A standby pump start-up device based on a DCS system

Abstract

This utility model provides a standby pump starting device based on a DCS system, relating to the field of electrical control equipment technology. The solution includes: when the DCS system generates a start command to start a standby pump, a standby pump selector identifies the standby pump corresponding to the timer with the shortest timing result based on the timing results of various timers, and sends the start command to that standby pump. After the standby pump starts, the timing result of its corresponding timer gradually increases. Therefore, this application selects and starts a standby pump based on the timing results of various timers when the main pump trips, rather than continuously starting a standby pump based on a fixed sequence number. This effectively prevents a standby pump from suffering serious life-threatening problems such as mechanical seal aging due to prolonged idleness.

Description

Technical Field

[0001] This utility model relates to the field of electrical control equipment technology, specifically to a standby pump start-up device based on a DCS system. Background Technology

[0002] In traditional process water pump systems, when the main pump trips due to a malfunction, the backup pump is started manually by the central control system and on-site operation. This process takes an average of more than 30 seconds. During the main pump trip, the pump cannot pump the medium into the pipeline, which will cause a sudden decrease in the flow rate in the pipeline. During this period, the process system will face risks such as a sudden drop in pipeline pressure and interruption of water supply to the water cooling system, which may force production to stop.

[0003] To improve the response speed of the standby pump, a DCS system is used to monitor the operating status of the main pump. When the main pump fails and stops, the standby pump is automatically started. However, traditional process water pump systems usually have multiple main pumps and multiple standby pumps. When the DCS system starts the standby pumps after the main pump stops, it starts the standby pumps according to a fixed number sequence. This method of starting the standby pumps will always start the first standby pump in the fixed number sequence, while the other standby pumps will remain idle. This will result in some standby pumps being idle for a long time, and the mechanical seals aging due to static aging, which will seriously reduce the lifespan of such standby pumps. Utility Model Content

[0004] In view of this, this utility model provides a standby pump starting device based on a DCS system to prevent the mechanical seal from aging due to prolonged idleness of some standby pumps.

[0005] To achieve the above objectives, the present invention provides the following technical solutions:

[0006] A standby pump starting device based on a DCS system includes a DCS system, which outputs a start command to start the standby pump when a main pump trips, and further includes:

[0007] A timer, which corresponds one-to-one with a standby pump, is used to measure the cumulative working time of the corresponding standby pump, and the number of standby pumps is not less than 2;

[0008] A standby pump selector has a first input interface, a second input interface, and an output interface. The first input interface is used to acquire the start command, the second input interface is used to input the timing result of a timer, and the output interface is used to send a working command to a target standby pump when the start command is acquired. The target standby pump is the standby pump that is in an idle state and has the shortest corresponding timing result.

[0009] Optionally, the aforementioned standby pump starting device based on the DCS system further includes:

[0010] An alarm device, which is connected to the DCS system, is used to acquire and respond to the activation command to execute an alarm action.

[0011] Optionally, the aforementioned standby pump starting device based on the DCS system further includes: a main pump selector and a timer corresponding to each main pump.

[0012] The first input interface of the main pump selector is connected to the DCS system, and the second input interface is connected to the timer corresponding to each main pump. The output terminal of the main pump selector is connected to the control switch of each main pump. When a main pump power-down command is received, the output terminal of the main pump selector is used to send the main pump power-down command to the main pump with the longest cumulative working time, and when a main pump power-on command is received, the output terminal of the main pump selector is used to send the main pump power-on command to the main pump with the shortest cumulative working time.

[0013] Optionally, in the above-mentioned standby pump starting device based on the DCS system, the standby pump includes a variable frequency pump and a diesel pump, and the number of both the variable frequency pump and the diesel pump is not less than two.

[0014] Optionally, in the above-mentioned standby pump start-up device based on the DCS system, the standby pump selector is integrated into the DCS system.

[0015] Optionally, in the above-mentioned standby pump starting device based on the DCS system, the standby pump selector integrates an ascending sorting unit, and the output interface of the standby pump selector is used to send a working command to the target standby pump based on the sorting result of the sorting unit when the start command is obtained.

[0016] Optionally, in the above-mentioned standby pump start-up device based on a DCS system, the timer is integrated into the DCS system.

