Remote control system for production of propionyl chloride and control method thereof

Abstract

The application discloses a remote control system for propionyl chloride production and a control method thereof, and the method comprises the following steps: S1, establishing a communication connection between a remote control center and each reaction kettle, and collecting temperature, air pressure and process running state data in real time; S2, comparing the collected data with a threshold value, and judging whether there is an abnormal working condition; S3, automatically triggering an alarm device and sending an evacuation notice to on-site personnel when an abnormality is detected; S4, automatically sending a cut-off instruction to the corresponding production process, and stopping the operation of the control device; and S5, sending a repair task instruction to maintenance personnel. The system comprises a remote control center, an intelligent monitoring air pressure gauge, an actuating mechanism, an alarm device and a communication notification module, can realize real-time monitoring of key process parameters, automatic early warning of abnormalities and remote centralized control of production processes, significantly improves the safety supervision strength and emergency response efficiency of the propionyl chloride production process, effectively reduces the probability of safety accidents and reduces product loss.

Description

Technical Field

[0001] This invention relates to the field of industrial process control, and in particular to a remote control system and control method for the production of propionyl chloride. Background Technology

[0002] With the rapid development of the chemical industry, propionyl chloride, as an important organic synthesis intermediate, is widely used in the synthesis of pharmaceuticals, pesticides, and fine chemicals. The production process of propionyl chloride involves multiple chemical reaction steps, usually carried out under specific pressure and temperature conditions. The safety and controllability of its production equipment are directly related to product quality and safe production for enterprises.

[0003] The remote monitoring and control system for propionyl chloride production is a crucial element in ensuring safe and stable production. In actual production, it is necessary to monitor key process parameters such as temperature and pressure in the reactor in real time, and to remotely control the start and stop of each production step to achieve centralized management of the entire production process.

[0004] The existing propionyl chloride production control system suffers from the following main drawbacks: First, monitoring methods are relatively outdated, relying primarily on manual inspections and periodic checks. This lack of continuous real-time monitoring of pressure and temperature changes within the reactor results in poor data timeliness and makes it difficult to detect anomalies promptly. Second, the safety early warning mechanism is inadequate. When abnormal pressure occurs within the reactor, there is a lack of automatic alarm and automatic shut-off device linkage capabilities, leading to a time lag in emergency response. Third, remote control capabilities are insufficient. The switching control of each production process still requires manual operation on-site, making centralized remote control from the control room impossible. Finally, personnel evacuation and emergency response mechanisms are lacking. In the event of a safety hazard, the system cannot automatically notify on-site personnel to evacuate quickly, creating blind spots in safety management. These problems collectively lead to a high risk of safety accidents during propionyl chloride production. Furthermore, any abnormal situation will result in product loss and production interruption, severely impacting production efficiency and economic benefits. Summary of the Invention

[0005] The purpose of this invention is to provide a remote control system and control method for the production of propionyl chloride, which solves the problems mentioned in the background art.

[0006] This invention is implemented as follows: a remote control system and control method for propionyl chloride production, comprising the following steps: S1, establishing a communication connection between the remote control center and each reactor at the production site, and collecting real-time data on the temperature, pressure, and operating status of each reactor's production process; S2, performing feature extraction and threshold comparison on the collected pressure and temperature data to determine if any abnormal operating conditions exist; S3, when an abnormal operating condition is detected, the remote control center automatically triggers an alarm device to issue an alarm and sends an evacuation notice to on-site personnel; S4, the remote control center automatically sends a cut-off command to the corresponding production process, controlling the equipment in that process to stop operating; S5, the remote control center sends a maintenance task instruction to maintenance personnel, arranging for professional maintenance personnel to go to the site for verification and maintenance.

[0007] Preferably, establishing a communication connection in step S1 specifically includes: installing an intelligent monitoring pressure gauge on each reactor, the intelligent monitoring pressure gauge having a built-in sensor module for real-time acquisition of pressure parameters inside the reactor; the intelligent monitoring pressure gauge establishing a two-way data channel with the monitoring system of the remote control center through a data cable or wireless communication module; the remote control center periodically sending data request commands to each intelligent monitoring pressure gauge and receiving real-time pressure values ​​returned by each pressure gauge.

[0008] Preferably, the threshold comparison of air pressure data in step S2 specifically includes: setting a preset pressure safety threshold range; when the pressure value collected by the intelligent monitoring air pressure gauge exceeds the upper limit of the preset safety threshold range, it is determined to be an abnormally high air pressure; when the pressure value is lower than the lower limit of the preset safety threshold range, it is determined to be an abnormally low air pressure; the threshold comparison module packages the judgment result and the specific parameter value to generate an abnormal alarm message and transmits it to the abnormal processing module of the remote control center.

[0009] Preferably, the automatic alarm triggering device in step S3 specifically includes: after receiving the abnormal alarm information, the abnormal handling module of the remote control center sends a trigger command to the alarm control module; the alarm control module drives the audible and visual alarm installed in the control center to emit sound and light signals to attract the attention of the control room staff; at the same time, the abnormal handling module activates the communication notification module to send an evacuation notification message to the preset personnel communication terminal.

[0010] Preferably, sending an evacuation notification message to a pre-set personnel communication terminal specifically includes: the communication notification module sending a voice broadcast command to a broadcast terminal in the production workshop via a wired or wireless communication network, and the broadcast terminal playing a pre-recorded evacuation prompt voice; the communication notification module simultaneously sending text messages or instant messages to the mobile communication devices worn by on-site personnel, the notification content including the number of the abnormal reaction vessel, the type of abnormality, and evacuation direction guidance.

