An electric heat tracing intelligent control system based on internet of things
The IoT-based intelligent control system for electric heat tracing enables real-time monitoring and automatic adjustment of the system, solving problems such as outdated monitoring, difficult wiring, and energy waste. It achieves timely fault detection and efficient energy utilization, reducing costs and construction difficulties.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- DATANG HUANGDAO POWER GENERATION
- Filing Date
- 2025-08-04
- Publication Date
- 2026-07-21
AI Technical Summary
Existing electric heat tracing systems suffer from outdated monitoring methods, difficult wiring, and energy waste, making it impossible to detect faults in a timely manner and incurring high costs.
An IoT-based intelligent electric heat tracing control system is adopted, including a field side and a monitoring center. It uses current detection modules, temperature detection modules, current ripple detection modules and intelligent controllers for real-time monitoring and data transmission, and combines wireless transceivers and servers for data analysis and alarms.
It enables real-time fault detection of electric heat tracing systems, reduces wiring costs and construction difficulty, improves system reliability and stability, and achieves efficient energy utilization.
Smart Images
Figure CN224538342U_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of electric heat tracing monitoring technology, and in particular to an intelligent electric heat tracing control system based on the Internet of Things. Background Technology
[0002] In many industrial production processes, such as petroleum, chemical, and power industries, numerous pipelines and equipment require maintaining a certain temperature to ensure normal operation and prevent freezing or solidification of the media. Electric heat tracing systems have emerged to address this need. These systems generate heat through heat tracing cables, providing thermal compensation to pipelines and equipment. However, traditional electric heat tracing systems have several problems: 1. Outdated monitoring methods: Currently, most electric heat tracing systems do not have real-time monitoring and rely on manual on-site inspections. This makes it impossible to detect problems such as damage or aging of the heat tracing cables in a timely manner. For example, if the heat tracing cable is open-circuited or short-circuited, it cannot be detected in time, leading to abnormal equipment operation.
[0003] 2. High cabling difficulty: Long-distance cable laying is generally used to transmit important data such as heat tracing current and cabinet temperature to the monitoring system. The cable laying process needs to cross complex terrain and buildings, which is difficult, time-consuming and costly.
[0004] 3. Some current detection uses current transformers, which requires disassembling cable joints and through-wire wiring, which is time-consuming, labor-intensive, and prone to damaging the cable insulation layer due to repeated disassembly.
[0005] 4. Energy waste: Most electric heat tracing systems do not adjust to changes in the ambient temperature. They operate at a fixed power regardless of the ambient temperature, resulting in a large amount of energy waste.
[0006] In summary, existing electric heat tracing systems have significant shortcomings in monitoring, wiring, and energy utilization, and there is an urgent need for a new type of intelligent cloud control system for electric heat tracing to solve these problems. Utility Model Content
[0007] The present invention aims to solve the aforementioned technical problems by providing an intelligent electric heat tracing control system based on the Internet of Things.
[0008] To achieve the above objectives, the present invention adopts the following technical solution: An IoT-based intelligent electric heat tracing control system comprises a field unit and a monitoring center. The field side includes a heat tracing cable wound around the outside of the pipe or equipment to be heat-traced; A current detection module is connected to the heat tracing cable and is used to collect the current data and current ripple signal of the heat tracing cable. Temperature detection module, used to monitor ambient temperature and pipeline medium temperature; The current ripple detection module is used to detect abnormal current fluctuations or brief interruptions caused by aging or poor contact of the heating cable. The intelligent controller is connected to the current detection module, temperature detection module, and current ripple detection module to receive and process the collected data. A field wireless transceiver, connected to the aforementioned intelligent controller, is used to transmit processed data; The monitoring center includes a computer room wireless transceiver for receiving data sent by the on-site wireless transceiver; The server is connected to the wireless transceiver in the computer room and is used for storing and analyzing data; The monitoring terminal is connected to the server and is used to display the system's operating status.
[0009] The aforementioned IoT-based intelligent electric heat tracing control system includes an ambient temperature sensor and a pipeline temperature sensor in its temperature detection module.
[0010] The aforementioned IoT-based intelligent control system for electric heat tracing uses a high-precision, openable Rogowski coil or clamp-on Hall current sensor in its current detection module.
[0011] The aforementioned IoT-based intelligent electric heat tracing control system further includes an early warning module in its monitoring center server. This early warning module includes a temperature alarm device, an overcurrent alarm device, and a poor contact alarm device.
