A method for electronic inspection and over-limit early warning of key parameters of diesel hydrogenation device based on DCS system

Abstract

The application discloses a diesel hydrogenation device key parameter electronic inspection and overrun early warning method based on a DCS system, and contains a parameter acquisition and processing module, a parameter display and early warning module with a touch screen, an electronic clock-in and confirmation module, and a data storage and traceability module. The parameter acquisition module acquires key process parameters in real time and processes the parameters in a standardized manner. The display module displays the parameters in a touch screen according to process flow units, and automatically changes color and flashes to give an alarm when the parameters overrun. An operator completes the inspection through a touch screen confirmation control, and the system automatically generates a record containing time, personnel and parameter values and stores the record in a DCS history database, and supports multi-dimensional query and traceability. The application realizes electronic, standardized and traceable inspection, and can be adapted to various DCS-controlled oil refining and chemical continuous production devices.

Description

Technical Field

[0001] This invention relates to the field of petrochemical production process control technology, specifically to a method for electronic inspection and over-limit early warning of key parameters of a diesel hydrotreating unit based on a DCS system. Background Technology

[0002] Diesel hydrocracking units are core continuous production units in the oil refining industry, and their operational safety and stability highly depend on real-time monitoring and regular inspections of key process parameters. Currently, the industry commonly uses a manual paper-based parameter recording method every two hours, which suffers from significant problems such as low efficiency, high error rates, lack of real-time early warnings, difficulty in long-term record storage and retrieval, difficulty in tracing responsibility, DCS interfaces not optimized for inspection scenarios, and incompatibility with paperless office requirements. Traditional inspection methods suffer from scattered parameters, lack of dynamic early warning prompts, and lack of electronic confirmation mechanisms, still relying on manual verification and paper-based records, which cannot meet the control requirements of smart factories and inherently safe production. Therefore, there is an urgent need for an efficient, reliable, and traceable electronic inspection and early warning solution. Summary of the Invention

[0003] The purpose of this invention is to provide a method for electronic inspection and over-limit early warning of key parameters of a diesel hydrogenation unit based on a DCS system. By connecting an electronic inspection and over-limit early warning system to the DCS system, the method enables centralized display of key parameters, automatic visual early warning of over-limit, electronic confirmation of inspection, real-time storage of records, and accurate traceability. This replaces the traditional paper-based recording method, improves inspection efficiency and accuracy, enhances the response capability to abnormal parameters, and ensures the safe, stable, and long-term operation of the diesel hydrogenation unit.

[0004] To achieve the above objectives, the present invention is implemented through the following technical solution: This invention provides a method for electronic inspection and over-limit early warning of key parameters of a diesel hydrogenation device based on a DCS system. The method includes an electronic inspection and over-limit early warning system that is communicatively connected to the DCS system. The electronic inspection and over-limit early warning system includes a parameter acquisition and processing module, an electronic check-in and confirmation module, a data storage and traceability module, and a parameter display and early warning module with a touch screen that are communicatively connected. The parameter acquisition and processing module is connected to the real-time data interface of the DCS system, acquiring and processing key process parameters of the diesel hydrotreating unit in real time. The module then transmits the processed data to the parameter display and early warning module. This module displays key process parameters categorized by process unit and provides visual warnings for exceeding preset thresholds. The module also transmits parameter status data to the electronic check-in and confirmation module. This module receives operator inspection confirmation instructions, generates inspection records containing time, personnel, and parameter values, and transmits these records to the data storage and traceability module. Finally, the module stores the inspection records in the DCS historical database and provides data query and traceability functions.

[0005] Preferably, the key process parameters include: reaction feed flow rate FIC11001, reaction heater F0101 outlet temperature TIC11053, purification reactor R0101 inlet pressure PIC11015, high-pressure separator D0101 liquid level LIC11020, high-pressure separator D0101 pressure PI11021, circulating hydrogen compressor C0101 inlet pressure PIC11005, and circulating hydrogen compressor C0101 outlet pressure PIC11006; the parameter acquisition and processing module performs real-time analysis, calibration, and formatting of the above parameters to form standardized data.