[0011] Preferably, the automatic sending of the cut-off command in step S4 specifically includes: the remote control center determining the production process to be cut off based on the abnormal reactor number contained in the abnormal alarm information; the control command generation module generating the corresponding cut-off command, which includes the identifier of the target device, the command type, and the execution timestamp; the remote control center sending the cut-off command to the electric actuator or pneumatic actuator of the corresponding process through the communication network; after receiving the cut-off command, the actuator drives the valve or switch to perform the action, thereby realizing the physical cut-off of the device in that process.

[0012] Preferably, the intelligent monitoring pressure gauge installed on the reactor has a linkage mechanism with the remote control center system. The linkage mechanism specifically includes: the intelligent monitoring pressure gauge integrates a comparator module, which continuously compares the real-time collected pressure value with a preset threshold; when the pressure value exceeds the normal range, the comparator module directly outputs an abnormal signal to the communication module built into the pressure gauge; the communication module encapsulates the abnormal signal and the reactor number into an alarm data packet, and actively reports it to the remote control center through the communication network; after receiving the alarm data packet, the remote control center completes the linkage operation of alarm triggering and device shutdown within a preset time threshold.

[0013] Preferably, the remote control method further includes a temperature monitoring sub-step: S11, installing an intelligent monitoring thermometer on the reactor, the intelligent monitoring thermometer working in conjunction with an intelligent monitoring pressure gauge; the intelligent monitoring thermometer collects the temperature parameters inside the reactor in real time and transmits the temperature data to the remote control center; the remote control center performs threshold comparison and anomaly handling procedures on the temperature data similar to those on the pressure data; when temperature anomalies and pressure anomalies occur simultaneously, the remote control center prioritizes handling the pressure anomaly, because pressure runaway is more dangerous.

[0014] A remote control system for propionyl chloride production, used to implement the above-mentioned method, includes: a remote control center, several intelligent monitoring pressure gauges, actuators, an alarm device, and a communication notification module; the remote control center is configured to receive pressure data uploaded by each intelligent monitoring pressure gauge, perform threshold comparison analysis on the pressure data, generate abnormal alarm information, and send control commands to the actuators and alarm devices; the intelligent monitoring pressure gauges are installed on each reactor, and are connected to the remote control center via a communication network for real-time acquisition and uploading of pressure data inside the reactor; the actuators are installed on the devices of each production process, and are connected to the remote control center for receiving and executing cut-off commands issued by the remote control center; the alarm devices are installed inside or near the remote control center for issuing audible and visual alarms upon receiving abnormal alarm information; the communication notification module is connected to the remote control center for sending evacuation notices to on-site personnel and sending maintenance task instructions to maintenance personnel when an abnormality occurs.

[0015] Compared with existing technologies, the beneficial effects of this invention are as follows: By installing an intelligent monitoring pressure gauge on the reactor and establishing a linkage mechanism with a remote control center, this invention achieves real-time monitoring of key process parameters and automatic early warning of abnormal operating conditions during the production of propionyl chloride. First, the intelligent monitoring pressure gauge can continuously collect pressure data inside the reactor in real time, overcoming the shortcomings of poor timeliness of manual inspection data, enabling the control center to grasp the production status immediately. Second, the linkage mechanism realizes an automated process of abnormal detection, automatic alarm, and equipment shutdown, significantly shortening the emergency response time and overcoming the time lag defect in emergency response in existing technologies. Third, the remote control center can remotely centrally control the start and stop of each production process, overcoming the deficiency of existing technologies where process switching control still requires on-site manual operation. Finally, the communication notification module can automatically send evacuation notices to on-site personnel and maintenance task instructions to maintenance personnel when an abnormality occurs, overcoming the problem of the lack of personnel evacuation and emergency response mechanisms in existing technologies. In summary, this invention significantly improves the safety supervision and emergency response efficiency of the propionyl chloride production process, effectively reduces the probability of sudden safety accidents, and reduces the loss of propionyl chloride products due to untimely handling of abnormalities.

[0016] Furthermore, through the direct linkage mechanism between the intelligent monitoring pressure gauge and the remote control center, the system will issue an early warning and automatically shut down the device when the pressure inside the reactor becomes abnormal, achieving full automation from anomaly detection to emergency response. The core of this linkage mechanism lies in the comparator module built into the intelligent monitoring pressure gauge, which can independently determine threshold values ​​and proactively report anomalies via the communication network. This allows for coordinated warning and shutdown actions without manual intervention, significantly improving the timeliness and reliability of safety supervision.

[0017] Furthermore, the remote control center establishes two-way communication connections with each production process, enabling centralized monitoring and unified management of multiple reactors. Under centralized management, operators at the control center can view the real-time status parameters of all reactors on a single interface, achieving unified aggregation and comprehensive analysis of production information. This improves the efficiency and accuracy of production management and provides data support for scientific decision-making.

[0018] Furthermore, the communication notification module integrates broadcast terminal control and mobile message push functions, enabling simultaneous triggering of both voice broadcasts and text messages in the event of an anomaly, ensuring that all on-site personnel receive evacuation information promptly. Voice broadcasts offer the advantage of immediacy, immediately alerting on-site personnel to safety; text messages provide traceability, facilitating subsequent accident analysis and liability determination.

[0019] Furthermore, the actuator employs either an electric or pneumatic actuator to remotely shut off the production unit. Upon receiving a shut-off command, it can complete the valve or switch action within a preset time, ensuring the reliability and timeliness of the shut-off operation. Electric actuators offer advantages such as fast response speed and high control precision, while pneumatic actuators offer advantages such as good explosion-proof performance and high reliability. The appropriate actuator type can be selected based on the actual production environment.