[0017] Optionally, in the above-mentioned standby pump start-up device based on the DCS system, the timer is equipped with a reset button, and when the reset button is triggered, the timing result of the timer is cleared to zero.

[0018] Optionally, the aforementioned standby pump start-up device based on the DCS system further includes a pressure sensor connected to the DCS system, which is used to detect the pipeline pressure in the pipelines connected to the standby pump and the main pump.

[0019] Optionally, in the above-mentioned standby pump starting device based on DCS system, the target standby pump is a standby pump that matches the main pump group to which the tripped main pump belongs;

[0020] The main pump group includes at least one main pump, and the DCS system is used to monitor the main pumps in multiple main pump groups.

[0021] Based on the above technical solution, the solution provided in this utility model embodiment, when the DCS system generates a start command for starting the standby pump, the standby pump selector identifies the standby pump corresponding to the timer with the shortest timing result based on the timing results of each timer, and sends the start command to that standby pump. After the standby pump starts, the timing result of its corresponding timer will gradually increase. Therefore, in this application, when the main pump trips, the standby pump is selected and started based on the timing results of each timer, rather than continuously starting a standby pump based on a fixed sequence number. This effectively prevents a standby pump from experiencing serious problems such as mechanical seal aging due to prolonged idleness, which severely affects the lifespan of the standby pump. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of the structure of a standby pump starting device based on a DCS system disclosed in an embodiment of this application. Detailed Implementation

[0024] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0025] First, some of the technical terms used in this application will be explained:

[0026] DCS system: Distributed control system, which automates industrial processes through distributed control units and centralized monitoring.

[0027] Feedback signal: Pump operating status signal fed back from contactor auxiliary contacts / current transmitter;

[0028] Cumulative runtime: Total historical operating time of the water pump (automatically recorded and updated by DCS).

[0029] In this embodiment, a technical solution is disclosed that can start a standby pump based on the operating time of the standby pump. When starting the standby pump through this solution, the standby pump with a shorter operating time can be selected for starting, which prevents serious problems such as mechanical seal aging caused by a standby pump being idle for a long time, which seriously affects the life of the standby pump.

[0030] See Figure 1 This application discloses a standby pump starting device based on a DCS system, comprising a DCS system 100. The DCS system outputs a start command to start the standby pump upon detecting a main pump trip. The DCS system can be an existing DCS system for managing main and standby pumps. The DCS system can monitor the operating status of each main pump in real time, and start the standby pump to replace the tripped main pump when it trips. Specifically, the DCS system can determine whether a main pump has tripped based on an operational feedback signal or a circuit breaker trip signal.

[0031] The DCS system described is a very mature technical solution in the prior art, and this application does not provide much explanation of its specific working principle and system structure.

[0032] See Figure 1 The aforementioned standby pump starting device also includes: a timer 200 and a standby pump selector 300;

[0033] Each timer corresponds one-to-one with a standby pump and is used to measure the cumulative operating time of the corresponding standby pump. The number of standby pumps is no less than two. Each timer corresponds to one standby pump and is used to record the cumulative operating time of its corresponding standby pump. The timer can be implemented by a built-in RTC chip or an industrial PLC controller. The RTC chip or industrial PLC controller has built-in non-volatile memory, which stores the cumulative operating time of each standby pump.

[0034] A standby pump selector 300 has a first input interface, a second input interface, and an output interface. The first input interface is used to acquire the start command, the second input interface is used to input the timing result of a timer, and the output interface is used to send a working command to a target standby pump when the start command is acquired. The target standby pump is the standby pump that is idle and has the shortest corresponding timing result. The standby pump selector has built-in comparison logic that identifies the smallest timing result among the various timers input through the second input interface. When the start command is acquired through its first input interface, the start command is forwarded to the standby pump corresponding to the smallest result to start the standby pump with the shortest usage time.

[0035] The target backup pump is a backup pump that matches the main pump group to which the tripped main pump belongs; each main pump group includes at least one main pump, and different main pump groups are connected to different pipelines, so the backup pumps corresponding to these main pump groups are also different. The DCS system can detect the working status of each main pump in each main pump group.

