duration exceeds a preset threshold to prevent uncontrolled interlock release; And / or, record the start time and duration of the interlock trigger to achieve timing tracking of the interlock trigger state.

[0012] This invention also provides a method for second-level monitoring of multiple states of DCS interlocking, the method comprising: Real-time data of various interlocking signals in the DCS system are collected and stored using industrial communication protocols; Based on the association rules in the pre-established interlocking ledger, the collected real-time data is associated with the interlocking logic online in real time to obtain the associated data; The associated data is transmitted and stored in a relational database in real time through a subscription service; Real-time processing of the associated data includes: comparing the real-time signal values ​​of each instrument at the interlock condition end with the interlock activation standard value to determine the activation status of the condition end; comparing the bypass status of each valve or device at the interlock execution end with the standard status to determine the activation status of the execution end; collecting interlock position signals to determine whether the interlock has been triggered; and jointly screening for abnormal interlocking triggered by the bypass at the execution end after the interlock has been triggered. The above judgment results are displayed in real time on the monitoring page at a refresh rate of seconds, realizing full-scale second-level monitoring of the DCS interlock activation status, deactivation status, and trigger status.

[0013] The beneficial effects of this invention are as follows: 1. This invention acquires DCS interlocking signals in real time, maps the signal data to the interlocking logic according to the preset association rules in the interlocking ledger, and then judges the interlocking condition end, execution end and triggering state item by item based on a unified commissioning standard value, and displays it at a refresh frequency of seconds, thereby realizing the continuous identification and dynamic presentation of multiple interlocking states, solving the problems of difficulty in real-time correspondence between interlocking signals and logical relationships and discontinuous state judgment in the prior art.

[0014] 2. This invention transforms basic interlocking information into a structured interlocking ledger and interlocking logic ledger containing signal addresses, logical relationships, and standard values ​​for use. This enables each interlocking element to have a clear correspondence and provides a unified basis for data association and status determination, thereby improving the standardization of the interlocking logic parsing process and reducing judgment errors caused by information dispersion or unclear rules.

[0015] 3. The present invention also compares the bypass state of the interlocking condition end and the execution end with the standard state, and makes a judgment in combination with the interlocking trigger signal. At the same time, it records the duration of interlock release and trigger and makes a threshold judgment, thereby being able to identify the triggering situation where the execution end does not actually participate in the action and the situation where the interlock is in an abnormal state for a long time. This allows the interlocking operation status to be reflected and prompted in a timely manner, reducing safety hazards during operation. Attached Figure Description

[0016] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0017] The above and other aspects of the invention will now be described by way of example only, with reference to the accompanying drawings, in which: Figure 1 This is a schematic diagram of data transmission of each module in an embodiment of the present invention; Figure 2 This is a schematic diagram of the interlocking logic in an embodiment of the present invention; Figure 3 This is a schematic diagram of the interlocking logic in another embodiment of the present invention. Detailed Implementation

[0018] To better understand the above technical solutions, the following will provide a detailed explanation of the technical solutions in conjunction with the accompanying drawings and specific implementation methods. Example

[0019] like Figure 1 As shown, this embodiment provides a second-level monitoring DCS interlocking multi-state system. The data acquisition module establishes a communication connection with the DCS system using the OPC protocol. It collects and stores the interlocking signals in the DCS system in real time through AVEVA's PI system. The collected data includes conditional signals, logic operation related signals, and execution device status signals.

[0020] The data association module uses AVEVA's AF software to build an interlocking logic framework based on the association rules in the pre-established interlocking ledger. It then matches the real-time data obtained from the PI system through the ASSETS address with the interlocking logic online in real time, forming associated data with relationships.

[0021] The data storage module receives related data from the AF software through a subscription service and transmits it to a relational database for storage, processing the data during the storage process.

[0022] Based on the associated data, the data processing module determines whether the interlock is triggered and the operational status of each instrument or valve on the interlock condition end and the execution end. Specifically, it determines the interlock trigger status by collecting interlock position signals and performs corresponding analysis on the condition end and the execution end signals.

[0023] Specifically, the data processing module is connected to the data storage module. Based on the associated data, it processes each interlock signal in real time, analyzes the condition input, logic operation, and execution output according to the interlock logic, determines whether the interlock is triggered and the status of each instrument or valve on the interlock condition end and execution end, and stores the output judgment results.

[0024] The monitoring and display module is connected to the data processing module, displaying the judgment results in real time on the monitoring page with a refresh rate of seconds, enabling continuous presentation of the interlock activation, deactivation, and trigger status. Specifically, the monitoring and display module is deployed on the company's internal digital management platform, and through front-end data processing, displays the judgment results in real time on the interlock data monitoring page with a refresh rate of seconds.