[0020] Furthermore, the remote control system reserves a data interface with the enterprise management information system, enabling the uploading of production process data and safety event records to the enterprise data center for storage and analysis, providing data support for production optimization and safety improvement. Through long-term accumulated operational data, the operating patterns of the reactor and the probability distribution of anomalies can be analyzed, further optimizing early warning thresholds and emergency response plans. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the remote control method for the production of propionyl chloride proposed in this invention; Figure 2 This is a block diagram of the overall architecture of the remote control system for propionyl chloride production proposed in this invention. Detailed Implementation

[0022] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0023] Example 1 This embodiment focuses on the core scenario of pressure monitoring and remote control of the reactor in the propionyl chloride production process, detailing the specific implementation process of the remote control system and its control method proposed in this invention. This embodiment uses a typical large-scale propionyl chloride production workshop as an example. The workshop is equipped with eight reactors, each used for different stages of the propionyl chloride synthesis reaction. Each reactor has a volume of 5,000 liters, a normal operating pressure range of 0.1 to 0.5 MPa, and a normal operating temperature range of 80 to 120 degrees Celsius. The remote control center is located in a separate, secure control room, 150 meters away from the production workshop, and the two communicate via industrial Ethernet.

[0024] In step S1, the remote control center establishes communication connections with each reactor in the production site. The specific implementation process is as follows: A smart pressure monitoring gauge is installed at the top end of each reactor. This smart pressure monitoring gauge consists of a housing, a sensor module, a comparator module, a communication module, and a power supply module. The housing is made of stainless steel, providing excellent sealing and corrosion resistance, and is suitable for the harsh environment of the propionyl chloride production workshop. The sensor module uses a piezoresistive pressure sensor, whose pressure-sensing element consists of a stainless steel diaphragm and a semiconductor strain gauge. When the internal pressure of the reactor acts on the stainless steel diaphragm, the diaphragm undergoes a slight deformation, and the resistance value of the semiconductor strain gauge changes accordingly. The sensor module converts the change in resistance value into an electrical signal output through a Wheatstone bridge circuit. The sensor module has a range of zero to one MPa and an accuracy class of 0.25, which meets the accuracy requirements for pressure monitoring in the propionyl chloride production process.

[0025] The communication module of the intelligent pressure gauge adopts a bidirectional communication interface supporting industrial protocols, which is compatible with commonly used industrial Ethernet protocols and wireless communication protocols. In this embodiment, the intelligent pressure gauge connects to the remote control center via wired communication. Specifically, Category 6 shielded twisted-pair cable is used to connect the communication interface of the intelligent pressure gauge to an industrial switch in the workshop. The industrial switch establishes a bidirectional data channel with the monitoring system of the remote control center through a fiber optic link. Wired communication has the advantages of stable transmission and strong anti-interference capability, ensuring the reliability of real-time pressure data transmission. In some application scenarios, when the installation location of the reaction vessel is far away or wiring is difficult, wireless communication can also be used. The wireless communication module supports industrial-grade wireless transmission protocols, with a communication distance of over 500 meters, which can meet the application needs of most production workshops.

[0026] The monitoring system software of the remote control center adopts a modular architecture design, mainly including a data acquisition module, a data storage module, a threshold comparison module, an anomaly handling module, an alarm control module, a communication notification module, and a control command generation module. These modules exchange data through an internal message queue, achieving loosely coupled inter-module communication. The data acquisition module is responsible for periodically sending data request commands to each intelligent monitoring barometer. The sending cycle of data request commands can be adjusted according to actual needs, with a default setting of once per second, meaning a data request is sent to each intelligent monitoring barometer once per second. After receiving the real-time pressure values ​​returned by each barometer, the data acquisition module stores the data in the real-time database of the data storage module and simultaneously triggers the threshold comparison module to perform anomaly detection. The real-time database adopts a circular buffer structure, capable of storing pressure data from all reactors within the last 24 hours, facilitating operators to query historical trends and perform data analysis.

[0027] In step S2, feature extraction and threshold comparison are performed on the collected pressure data to determine whether there are any abnormal operating conditions. The specific implementation process is as follows: The threshold comparison module reads the latest pressure data from the real-time database and compares it with the preset pressure safety threshold range. The preset pressure safety threshold range is determined according to the design parameters and process requirements of the reactor. In this embodiment, the pressure safety threshold range is set to a lower limit of 0.08 MPa and an upper limit of 0.6 MPa. When the pressure value collected by the intelligent monitoring pressure gauge exceeds 0.6 MPa, it is determined to be an abnormally high pressure; when the pressure value is lower than 0.08 MPa, it is determined to be an abnormally low pressure. An abnormally high pressure usually indicates that an abnormal reaction acceleration has occurred inside the reactor or that the external gas supply pressure is abnormal. An abnormally low pressure usually indicates that the reactor has leaked or that the stirring system has malfunctioned.

[0028] When performing threshold comparison, the threshold comparison module not only determines whether the current pressure value exceeds the threshold range, but also calculates and analyzes the pressure change rate. The pressure change rate is obtained by dividing the difference between the current pressure value and the pressure value at the previous moment by the sampling period. When the pressure change rate exceeds the preset safe rate threshold, an abnormal alarm will be triggered even if the pressure value has not yet exceeded the absolute threshold range. The preset safe rate threshold is 0.03 MPa per second. This value is set by comprehensively considering the pressure fluctuation range that may occur during normal operation of the reactor and the pressure change characteristics under abnormal conditions.