[0006] Preferably, the parameter display and early warning module divides the key process parameters according to the diesel hydrotreating unit process flow into a sequentially connected reaction feed unit, reaction heater F0101 unit, refining reactor R0101 unit, high-pressure separator D0101 unit, and circulating hydrogen compressor C0101 unit; it configures an editable normal control range threshold for each key process parameter. When the parameter is normal, the touch screen displays the parameter with a first color background. When the real-time value exceeds the threshold, it automatically switches to the second color background of the touch screen and generates a flashing warning signal at the early warning output terminal. At the same time, it records the time when the parameter exceeds the limit in the background.

[0007] Preferably, the electronic check-in and confirmation module is configured with an inspection confirmation trigger control on the touch screen display interface of the parameter display and early warning module; after the operator completes the parameter status confirmation according to the preset cycle, the operator triggers the inspection confirmation trigger control, and the electronic check-in and confirmation module automatically executes: recording the current timestamp, obtaining the current operator's identity identifier, generating a unique and valid confirmation mark within a single inspection cycle, and generating an inspection record containing the timestamp, operator's identity identifier, and the current parameter real-time value.

[0008] Preferably, the inspection records stored in the data storage and traceability module include check-in time, operator identification, device main item number, instrument tag number, and real-time parameter values; the data storage and traceability module supports combined queries by at least one dimension among time interval, device main item number, instrument tag number, and operator identification, so as to realize traceable management of inspection data.

[0009] Preferably, the preset inspection cycle is once every 2 hours. The operator completes the parameter viewing and confirmation operation through the electronic inspection and over-limit early warning system, eliminating paper copying throughout the process and realizing the electronic, standardized and traceable inspection process.

[0010] Preferably, when a key process parameter exceeds the control range threshold, a dual warning is triggered simultaneously: the background color of the parameter display area changes and the warning output terminal flashes, thus shortening the response time for parameter exceeding the limit to less than 1 minute.

[0011] Preferably, the unique valid confirmation mark within a single inspection cycle remains valid within the current inspection cycle, and repeated triggering of the inspection confirmation trigger control within the same cycle does not generate new inspection records.

[0012] Preferably, the electronic inspection and over-limit early warning system can be adapted to continuous production in oil refining, chemical and coal chemical industries by replacing the set of key process parameters and adjusting the control range threshold.

[0013] Beneficial effects: It can eliminate paper inspection records, realize paperless office, and reduce paper and management costs; the parameter over-limit is detected by a dual visual warning of background color change and flashing warning, shortening the response time to less than 1 minute and significantly improving the efficiency of abnormal handling; the inspection process is fully electronic and standardized, and all confirmed actions can be accurately traced to personnel, time and parameter status, with clear responsibilities; the touch screen is used for centralized display, which is intuitive and easy to operate, reducing the labor intensity of operators and improving the accuracy and efficiency of inspections; by replacing the set of key process parameters and adjusting the control range threshold, it can be adapted to various continuous production units in oil refining, chemical and coal chemical industries such as catalytic cracking, hydrorefining, reforming and ethylene cracking, with strong versatility and broad application prospects. Attached Figure Description

[0014] Figure 1 This is a block diagram illustrating the principle of the present invention. Detailed Implementation

[0015] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0016] The existing DCS system adopts a layered distributed architecture, consisting of four layers interconnected via redundant industrial Ethernet: the information management layer interfaces with systems such as MES and ERP to realize production data statistics, scheduling, and management decisions. The monitoring and operation layer comprises operator stations, engineer stations, and servers for centralized monitoring, operation, configuration, and data storage. The process control layer, centered on redundant controllers and I / O modules, completes field signal acquisition, PID regulation, and interlocking logic control. The field equipment layer includes various transmitters, control valves, actuators, etc., directly interfaced with the production process. The system as a whole follows the principle of distributed control and centralized management, with redundant configurations for the network, controllers, and power supply to ensure continuous and stable operation. The existing DCS system is a mature, existing technology and will not be described in detail in this application.