[0025] like Figure 2 As shown, "Condition A" and "Condition B" at the interlocking condition end serve as input signals. After being processed by "OR" in the logic, they drive the "cut-off valve" and "regulating valve" at the execution end. The data processing module makes corresponding judgments on each signal according to this logical relationship, thereby realizing the real-time identification and display of the complete link status from the condition end to the execution end in the diagram. Example

[0026] Based on Embodiment 1, the system in this embodiment further includes a ledger management module, which receives interlocking basic information ledger A. Interlocking basic information ledger A includes interlocking description, interlocking instrument, interlocking instrument description, interlocking category, interlocking level, interlocking logic, interlocking value, interlocking relationship, and interlocking signal ASSETS address. It then converts this into interlocking ledger B according to preset logic to establish association rules between interlocking signal address and interlocking logic and set interlocking activation standard values. Furthermore, it converts interlocking ledger B into interlocking logic ledger C, which is used to display the system on the monitoring and display module according to the structure of condition end, logic end, and execution end.

[0027] Specifically, the ledger A includes interlock description, interlock instrument, interlock instrument description, interlock category, interlock level, interlock logic, interlock value, interlock relationship, and interlock signal ASSETS address; during the statistical process, the interlock judgment logic is sorted out and the design data is checked by entering the DCS system Chart page, and the effectiveness of the condition-side instrument bypass function is confirmed at the same time.

[0028] The ledger management module transforms the basic interlocking information ledger A into an interlocking ledger B according to the set logic. The interlocking ledger B is used to directly display interlocking information on the monitoring page, establish association rules between interlocking signal ASSETS addresses and interlocking logic, and establish interlocking activation standard values ​​or statuses. It is further transformed into an interlocking logic ledger C, which is used to display the interlocking logic in the monitoring display module according to the structure of condition end, logic end and execution end.

[0029] During operation, the data processing module collects the real-time set values ​​of each instrument on the condition terminal and compares them with the interlocking commissioning standard values ​​to determine whether the instrument is in operation. At the same time, it collects the bypass signal of the condition terminal and compares the bypass status with the standard status to determine whether the instrument is bypassed, thereby determining the condition terminal's commissioning or deactivation status.

[0030] For the actuator, the bypass status of each valve or device is collected and compared with the standard status to determine whether the actuator is in operation.

[0031] like Figure 3 As shown, after the condition "Condition A" and "Bypass A" are ANDed, and "Condition B" and "Bypass B" are ANDed, the execution end "Shut-off Valve" and "Regulating Valve" are driven by "OR" logic. The data processing module performs step-by-step judgment on each node according to this logical relationship. At the same time, when an interlock trigger signal is detected and a valve or equipment at the execution end is in a bypass state, the corresponding interlock is marked as an abnormal trigger interlock and an alarm prompt is issued.

[0032] The monitoring and display module simultaneously records the start time and duration of interlock release, and issues a timeout alarm when the release duration exceeds a preset threshold. It also records the start time and duration of interlock triggering, enabling time-series tracking of the interlock status. Through this process, the status, bypass status, and duration of each interlock node can be identified and displayed, reflecting changes in the interlock's status that were not actually executed or remained abnormal for an extended period. Example

[0033] This embodiment also provides an operation method based on the above-mentioned second-level monitoring DCS interlocking multi-state system, including the following steps: Real-time data of various interlocking signals in the DCS system are collected and stored using industrial communication protocols; Based on the association rules in the pre-established interlocking ledger, the collected real-time data is associated with the interlocking logic online in real time to obtain the associated data; The associated data is transmitted and stored in a relational database in real time through a subscription service; Real-time processing of the associated data includes: comparing the real-time signal values ​​of each instrument at the interlock condition end with the interlock activation standard value to determine the activation status of the condition end; comparing the bypass status of each valve or device at the interlock execution end with the standard status to determine the activation status of the execution end; collecting interlock position signals to determine whether the interlock has been triggered; and jointly screening for abnormal interlocking triggered by the bypass at the execution end after the interlock has been triggered. The above judgment results are displayed in real time on the monitoring page at a refresh rate of seconds, realizing full-scale second-level monitoring of the DCS interlock activation status, deactivation status, and trigger status.

[0034] The description herein is provided to enable those skilled in the art to implement or use the present disclosure. Various modifications to the present disclosure will be readily apparent to those skilled in the art, and the general principles defined herein can be applied to other variations without departing from the scope of the disclosure. Therefore, this disclosure is not limited to the examples and designs described herein, but should be given the broadest scope consistent with the principles and novel features disclosed herein.

[0035] Although one or more exemplary embodiments of this disclosure have been described with reference to the accompanying drawings, those skilled in the art will understand that various changes in form and detail may be made therein without departing from the spirit and scope of this disclosure as defined by the appended claims.

[0036] The foregoing description is merely illustrative of this disclosure, and modifications may be made to the invention in light of the above detailed description. The terminology used in the appended claims should not be construed as limiting the invention to the specific embodiments disclosed in the specification. Rather, the scope of the invention will be fully defined by the appended claims, which will be interpreted according to established principles of claim interpretation.