[0029] The threshold comparison module packages the judgment result and specific parameter values ​​to generate anomaly alarm information. This alarm information includes the following: the identification number of the abnormal reactor, the anomaly type, whether the pressure is too high or too low, or the rate of pressure change is abnormal, the specific pressure measurement value, the rate of pressure change, the anomaly judgment timestamp, and the anomaly level. The anomaly level is graded according to the degree of pressure deviation from the threshold. A deviation exceeding 150% of the threshold is a Level 1 alarm (the highest level); a deviation between 120% and 150% is a Level 2 alarm; and a deviation between 100% and 120% is a Level 3 alarm. Different alarm levels correspond to different handling procedures and response levels. The anomaly alarm information generated by the threshold comparison module is transmitted to the anomaly handling module in the remote control center via an internal message queue.

[0030] In step S3, when an abnormal operating condition is detected, the remote control center automatically triggers the alarm device to issue an alarm and sends an evacuation notice to on-site personnel. The specific implementation process is as follows: After receiving the abnormal alarm information, the abnormal handling module of the remote control center selects the corresponding handling procedure according to the abnormality level. For level 1 and level 2 alarms, the abnormal handling module immediately sends a trigger command to the alarm control module and simultaneously activates the communication notification module to send an evacuation notice to on-site personnel. For level 3 alarms, the abnormal handling module first records the alarm information and displays it on the control interface, waiting for operator confirmation before deciding whether to trigger the alarm and evacuation procedures.

[0031] Upon receiving a trigger command, the alarm control module activates the audible and visual alarm installed in the control center, emitting both sound and light signals. The alarm, mounted on the ceiling of the control room, combines a high-decibel buzzer with a high-brightness flashing light. The sound pressure level of the sound signal reaches over 120 decibels, sufficient to attract attention in noisy production environments. The light signal flashes red twice per second, triggered synchronously with the sound signal, ensuring a warning effect even in noisy environments or when personnel are wearing protective headphones. The alarm also integrates a voice broadcast function, playing a pre-recorded voice prompt simultaneously with the alarm, stating that an anomaly has been detected and requesting immediate evacuation to a safe area.

[0032] Upon receiving the trigger command from the anomaly handling module, the communication notification module immediately initiates the evacuation notification process. The communication notification module sends a voice broadcast command via the wired communication network to the broadcast terminals located in the four corners of the workshop, covering the entire production area. Upon receiving the voice broadcast command, the broadcast terminal plays a pre-recorded evacuation prompt message: "Alarm! An abnormal pressure has been detected in the reactor. All personnel are requested to immediately evacuate to the designated safe assembly point outside the workshop according to the predetermined route." The evacuation prompt message plays in a loop, repeating every five seconds until a cancellation command is received.

[0033] Simultaneously, the communication notification module sends text messages or instant messages to the mobile communication devices worn by on-site personnel via the mobile communication network. Each on-site personnel is equipped with an explosion-proof smartphone or smart bracelet, and the communication notification module pre-stores the communication terminal identifiers and contact information of all on-site personnel. When an anomaly occurs, the communication notification module generates an evacuation notification message based on the anomaly alarm information. The message content includes the number of the abnormal reactor, the anomaly type, the anomaly parameter value, and evacuation direction guidance. The evacuation direction guidance is pre-set based on the location of the abnormal reactor and the workshop floor plan, instructing on-site personnel to move away from the abnormal reactor and evacuate to the nearest safety exit. Text messages have the advantage of traceability; the system automatically records the sending time and receipt confirmation status of each message, facilitating subsequent accident analysis and liability determination.

[0034] In step S4, the remote control center automatically sends a cut-off command to the corresponding production process, controlling the equipment in that process to stop operating. The specific implementation process is as follows: Simultaneously with triggering the alarm and evacuation notification, the anomaly handling module sends a cut-off command generation request to the control command generation module. The control command generation module queries the production process corresponding to the anomaly reactor number contained in the anomaly alarm information and the list of equipment requiring cut-off. Each reactor corresponds to an independent feeding system and discharging system. The feeding system includes a raw material storage tank, a transfer pump, and a feed valve; the discharging system includes a discharge valve and a finished product collection tank. The control command generation module generates the corresponding cut-off command, which includes the identifier of the target equipment, the command type (closed or disconnected), and an execution timestamp.

[0035] The remote control center sends shut-off commands to the corresponding electric or pneumatic actuators via a communication network. These actuators are installed at the locations of various valves and switches to drive valve movements and control the flow of the medium. In this embodiment, the feed valve and discharge valve are driven by pneumatic actuators, which use compressed air as a power source and offer advantages such as simple structure, good explosion-proof performance, and high reliability. The compressed air pressure is 0.4 to 0.6 MPa. When the actuator receives a shut-off command, compressed air enters the actuator's shut-off chamber, pushing the piston rod to rotate the valve stem, causing the valve to turn from the open position to the closed position. The time from receiving the shut-off command to the valve fully closing is less than three seconds, meeting the requirement for rapid shut-off.

[0036] For electrical equipment that needs to be disconnected, the control command generation module generates a corresponding power-off command and sends it to the appropriate electric actuator or electrical control cabinet. The electric actuator drives the circuit breaker or contactor to actuate, thereby cutting off the power supply to the electrical equipment. The execution time of the power-off command, from receiving the command to completing the power-off, is within two seconds, ensuring that abnormal equipment can be quickly disconnected from the power supply. For particularly critical equipment, the system employs dual safeguards: sending a cut-off command to drive the actuator, and sending a power-off command to ensure electrical isolation.