[0017] Technical solution / content: This invention is based on an existing DCS system. The core of the solution is an electronic inspection and over-limit early warning system that is connected to the DCS system. The system includes a parameter acquisition and processing module, a parameter display and early warning module with a touch screen, an electronic check-in and confirmation module, and a data storage and traceability module that are connected in sequence. All functions are developed and implemented based on the DCS system, without the need for additional hardware investment, and can run directly on the DCS operator station.

[0018] The parameter acquisition and processing module is connected to the real-time data interface of the DCS system. Through OPC, Modbus, or a dedicated DCS real-time data interface, it acquires key process parameters of the diesel hydrotreating unit at fixed intervals. The module then filters, denoises, calibrates ranges, standardizes units, and formats the acquired raw data, eliminating abnormal fluctuations to form stable, standardized parameter data that can be directly used for display and analysis. After acquisition, the parameter acquisition and processing module transmits the standardized data to the parameter display and early warning module in real time, providing a unified data foundation for parameter display, over-limit judgment, early warning triggering, and inspection record generation.

[0019] The parameter display and early warning module with a touchscreen is connected to the parameter acquisition and processing module. It receives and parses the processed standard parameter data. Following the diesel hydrotreating unit process flow, it categorizes key process parameters into sequentially connected reaction feed unit, reaction heater F0101 unit, refining reactor R0101 unit, high-pressure separator D0101 unit, and circulating hydrogen compressor C0101 unit. These parameters are displayed centrally on the touchscreen in the form of tables, cards, or grouped panels. Each parameter simultaneously displays its tag number, name, real-time value, engineering unit, and status indicator. Simultaneously, this module configures editable and modifiable normal control range thresholds for each key process parameter. When the real-time value of a parameter is within the threshold range, the corresponding parameter area on the touchscreen displays with a first-color background. When the real-time value exceeds the control range threshold, the corresponding area automatically switches to a second-color background, and a continuously flashing warning signal is generated at the early warning output end. Simultaneously, the system background records the accurate time, tag number, and exceeding value of the parameter exceeding the limit, achieving visualized and real-time over-limit early warning.

[0020] The electronic check-in and confirmation module is connected to the parameter display and early warning module. A patrol confirmation trigger control is configured in a preset area of ​​the touchscreen display interface. After the operator completes parameter browsing, status confirmation, and anomaly verification according to the preset patrol cycle, they can trigger the patrol confirmation trigger control via touch or mouse operation. Upon triggering, the electronic check-in and confirmation module automatically performs the following operations: (1) Record the current system timestamp, accurate to the second; (2) Obtain the identity identifier of the current DCS login operator; (3) Generate a unique and valid confirmation mark within a single inspection cycle to prevent duplicate confirmation; (4) Read the real-time values ​​of each key process parameter, generate a complete inspection record including timestamp, operator identification, and real-time parameter values, and transmit the inspection record to the data storage and traceability module in real time.

[0021] The data storage and traceability module is connected to the electronic check-in and confirmation module. It receives and persistently stores inspection records in the DCS historical database in real time. Each record includes: check-in time, operator identification, main unit number, instrument tag number, real-time parameter value, and record generation time. This module provides multi-dimensional combined query functions, supporting searches by one or more conditions such as time interval, main unit number, instrument tag number, and operator identification. It can quickly retrieve historical inspection data, parameter trends, and anomaly records, achieving full traceability of inspection behavior, parameter status, and abnormal events, providing data support for accident analysis, operation verification, and safety management.

[0022] The workflow of this invention is as follows: The DCS system acquires key process parameters in real time; the parameter acquisition and processing module performs data parsing, filtering, calibration and formatting; the parameter display and early warning module with a touch screen displays parameters centrally according to process flow units and provides color-changing and flashing warnings based on thresholds; the operator triggers the inspection confirmation control on the touch screen according to a preset cycle; the electronic check-in and confirmation module generates inspection records containing time, personnel and parameter values; the data storage and traceability module stores the records in the DCS historical database and provides query, statistics and traceability functions.