[0012] The aforementioned IoT-based intelligent electric heat tracing control system uses one or more of the following communication methods between the field wireless transceiver and the computer room wireless transceiver: WiFi, LoRa, or NB-IoT.
[0013] The aforementioned IoT-based intelligent electric heat tracing control system includes a web monitoring terminal and a mobile phone monitoring terminal as monitoring terminals. Beneficial effects
[0014] 1. This utility model, through the coordinated operation of a current detection module, a temperature detection module, a current ripple detection module, and an intelligent controller, can collect and monitor parameters such as current, ambient temperature, pipe temperature, and current ripple of the heat tracing cable in real time, promptly detect potential faults in the electric heat tracing system, such as short circuits, open circuits, and aging of the heat tracing cable, and improve the reliability and stability of the system.
[0015] 2. This utility model uses field wireless transceivers and computer room wireless transceivers for data transmission, avoiding the hassle of long-distance cable laying, reducing wiring costs and construction difficulty, while improving the system's flexibility and scalability. Wireless monitoring devices can be easily installed in different areas and on different equipment to achieve comprehensive monitoring of the entire electric heat tracing system.
[0016] 3. The intelligent controller of this utility model automatically adjusts the current of the heat tracing cable according to the ambient temperature and pipeline temperature, keeping the heat tracing temperature within a reasonable range, avoiding energy waste, and achieving efficient energy utilization. For example, when the ambient temperature is high, the intelligent controller automatically reduces the current of the heat tracing cable to reduce heat generation; when the ambient temperature is low, it automatically increases the current to increase heat generation. Attached Figure Description
[0017] Figure 1 System overall structure diagram; Figure 2 : Schematic diagram of the detection module installation; In the diagram: 1. Current detection module; 2. Temperature detection module; 3. Current ripple detection module; 4. Intelligent controller; 5. On-site wireless transceiver; 6. Computer room wireless transceiver; 7. Server; 8. WEB monitoring terminal; 9. Mobile phone monitoring terminal. Detailed Implementation
[0018] Reference Figures 1-2 An intelligent electric heat tracing control system based on the Internet of Things (IoT) comprises a field side and a monitoring center. The field side includes a heat tracing cable wound around the outside of the pipe or equipment to be heat-traced; The current detection module 1 is connected to the heat tracing cable and is used to collect the current data and current ripple signal of the heat tracing cable. Temperature detection module 2 is used to monitor ambient temperature and pipeline medium temperature; The current ripple detection module 3 is used to detect abnormal current fluctuations or brief interruptions caused by aging or poor contact of the heating tape. The intelligent controller 4 is connected to the current detection module, temperature detection module, and current ripple detection module to receive and process the collected data. The on-site wireless transceiver 5 is connected to the intelligent controller and is used to send processed data; The monitoring center includes a computer room wireless transceiver 6, which is used to receive data sent by the on-site wireless transceiver. Server 7 is connected to the wireless transceiver in the computer room and is used for storing and analyzing data; The monitoring terminal is connected to the server and is used to display the system's operating status.
[0019] The temperature detection module includes an ambient temperature sensor and a pipeline temperature sensor.
[0020] The current detection module uses a high-precision, openable Rogowski coil or clamp-on Hall current sensor.
[0021] The monitoring center server also includes an early warning module, which includes a temperature alarm device, an overcurrent alarm device, and a poor contact alarm device.
[0022] The communication method between the field wireless transceiver and the computer room wireless transceiver is one or more of WiFi, LoRa, or NB-IoT.
[0023] The monitoring terminals include a web monitoring terminal 8 and a mobile monitoring terminal 9.
[0024] Heat tracing cable: Wrapped around the outside of pipes or equipment that require heat tracing to provide them with heat.
[0025] Current detection module: Installed on the heat tracing cable line, used to collect the current data of the heat tracing cable in real time.
[0026] Temperature detection module: includes an ambient temperature sensor and a pipe temperature sensor. The ambient temperature sensor is installed in the environment around the pipe to measure the ambient temperature; the pipe temperature sensor is installed on the surface or inside the pipe to measure the temperature of the medium inside the pipe.