[0037] Upon receiving a shut-off command, the actuator drives the valve or switch to physically shut off the process unit. The actuator integrates a position sensor that detects the actual position of the valve or switch and feeds this information back to the remote control center. Upon receiving this feedback, the remote control center displays the corresponding unit status on its monitoring interface, ensuring that operators can confirm the shut-off operation has been completed. If the actuator fails to complete its action within a preset time or its position does not reach the target position, the system generates a secondary alarm, prompting the operator to take manual intervention measures.

[0038] In step S5, the remote control center sends a maintenance task instruction to the maintenance personnel, arranging for professional maintenance personnel to go to the site for verification and maintenance. The specific implementation process is as follows: After triggering the alarm, evacuation notification, and cut-off command, the anomaly handling module automatically generates a maintenance task work order. The maintenance task work order includes the following: the number and location information of the abnormal reactor, the anomaly type and specific parameters, the measures already taken, the fault description, and the maintenance requirements. After the maintenance task work order is generated, the communication notification module determines the currently on-duty professional maintenance personnel based on the preset maintenance personnel schedule information and sends the maintenance task instruction to them through the mobile communication network.

[0039] After receiving a maintenance task instruction, the mobile communication device carried by the maintenance personnel displays the work order details and emits a prompt tone. After the maintenance personnel click to confirm, the system automatically records the confirmation time and the maintenance personnel information. The maintenance personnel then proceed to the site according to the work order information. First, they conduct an on-site inspection of the abnormal reactor, using portable testing instruments to re-measure the actual pressure and temperature of the reactor to confirm whether the abnormality still exists. If the abnormality is confirmed to have been eliminated, the maintenance personnel submit a resumption request to the remote control center via their mobile terminal. After review by the control center operators, a resumption command can be remotely sent to restart the production process. If the cause of the abnormality is unclear or a equipment malfunction exists, the maintenance personnel fill out a detailed fault inspection record and request further maintenance support.

[0040] The remote control method also includes a temperature monitoring sub-step S11, in which an intelligent monitoring thermometer is installed on the reactor. This intelligent monitoring thermometer works in conjunction with an intelligent monitoring pressure gauge. The intelligent monitoring thermometer uses a platinum resistance temperature sensor, with a measurement range of 0 to 200 degrees Celsius and an accuracy class of 0.1 degrees Celsius. The temperature sensor is installed at the side insertion port of the reactor, directly contacting the reaction medium inside, and can accurately reflect the actual temperature inside the reactor. The intelligent monitoring thermometer transmits temperature data to the remote control center through the same communication network as the intelligent monitoring pressure gauge. The remote control center performs threshold comparison and anomaly handling procedures on the temperature data, similar to those for pressure data. The preset temperature safety threshold range is a lower limit of 70 degrees Celsius and an upper limit of 130 degrees Celsius. When the temperature exceeds this range, a temperature anomaly alarm is triggered.

[0041] When both temperature and air pressure anomalies occur simultaneously, the remote control center prioritizes handling the air pressure anomaly because uncontrolled air pressure is more dangerous and could lead to reactor rupture or explosion. The anomaly handling module has built-in priority logic; when both temperature and air pressure anomaly alarms are received simultaneously, the air pressure anomaly is automatically selected as the primary focus, and its alarm and shutdown procedures are executed first. Temperature anomaly alarm information will be displayed on the interface, but the evacuation procedure will not be triggered immediately. Further assessment and handling of the temperature anomaly will only occur after the air pressure anomaly has been resolved.

[0042] Example 2 This embodiment provides a detailed description of the linkage mechanism between the intelligent monitoring barometer and the remote control center. This linkage mechanism enables automated early warning and cut-off functions without manual intervention, further improving the system's response speed and reliability.

[0043] The intelligent pressure monitoring gauge installed on the reactor vessel has a linkage mechanism with the remote control center system. The core of this mechanism lies in the comparator module integrated within the intelligent pressure monitoring gauge. The comparator module uses a dedicated analog integrated circuit chip, characterized by high speed, low power consumption, and high accuracy. The input terminal of the comparator module is connected to the output terminal of the sensor module, and the preset threshold parameter is stored in the comparator module's programmable memory. The comparator module continuously compares the real-time collected pressure value with the preset threshold at a comparison frequency of once per millisecond, i.e., one thousand comparison operations per second.

[0044] When the pressure value exceeds the normal range, the comparator module outputs an abnormal signal to the communication module built into the pressure gauge. The abnormal signal output uses a hardware interrupt method, which has a lower latency compared to software polling, completing the signal output within milliseconds after the pressure anomaly occurs. Upon receiving the abnormal signal, the communication module encapsulates the abnormal signal and the reactor number into an alarm data packet. The alarm data packet uses a compact binary structure, containing two bytes for the reactor number, one byte for the abnormality type, four bytes for the pressure measurement value, eight bytes for the timestamp, and two bytes for the checksum. The entire data packet is seventeen bytes long, enabling transmission in a very short time.

[0045] The communication module actively reports alarm data packets to the remote control center via the communication network. Compared to the remote control center's periodic polling data collection method, the proactive reporting method has a significant timeliness advantage. In periodic polling mode, the maximum delay from the occurrence of an anomaly to its detection is typically one second per polling cycle, while the delay time of the proactive reporting method can be controlled within two hundred milliseconds. After receiving the alarm data packet, the remote control center completes the alarm triggering and device shutdown linkage operation within a preset time threshold. The preset time threshold is set to three seconds, meaning that the total time from receiving the alarm data packet to completing the audible and visual alarm triggering and shutdown command transmission does not exceed three seconds.