[0023] System setup and communication configuration: In the existing DCS operator station system, an electronic inspection and over-limit early warning system can be built through software configuration and script development; complete the sequential communication connection of the parameter acquisition and processing module, the parameter display and early warning module with touch screen, the electronic check-in and confirmation module, and the data storage and traceability module to ensure real-time data exchange and real-time command response between the modules.

[0024] The key process parameters and thresholds for the diesel hydrotreating unit are configured by inputting these parameters into the system, including: reaction feed flow rate FIC11001, reaction heater F0101 outlet temperature TIC11053, refining reactor R0101 inlet pressure PIC11015, high-pressure separator D0101 level LIC11020, high-pressure separator D0101 pressure PI11021, circulating hydrogen compressor C0101 inlet pressure PIC11005, and circulating hydrogen compressor C0101 outlet pressure PIC11006. Corresponding engineering units and normal control range thresholds are configured for each parameter, and touchscreen display rules are set: normal conditions are displayed with a first-color (gray) background, and out-of-limit conditions are displayed with a second-color (yellow) background. Simultaneously, flashing warning signals and out-of-limit time recording functions are enabled.

[0025] The display interface and unit divisions are arranged on the touch screen according to the process flow. The above parameters are divided into sequentially connected reaction feed unit, reaction heating furnace F0101 unit, refining reactor R0101 unit, high pressure separator D0101 unit, and circulating hydrogen compressor C0101 unit, and are displayed in groups to ensure that the parameter layout is clear and facilitates rapid inspection.

[0026] The inspection cycle and confirmation control configuration sets the system's preset inspection cycle to once every 2 hours; the inspection confirmation trigger control is configured on the touch screen display interface, and a unique valid confirmation mark mechanism for each inspection cycle is enabled to ensure that repeated triggering within the same cycle does not generate redundant records.

[0027] The data storage and query function configuration establishes a connection between the electronic inspection and over-limit early warning system and the DCS historical database, and configures the record storage strategy: inspection records are uploaded in real time, stored for a long time, and backed up at regular intervals; and enables multi-dimensional combined query function, supporting retrieval and export by time, device, tag number, and operator.

[0028] On-site operators can access a dedicated inspection interface on the DCS operator station touchscreen to view the real-time status and color indicators of each unit's parameters. If the parameters are normal, the inspection confirmation control is triggered directly to complete the confirmation; if the parameters display an out-of-limit warning, the abnormality is handled according to the procedure first, and then the confirmation control is triggered. The system automatically records and stores time, personnel, and parameter values, realizing fully electronic and traceable inspections.

[0029] When applied to other units, the extended adaptation implementation can be quickly adapted to continuous production units in oil refining, chemical, and coal chemical industries, such as catalytic cracking, hydrorefining, reforming, and ethylene cracking, by replacing the set of key process parameters and re-editing the control range thresholds, without changing the system architecture and core logic.

[0030] Scope of application: This invention is mainly applicable to electronic inspection and over-limit early warning of key parameters in diesel hydrocracking units; by replacing the set of key process parameters and adjusting the control range threshold, it can be extended to continuous production units of oil refining, chemical and coal chemical industries that adopt DCS control, such as catalytic cracking, hydrorefining, reforming and ethylene cracking.

[0031] Finally, it should be noted that the present invention is not limited to the above embodiments, and many variations are possible. All variations that can be directly derived or conceived by those skilled in the art from the disclosure of the present invention should be considered within the scope of protection of the present invention.

Claims

1. A method for electronic inspection and over-limit early warning of key parameters of a diesel hydrotreating unit based on a DCS system, characterized in that, The system includes an electronic inspection and over-limit early warning system that communicates with a DCS system. The electronic inspection and over-limit early warning system includes a parameter acquisition and processing module, an electronic check-in and confirmation module, a data storage and traceability module, and a parameter display and early warning module with a touch screen. The parameter acquisition and processing module is connected to the real-time data interface of the DCS system to acquire key process parameters of the diesel hydrotreating unit in real time and perform data processing; the parameter acquisition and processing module transmits the processed data to the parameter display and early warning module; The parameter display and early warning module centrally displays key process parameters according to process units and provides visual early warnings for exceeding limits based on preset thresholds. The parameter display and early warning module transmits parameter status data to the electronic check-in and confirmation module; the electronic check-in and confirmation module receives the operator's inspection confirmation instruction, generates an inspection record containing time information, personnel information, and parameter value information, and transmits it to the data storage and traceability module; the data storage and traceability module stores the inspection record in the DCS historical database and provides data query and traceability functions.