[0027] Current ripple detection module: This module is primarily designed for highly sensitive detection and diagnosis of abnormal waveforms in the heating current. Through an internal signal conditioning circuit, it filters out the fundamental frequency (50 / 60Hz), retains the high-frequency ripple component (>100Hz), captures the amplitude of ripple voltage fluctuations in real time, compares the ripple amplitude with a preset threshold, and outputs an out-of-range pulse signal.
[0028] The intelligent controller connects to the current detection module, temperature detection module, and current ripple detection module, receiving data collected by them. Based on preset parameters and algorithms, the intelligent controller can control the current of the heating cable according to the ambient temperature, pipe temperature, and the magnitude of the heating cable current, thereby adjusting the heat output of the heating cable and achieving intelligent regulation of the heating temperature. Simultaneously, the intelligent controller also has data processing and storage functions, capable of analyzing and processing the collected data and storing historical data within a certain period.
[0029] Field wireless transceiver: Connected to the intelligent controller, it transmits the data processed by the intelligent controller via wireless signals. The wireless transceiver can use one or more wireless communication technologies such as WiFi, LoRa, or NB-IoT to achieve stable data transmission.
[0030] 2. Monitoring Center: Computer room wireless transceiver: Receives wireless signals sent by on-site wireless transceivers and converts them into digital signals.
[0031] Server: Connected to the wireless transceiver in the server room, it receives and stores data transmitted by the wireless receiver. The server also has data analysis software installed, capable of performing in-depth analysis of the received data to determine whether the electric heat tracing system is operating normally. For example, by analyzing the trend of current data changes, it can determine whether the heat tracing cable has problems such as aging or damage; based on the correlation analysis of temperature and current data, it can assess whether the heat tracing effect has met expectations.
[0032] The monitoring terminal includes a web-based monitoring terminal and a mobile monitoring terminal: connected to the server, staff can view various parameters of the electric heat tracing system in real time, such as the current of the heat tracing cable, ambient temperature, and pipe temperature. The monitoring terminal can also display the operating status of the electric heat tracing system. When abnormalities occur, such as excessive or insufficient current, or excessively high or low temperature, the monitoring terminal will issue audible and visual alarm signals to remind staff to handle the situation promptly.
[0033] On-site installation: 1. Wrap the heat tracing cable evenly around the outside of the pipe or equipment that needs heat tracing according to the specified winding method to ensure uniform heat tracing effect.
[0034] 2. Install a current detection module and a current ripple detection module below the circuit breaker for the heat tracing cable to ensure accurate acquisition of current data.
[0035] 3. Install the temperature detection module for ambient temperature measurement in a well-ventilated location around the pipeline that represents the ambient temperature; install the pipeline temperature detection module on the surface or inside the pipeline to ensure accurate measurement of the temperature of the medium inside the pipeline.
[0036] 4. Install the intelligent controller in a location that is easy to operate and maintain, such as in a field instrument cabinet, and connect the current detection module, temperature detection module, and current ripple detection module to the intelligent controller via cables to ensure stable data transmission.
[0037] 5. Connect the on-site wireless transceiver to the intelligent controller, and select the appropriate wireless communication frequency band and parameters according to the actual situation to ensure that the wireless signal can be stably transmitted to the monitoring center.
[0038] Monitoring center settings: 1. Install the wireless receiver in the computer room at a location where it can receive wireless signals from the field side and connect it to the server.
[0039] 2. Install data analysis software and database management system on the server to store and analyze the received data.
[0040] 3. By connecting the WEB monitoring terminal, mobile monitoring terminal and server through the network, staff can view the operating status and various parameters of the electric heat tracing system in real time through the monitoring terminal.
[0041] System operation and maintenance: 1. During system operation, the current detection module, temperature detection module, and current ripple detection module collect data in real time and transmit the data to the intelligent controller.
[0042] 2. The intelligent controller analyzes and processes the collected data according to preset algorithms and parameters, controls the current of the heating cable, and adjusts the heating temperature. Simultaneously, the intelligent controller transmits the processed data to the monitoring center via a field wireless transceiver.
[0043] 3. The wireless receiver in the monitoring center's computer room receives data and transmits it to the server. The server stores and analyzes the data to determine whether the electric heat tracing system is operating normally.
[0044] Staff can monitor the operating status and parameters of the electric heat tracing system in real time through web and mobile monitoring terminals. When abnormalities occur, timely measures are taken to address them. Simultaneously, the system is regularly maintained and inspected to ensure the normal operation of all components, such as checking the accuracy of sensors, the stability of wireless signals, and the working status of the intelligent controller.