[0046] The triggering process of the linkage mechanism is as follows: When the comparator module detects that the pressure value exceeds the upper limit threshold of 0.6 MPa, it immediately outputs a high-level abnormal signal to the communication module. The communication module starts the data encapsulation program, encapsulating the abnormal signal, reactor number, current pressure value, and system timestamp into an alarm data packet. The communication module sends the alarm data packet to the remote control center through the communication network, using an acknowledgment mechanism to ensure reliable arrival of the data packet. After receiving the alarm data packet, the abnormality handling module at the remote control center parses the data packet content and immediately triggers the alarm control module and the communication notification module. Within 500 milliseconds of receiving the trigger command, the alarm control module activates the audible and visual alarm, and the communication notification module simultaneously sends an evacuation notice to on-site personnel. The abnormality handling module sends a cut-off command generation request to the control command generation module, which generates the cut-off command within one second of receiving the request and sends it to the actuator. The actuator completes the valve closing action within three seconds of receiving the cut-off command. The total time from the occurrence of the abnormality to the completion of the device cut-off is controlled within five seconds, significantly shortening the emergency response time compared to manual intervention.

[0047] Example 3 This embodiment provides a detailed description of the system architecture and composition of the remote control system, focusing on the system's redundancy design and reliability assurance measures.

[0048] The remote control system for propionyl chloride production proposed in this invention includes a remote control center, several intelligent monitoring barometers, actuators, alarm devices, and a communication and notification module. The remote control center, as the core of the entire system, is responsible for receiving, processing, and analyzing data from each intelligent monitoring barometer and generating corresponding control commands. The hardware of the remote control center includes a server cluster, display terminals, operator stations, and network switching equipment. The server cluster adopts a dual-machine hot standby architecture, with the primary and backup servers monitoring each other in real time via a heartbeat line. When the primary server fails, the backup server automatically switches over and takes over system operation within seconds, ensuring system continuity and reliability.

[0049] The server cluster's storage system employs a disk array configuration with a capacity of over 10 TB, capable of storing at least one year's worth of production process data. The storage system utilizes RAID 6 technology, allowing for data loss even if two hard drives fail simultaneously. The server operating system is a highly reliable industrial-grade operating system with real-time processing and fault tolerance capabilities. The display terminal uses a 45-inch high-resolution LCD screen, capable of simultaneously displaying the status parameters and alarm information of all reactors. The operator station is equipped with a keyboard, mouse, and touchscreen for convenient system monitoring and control.

[0050] Intelligent pressure gauges are installed on each reaction vessel, with one gauge per vessel. These gauges are connected to the remote control center via a ring network topology. The ring network topology offers the advantage of self-healing; if any link in the ring network fails, data can be transmitted via the reverse path, ensuring uninterrupted communication. In this embodiment, the communication network uses industrial Ethernet switches to form a gigabit ring network, with a total bandwidth in the gigabit range, sufficient to meet the real-time transmission requirements of large amounts of sensor data. The communication network is also equipped with a firewall and intrusion detection system to prevent unauthorized external access and network attacks, ensuring system information security.

[0051] Actuators are installed on the equipment at each production stage, including raw material valve actuators in the feeding system, finished product valve actuators in the discharging system, and circuit breaker actuators for various electrical equipment. The actuators are connected to a remote control center, receiving control commands to remotely control the production equipment. Each actuator is equipped with an independent controller, which receives commands from the remote control center and drives the actuator to complete the corresponding actions. The actuator controller uses a programmable logic controller or a dedicated control chip, possessing both local manual operation and remote automatic control functions. When the remote control function fails, the local manual operation function serves as a backup, ensuring the safe shutdown of the production equipment.

[0052] Alarm systems are installed inside or near the remote control center, including audible and visual alarms, voice broadcasting equipment, and visual alarm displays. The audible and visual alarms are installed in the four corners of the control room and emit high-decibel sound and high-brightness light signals when an anomaly occurs. The voice broadcasting equipment is connected to the public address system and can broadcast evacuation notices and other safety alerts to the production workshop. The visual alarm displays use large-screen LED displays, located in the control room and at the workshop entrance, showing the location and type of the abnormal reactor when an anomaly occurs, facilitating rapid identification of hazardous areas by on-site personnel.

[0053] The communication notification module connects to the remote control center to send evacuation notices to on-site personnel and maintenance task instructions to maintenance personnel in the event of an anomaly. The module integrates multiple communication methods, including wired telephone communication, wireless mobile communication, broadcast system communication, and instant messaging. It interfaces with the company's employee information management system, pre-storing contact information and job responsibilities for all on-site personnel. When an anomaly occurs, the module automatically selects the appropriate communication method and notification recipients based on preset notification rules and personnel configuration, ensuring timely information delivery.

[0054] The system's reliability design is also reflected in its power supply. The servers, network equipment, and alarm devices in the remote control center are all equipped with uninterruptible power supplies (UPS), whose battery capacity can support continuous operation for more than eight hours. The intelligent pressure gauge uses an independent power supply and is equipped with an intrinsically safe power module, which can automatically switch to backup battery power in the event of a main power failure, ensuring uninterrupted pressure monitoring. The actuator's control unit is also equipped with a backup power supply, enabling it to maintain communication and control functions for a certain period of time in the event of a power outage.

[0055] Example 4 This embodiment provides a detailed description of the system's data interface and the application scenario of enterprise information system integration, describing the interaction methods and data utilization methods between the system and the enterprise production management system.

[0056] The remote control system has a reserved data interface with the enterprise management information system, enabling the uploading of production process data and safety event records to the enterprise data center for storage and analysis. The data interface adopts standardized data exchange protocols and formats, supporting data integration with enterprise resource planning systems, production execution systems, and data analysis platforms. The data interface is designed with openness and scalability in mind, facilitating future system upgrades and functional expansion.