Claims

1. A second-level monitoring DCS interlocking multi-state system, characterized in that, include: The data acquisition module communicates with the DCS system through an industrial communication protocol to collect and store real-time data of various interlocking signals in the DCS system. The data association module is connected to the data acquisition module. Based on the association rules in the pre-established interlocking ledger, it associates the collected real-time data with the interlocking logic online in real time to generate associated data. The data storage module is connected to the data association module and transmits and stores the associated data to a relational database in real time through a subscription service. The data processing module is connected to the data storage module. Based on the associated data, it processes each interlock signal in real time, determines whether the interlock is triggered and the status of each instrument or valve at the interlock condition end and the execution end, and stores the output judgment result. The monitoring and display module is connected to the data processing module and displays the judgment results on the monitoring page in real time at a refresh rate of seconds, thereby enabling second-level monitoring of the DCS interlock activation status, deactivation status, and trigger status.

2. The second-level monitoring DCS interlocking multi-state system according to claim 1, characterized in that, The system also includes a ledger management module, which is configured as follows: Receive interlocking basic information ledger A, which includes interlocking description, interlocking instrument, interlocking instrument description, interlocking category, interlocking level, interlocking logic, interlocking value, interlocking relationship and interlocking signal ASSETS address; The interlocking basic information ledger A is converted into interlocking ledger B according to preset logic. Interlocking ledger B is used to establish the association rules between interlocking signal addresses and interlocking logic, and to set the interlocking activation standard value. The interlocking ledger B is converted into an interlocking logic ledger C, which is used to display the interlocking logic on the monitoring and display module according to the structure of condition end, logic end and execution end.

3. The second-level monitoring DCS interlocking multi-state system according to claim 2, characterized in that, The data processing module is configured to determine the activation status of the interlocking condition terminal in the following way: The system collects the real-time set values ​​of the signals from each instrument at the interlocking condition terminal, compares the real-time set values ​​with the corresponding interlocking activation standard values, and determines that the corresponding instrument is in an inactive state if the real-time set values ​​are inconsistent with the standard values. The system then marks the determination result, stores it, and displays it.

4. The second-level monitoring DCS interlocking multi-state system according to claim 3, characterized in that, The interlocking logic of the DCS system has a pre-set conditional bypass function. The interlocking release and activation operations are both performed in a standardized manner through the conditional bypass function. The data acquisition module also acquires the real-time bypass status of the condition terminal bypass. The data processing module compares the condition terminal bypass status with the corresponding standard status and, together with the interlock setting value comparison result, jointly determines the activation or deactivation status of each instrument at the interlock condition terminal.

5. The second-level monitoring DCS interlocking multi-state system according to claim 4, characterized in that, The data processing module is also configured to determine the activation status of the interlocking execution end in the following ways: Collect the bypass status of each valve or device at the interlocking execution end, and compare the bypass status with the corresponding standard status; If the bypass status is inconsistent with the standard status, the corresponding valve or equipment is determined to be in an unused state, and the judgment result is marked, stored, and displayed.

6. The second-level monitoring DCS interlocking multi-state system according to claim 5, characterized in that, The data processing module is also configured to trigger interlocks through joint screening of anomalies: When an interlock trigger signal is acquired, and at least one valve or device at the interlock execution end is in a bypass state, the corresponding interlock is marked as an abnormally triggered interlock and an alarm is issued. An abnormally triggered interlock refers to an interlock in which the execution end cannot perform the interlock action due to bypass after the interlock is triggered.

7. The second-level monitoring DCS interlocking multi-state system according to any one of claims 1-6, characterized in that, The monitoring and display module is also configured as follows: Record the start time and duration of interlock release, and issue a timeout alarm when the interlock release duration exceeds a preset threshold to prevent uncontrolled interlock release; And / or, record the start time and duration of the interlock trigger to achieve timing tracking of the interlock trigger state.

8. A method for monitoring multiple states of DCS interlocking at the second level, characterized in that, The method includes: Real-time data of various interlocking signals in the DCS system are collected and stored using industrial communication protocols; Based on the association rules in the pre-established interlocking ledger, the collected real-time data is associated with the interlocking logic online in real time to obtain the associated data; The associated data is transmitted and stored in a relational database in real time through a subscription service; Real-time processing of the associated data includes: comparing the real-time signal values ​​of each instrument at the interlock condition end with the interlock activation standard value to determine the activation status of the condition end; comparing the bypass status of each valve or device at the interlock execution end with the standard status to determine the activation status of the execution end; collecting interlock position signals to determine whether the interlock has been triggered; and jointly screening for abnormal interlocking triggered by the bypass at the execution end after the interlock has been triggered. The above judgment results are displayed in real time on the monitoring page at a refresh rate of seconds, realizing full-scale second-level monitoring of the DCS interlock activation status, deactivation status, and trigger status.

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