2. The method for electronic inspection and over-limit early warning of key parameters of a diesel hydrotreating unit based on a DCS system according to claim 1, characterized in that, The key process parameters include: reaction feed flow rate FIC11001, reaction heater F0101 outlet temperature TIC11053, purification reactor R0101 inlet pressure PIC11015, high-pressure separator D0101 liquid level LIC11020, high-pressure separator D0101 pressure PI11021, circulating hydrogen compressor C0101 inlet pressure PIC11005, and circulating hydrogen compressor C0101 outlet pressure PIC11006. The parameter acquisition and processing module performs real-time analysis, calibration, and formatting of the above parameters to form standardized data.

3. The method for electronic inspection and over-limit early warning of key parameters of a diesel hydrotreating unit based on a DCS system according to claim 2, characterized in that, The parameter display and early warning module divides the key process parameters according to the diesel hydrotreating unit process flow into sequentially connected reaction feed unit, reaction heater F0101 unit, refining reactor R0101 unit, high pressure separator D0101 unit, and circulating hydrogen compressor C0101 unit. Each key process parameter is configured with an editable normal control range threshold. When the parameter is normal, the touchscreen displays a first-color background. When the real-time value exceeds the threshold, it automatically switches to a second-color background on the touchscreen and generates a flashing warning signal at the early warning output terminal. Simultaneously, the time of parameter exceeding the limit is recorded in the background.

4. The method for electronic inspection and over-limit early warning of key parameters of a diesel hydrotreating unit based on a DCS system according to claim 1, characterized in that, The electronic check-in and confirmation module is configured with an inspection confirmation trigger control on the touch screen display interface of the parameter display and early warning module. After the operator completes the parameter status confirmation according to the preset cycle, the operator triggers the inspection confirmation trigger control, and the electronic check-in and confirmation module automatically executes: record the current timestamp, obtain the current operator identity identifier, generate a unique and valid confirmation mark within a single inspection cycle, and generate an inspection record containing the timestamp, operator identity identifier, and real-time value of the current parameter.

5. The method for electronic inspection and over-limit early warning of key parameters of a diesel hydrotreating unit based on a DCS system according to claim 1, characterized in that, The inspection records stored in the data storage and traceability module include check-in time, operator identification, device main item number, instrument tag number, and real-time parameter values. The data storage and traceability module supports combined queries based on at least one of the following dimensions: time interval, device main item number, instrument tag number, and operator identification, to achieve traceable management of inspection data.

6. The method for electronic inspection and over-limit early warning of key parameters of a diesel hydrotreating unit based on a DCS system according to claim 1, characterized in that, The preset inspection cycle is once every 2 hours. Operators can view and confirm parameters through the electronic inspection and over-limit early warning system, eliminating paper records throughout the process and realizing the electronic, standardized and traceable inspection process.

7. The method for electronic inspection and over-limit early warning of key parameters of a diesel hydrotreating unit based on a DCS system according to claim 3, characterized in that, When a key process parameter exceeds the control range threshold, a dual warning is triggered simultaneously: the background color of the parameter display area changes and the warning output flashes, reducing the response time for parameter over-limit to less than 1 minute.

8. The method for electronic inspection and over-limit early warning of key parameters of a diesel hydrotreating unit based on a DCS system according to claim 4, characterized in that, The unique valid confirmation mark within a single inspection cycle remains valid within the current inspection cycle, and repeated triggering of the inspection confirmation trigger control within the same cycle does not generate new inspection records.

9. The method for electronic inspection and over-limit early warning of key parameters of a diesel hydrotreating unit based on a DCS system according to claim 1, characterized in that, The electronic inspection and over-limit early warning system can be adapted to continuous production in oil refining, chemical and coal chemical industries by replacing the set of key process parameters and adjusting the control range threshold.

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