[0057] Production process data is uploaded using a combination of scheduled batch uploads and real-time streaming uploads. Scheduled batch uploads are executed hourly, packaging and uploading all pressure, temperature, and system operating status data collected over the past hour to the enterprise data center. Real-time streaming uploads are executed immediately upon detecting anomalies, pushing anomaly alarm information, handling records, and recovery information to the enterprise data center in real time, allowing managers to promptly understand the progress of anomaly handling.

[0058] After receiving production process data, the enterprise data center utilizes big data analytics for in-depth analysis and mining. Through long-term accumulated operational data, it can analyze the operating patterns of reactors and the probability distribution of anomalies. Analysis results include pressure fluctuation characteristic curves, temperature change trends, and equipment failure interval statistics for each reactor. These results provide data support for optimizing early warning thresholds and emergency response plans. For example, by analyzing historical anomaly data, it can be discovered that certain reactors are more prone to pressure anomalies within specific time periods, thereby adjusting inspection plans and maintenance cycles.

[0059] The system can also be integrated with an enterprise's personnel positioning system to achieve real-time monitoring of on-site personnel locations. The personnel positioning system uses RFID or UWB technology to acquire the real-time coordinates of each on-site personnel. When an anomaly occurs, the system can prioritize sending evacuation notices to those closer to the danger zone based on their location information, improving the targeting and effectiveness of evacuation notifications. Simultaneously, the personnel positioning system can track evacuation times, evaluate the effectiveness of emergency response plans, and provide a reference for optimizing evacuation routes and assembly points.

[0060] The system is also integrated with the enterprise's emergency response plan management system, enabling electronic management of emergency plans. The emergency response plan management system stores emergency plans for various abnormal situations, including abnormal handling procedures, personnel responsibilities, emergency contact information, and resource allocation plans. When an abnormality occurs, the system automatically matches the corresponding emergency plan and pushes the plan information to relevant personnel, guiding on-site personnel in emergency response. The entire execution process of the emergency plan is recorded, facilitating post-event review and continuous improvement.

[0061] Example 5 This embodiment describes the different deployment forms and application scenarios of the system, illustrating how the system adapts to different production scales and field conditions.

[0062] For small to medium-sized propionyl chloride production enterprises, production workshops typically only have two to four reaction vessels, allowing for a compact system architecture deployment. This compact architecture integrates the functions of a remote control center onto a single industrial server. The server is equipped with data acquisition cards and communication interface cards, enabling direct connection to on-site intelligent monitoring pressure gauges and actuators. The control software running on the server utilizes virtualization technology, deploying each functional module in an independent virtual container, achieving isolation and independent operation between modules. This compact architecture offers lower system construction costs and is suitable for the safety monitoring needs of small-scale production enterprises.

[0063] For large-scale propionyl chloride production enterprises, a production workshop may be equipped with more than ten reactors, requiring a distributed architecture for system deployment. This distributed architecture divides the remote control center into two levels: field control stations and a centralized monitoring center. Field control stations are located in each production workshop, responsible for data acquisition and local control of all reactors within that workshop. The centralized monitoring center is located at the company headquarters or in the safety management department, responsible for centralized monitoring and unified management of multiple workshops. The field control stations and the centralized monitoring center are connected via the enterprise wide area network, employing data compression and incremental transmission technologies to reduce network bandwidth consumption. The distributed architecture offers good system scalability and can adapt to the management needs of large-scale production enterprises.

[0064] For newly constructed propionyl chloride production projects, the system can be integrated into the overall automation solution during the design phase, achieving seamless integration with other automated equipment on the production line. The system can also be linked with distributed control systems, combustible gas detection systems, fire alarm systems, and other safety systems to form a complete safety monitoring system. In retrofit projects on existing production lines, the system can utilize wireless communication, reducing wiring work and shortening the construction period. The wireless communication solution uses industrial-grade wireless access points, supporting simultaneous access for multiple devices and meeting the application requirements of retrofit projects.

[0065] The system also supports mobile terminal access. By installing a dedicated application on a smartphone or tablet, operators can view production status and receive alarm information from any location. The mobile terminal application uses the same interface design as the control room display terminal, ensuring a consistent user experience. The mobile terminal application supports offline operation mode, caching recent data in situations with poor network signal and automatically synchronizing once the network is restored.

[0066] Example 6 This embodiment describes the debugging, acceptance, operation and maintenance of the system, outlining a complete lifecycle management method for the system from installation and debugging to daily operation and maintenance.

[0067] After system installation, comprehensive debugging and testing are required to ensure that all functions meet design requirements. Debugging is divided into three phases: stand-alone debugging, system debugging, and linkage debugging. Stand-alone debugging primarily tests the individual functions of the intelligent monitoring barometer, actuators, and alarm devices, checking sensor accuracy, actuator reliability, and alarm audible and visual effects. System debugging primarily tests the various software functions of the remote control center, including data acquisition, threshold comparison, anomaly handling, command generation, and communication notification. Linkage debugging primarily tests the coordinated actions between different parts of the system, simulating various abnormal scenarios to verify the correctness of the complete process from anomaly detection, alarm triggering, shutdown execution, and personnel notification.