[0045] The specific analysis indicators are as follows: (1) Current detection standard table:
[0046] (2) Temperature detection standard table:
[0047] (3) Current ripple detection judgment standard table:
[0048] Application scenario example: Scenario: An oil pipeline (freezing point 15℃) is operating during a cold wave; Ambient temperature: -10℃ → Triggers heat tracing start; Pipeline temperature: dropped to 18℃ (close to freezing point +3℃) → Low temperature warning; Current detection: Rated current 20A → Actual current 12A (only 60%) → Risk warning of breakage; Ripple detection: Simultaneous capture of 1.5A@600Hz ripple → Determine "interconnection arc discharge at the break point"; System actions: The intelligent controller provides local audible and visual alarms, and remotely pushes fault location maps to the WEB monitoring terminal and mobile monitoring terminal, prompting maintenance personnel: "The XX section of the heat tracing line has broken and requires emergency repair."
[0049] Through the coordinated operation of the current detection module, temperature detection module, current ripple detection module, and intelligent controller, parameters such as current, ambient temperature, pipe temperature, and current ripple of the heat tracing cable can be collected and monitored in real time, enabling timely detection of potential faults in the electric heat tracing system, such as short circuits, open circuits, and aging of the heat tracing cable, thereby improving the reliability and stability of the system.
[0050] Data transmission is achieved using on-site and in-room wireless transceivers, avoiding the hassle of long-distance cable laying, reducing wiring costs and construction difficulty, while improving system flexibility and scalability. Wireless monitoring devices can be easily installed in different areas and on different equipment, enabling comprehensive monitoring of the entire electric heat tracing system.
[0051] The intelligent controller automatically adjusts the current of the heat tracing cable based on the ambient temperature and pipe temperature, keeping the heat tracing temperature within a reasonable range, avoiding energy waste, and achieving efficient energy utilization. For example, when the ambient temperature is high, the intelligent controller automatically reduces the current of the heat tracing cable to reduce heat generation; when the ambient temperature is low, it automatically increases the current to increase heat generation.
[0052] The server analyzes and processes the collected data, providing strong support for the maintenance and management of electric heat tracing systems. By analyzing historical data, the operating patterns of the electric heat tracing system can be understood, potential faults can be predicted, and preventative measures can be taken in advance to reduce equipment failure rates and maintenance costs. Furthermore, the data analysis results can also provide a reference for optimizing the design and operation of the electric heat tracing system.
Claims
1. An intelligent electric heat tracing control system based on the Internet of Things, characterized by: Its components include the on-site side and the monitoring center. The field side includes a heat tracing cable wound around the outside of the pipe or equipment to be heat-traced; A current detection module is connected to the heat tracing cable and is used to collect the current data and current ripple signal of the heat tracing cable. Temperature detection module, used to monitor ambient temperature and pipeline medium temperature; The current ripple detection module is used to detect abnormal current fluctuations or brief interruptions caused by aging or poor contact of the heating cable. The intelligent controller is connected to the current detection module, temperature detection module, and current ripple detection module to receive and process the collected data. A field wireless transceiver, connected to the aforementioned intelligent controller, is used to transmit processed data; The monitoring center includes a computer room wireless transceiver for receiving data sent by the on-site wireless transceiver; The server is connected to the wireless transceiver in the computer room and is used for storing and analyzing data; The monitoring terminal is connected to the server and is used to display the system's operating status.
2. The IoT-based intelligent electric heat tracing control system according to claim 1, characterized in that: The temperature detection module includes an ambient temperature sensor and a pipeline temperature sensor.
3. The IoT-based intelligent electric heat tracing control system according to claim 2, characterized in that: The current detection module uses a high-precision, openable Rogowski coil or clamp-on Hall current sensor.
4. The IoT-based intelligent electric heat tracing control system according to claim 3, characterized in that: The monitoring center server also includes an early warning module, which includes a temperature alarm device, an overcurrent alarm device, and a poor contact alarm device.
5. The IoT-based intelligent control system for electric heat tracing according to claim 4, characterized in that: The communication method between the field wireless transceiver and the computer room wireless transceiver is one or more of WiFi, LoRa, or NB-IoT.
6. The IoT-based intelligent electric heat tracing control system according to claim 5, characterized in that: The monitoring terminals include web monitoring terminals and mobile monitoring terminals.