[0068] After debugging, acceptance testing is required, including functional acceptance, performance acceptance, and safety acceptance. Functional acceptance verifies whether the system implements all functions specified in the design documents, including pressure monitoring, anomaly detection, alarm triggering, remote shutdown, personnel notification, and task assignment. Performance acceptance verifies whether the system meets the performance indicators specified in the design documents, including data acquisition cycle, anomaly detection delay, alarm triggering time, actuator action time, and communication notification response time. Safety acceptance verifies the effectiveness of the system's safety protection functions, including backup power switching in case of failure, communication assurance in case of network interruption, and protection measures against misoperation.

[0069] After the system is put into operation, routine operation and maintenance, as well as regular inspections and repairs, are required. Routine operation and maintenance includes monitoring the system's operating status, reviewing alarm records, handling abnormal alarms, and backing up data. The system software needs to be updated regularly to fix known issues and optimize performance. The intelligent barometer needs to be calibrated regularly to ensure that the measurement accuracy meets requirements. The actuators need to be checked regularly to ensure that their movements are flexible and their seals are reliable. The alarm devices need to be tested regularly to ensure that the audible and visual effects are normal. The communication equipment needs to have its network connection status and signal strength checked regularly.

[0070] The system is also equipped with comprehensive fault diagnosis and logging functions, which can automatically record various events that occur during system operation, including normal operations, parameter modifications, abnormal alarms, and fault occurrences. Log recording uses a cyclic overwrite method, saving log data from the most recent month or more, facilitating fault diagnosis and root cause analysis. The system also provides statistical analysis functions, automatically generating daily, monthly, and annual reports. Report content includes indicators such as production operation time, number of anomalies, timeliness of response, and equipment availability, providing decision support for production management.

[0071] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A remote control method for the production of propionyl chloride, characterized in that, Includes the following steps: S1. Establish communication connections between the remote control center and each reactor on the production site to collect real-time data on temperature, pressure, and operating status of each reactor's processes. S2. Extract features and compare thresholds from the collected pressure and temperature data to determine if any abnormal operating conditions exist. S3. When an abnormal operating condition is detected, the remote control center automatically triggers an alarm and sends an evacuation notice to on-site personnel. S4. The remote control center automatically sends a cut-off command to the corresponding production process to stop the operation of the equipment in that process. S5. The remote control center sends a maintenance task instruction to maintenance personnel, arranging for professional maintenance personnel to go to the site for verification and repair.

2. The remote control method for propionyl chloride production according to claim 1, characterized in that: Establishing a communication connection in step S1 includes installing a smart monitoring pressure gauge on each reactor. The smart monitoring pressure gauge has a built-in sensor module for real-time acquisition of pressure parameters inside the reactor. The smart monitoring pressure gauge establishes a two-way data channel with the monitoring system of the remote control center through a data cable or wireless communication module. The remote control center periodically sends data request commands to each smart monitoring pressure gauge and receives the real-time pressure values ​​returned by each pressure gauge.

3. The remote control method for propionyl chloride production according to claim 1, characterized in that: The intelligent monitoring barometer integrates a comparator module, which continuously compares the real-time collected pressure value with a preset threshold. When the pressure value exceeds the normal range, the comparator module directly outputs an abnormal signal to the barometer's built-in communication module. The communication module encapsulates the abnormal signal and the reactor number into an alarm data packet, which is then actively reported to the remote control center via the communication network. Upon receiving the alarm data packet, the remote control center completes the linkage operation of alarm triggering and device shutdown within a preset time threshold.

4. A remote control system for the production of propionyl chloride, characterized in that, include: The system includes a remote control center, several intelligent barometers, actuators, alarm devices, and a communication and notification module. The remote control center is configured to receive pressure data uploaded by each intelligent monitoring pressure gauge, perform threshold comparison analysis on the pressure data, generate abnormal alarm information, and send control commands to the actuators and alarm devices. The intelligent monitoring pressure gauges are installed on each reactor and connected to the remote control center via a communication network to collect and upload pressure data inside the reactor in real time. The actuators are installed on the devices in each production process and connected to the remote control center to receive and execute cut-off commands issued by the remote control center. The alarm devices are located inside or near the remote control center and are used to issue audible and visual alarms upon receiving abnormal alarm information. The communication notification module is connected to the remote control center and is used to send evacuation notices to on-site personnel and maintenance task instructions to maintenance personnel when an abnormality occurs.

5. The remote control system for propionyl chloride production according to claim 4, characterized in that: The intelligent pressure monitoring gauge includes a housing, a sensor module, a comparator module, a communication module, and a power supply module. The sensor module is used to collect pressure parameters inside the reactor and convert the pressure parameters into electrical signals for output. The comparator module is connected to the sensor module and is used to continuously compare the real-time collected pressure value with a preset threshold. When the pressure value exceeds the normal range, an abnormal signal is output. The communication module is connected to the comparator module and is used to encapsulate the abnormal signal and the reactor number into an alarm data packet and upload it to the remote control center.

6. The remote control system for propionyl chloride production according to claim 4, characterized in that: The actuator is an electric actuator or a pneumatic actuator; after receiving a cut-off command from the remote control center, the actuator drives the valve or switch to operate, thereby physically cutting off the process device; the actuator has an integrated position sensor that can detect the actual position status of the valve or switch and feed the position status back to the remote control center.

7. The remote control system for propionyl chloride production according to claim 4, characterized in that: It also includes intelligent monitoring thermometers, which are installed on each reactor and work in conjunction with intelligent monitoring pressure gauges. The intelligent monitoring thermometers collect the temperature parameters inside the reactors in real time and transmit the temperature data to a remote control center. The remote control center performs threshold comparison and anomaly handling procedures on the temperature data, similar to those for pressure data. When both temperature and air pressure anomalies occur simultaneously, the remote control center prioritizes handling the air pressure anomaly.

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