[0036] As can be seen from the above scheme, when the DCS system generates a start command to start the standby pump, the standby pump selector identifies the standby pump corresponding to the timer with the shortest timing result based on the timing results of each timer, and sends the start command to that standby pump. After the standby pump starts, the timing result of its corresponding timer will gradually increase. Therefore, in this application, when the main pump trips, the standby pump is selected and started based on the timing results of each timer, rather than continuously starting a standby pump based on a fixed sequence number. This effectively prevents a standby pump from experiencing serious problems such as mechanical seal aging due to prolonged idleness, which severely affects the lifespan of the standby pump.

[0037] In this embodiment, the timer can be a counter. Each time the standby pump starts, the counter increments by one. The timing result mentioned earlier refers to the counter's count. A counter is less expensive than a timer.

[0038] In this embodiment, the backup pump can also interact with the main pump. When the backup pump starts, it can send a feedback signal to the DCS system. The DCS system starts timing after sending the start command. If no feedback signal indicating backup pump startup is received within a target duration (which can be 6 seconds or other durations), a start command is generated and sent again. When the backup pump selector receives the start command again within a short time (e.g., within 7 seconds), it selects the backup pump corresponding to the second shortest timing duration as the target pump. Therefore, backup pumps in a faulty or maintenance state can be skipped, and other backup pumps can be started, effectively preventing the logic from entering an infinite loop.

[0039] In this embodiment, when the main pump trips, it may continue to operate for a period of time due to inertia. If the standby pump is started during this period, the flow rate in the pipeline may be too high. Therefore, the DCS system can trigger an interlock based on T+3 seconds and execute the interlock procedure after a 3-second delay (the delay improves the fault tolerance and prevents multiple devices from being started). That is, after the DCS system detects the main pump trips, it generates and outputs the start command after a 3-second delay or other target duration.

[0040] Furthermore, in this embodiment, each main pump also corresponds to a timer, which is used to count the operating time of the main pump. The device may also include a main pump selector, which can determine the main pump with the longest cumulative operating time based on the timing result of the main pump's timer. When the DCS system receives a main pump power-down command, it sends the main pump power-down command to the main pump selector, which then sends the main pump power-down command to the main pump with the longest cumulative operating time. The main pump power-down command refers to a control command used to non-directionally select a specific main pump for power-down. If the main pump power-down command is a directional command, the DCS system will directly send the command to the main pump corresponding to that command. Similarly, the main pump selector can also determine the main pump with the shortest cumulative operating time based on the timing result of the main pump's timer. When the DCS system receives a main pump power-on command, it sends the main pump power-on command to the main pump selector, which then sends the main pump power-on command to one or more main pumps with the shortest cumulative operating time. The main pump power-on command refers to a control command used to non-directionally select one or more main pumps for power-on.

[0041] In this embodiment, the main pump selector for controlling the main pump, the standby pump selector for controlling the standby pump, and each timer can be integrated into the DCS system. This can be implemented through software or through a control chip.

[0042] In this embodiment, to facilitate the main pump selector and standby pump selector in quickly identifying the target pump for responding to control commands, the standby pump selector integrates an ascending sorter. This ascending sorter sorts the output results of each timer in ascending order, with the first-ranked pump being the main / standby pump with the shortest cumulative working time. Taking the standby pump selector as an example, its output interface, upon receiving the start command, sends a working command to the target standby pump based on the sorting result of the sorter. Specifically, the standby pump corresponding to the first-ranked timer result in the sorting result is selected as the target pump, and the start command is sent to that target pump.

[0043] In this embodiment, the standby pump starting device based on the DCS system may further include an alarm device. The alarm device is connected to the DCS system and is used to acquire and respond to the start command to execute an alarm action. That is, the alarm device acquires the start command for starting the standby pump output by the DCS system. When the start command is detected, it indicates that the main pump has tripped. At this time, the alarm device outputs an alarm signal. Alternatively, the DCS system detects the main pump tripping and sends a trigger signal to the alarm device to actively trigger the alarm device to work.

[0044] In this embodiment, the backup pump may include a variable frequency pump and a diesel pump. The variable frequency pump is used to operate when the power grid is available, and its operating cost is low. The diesel pump is used to operate when the power grid is interrupted, and its operating cost is higher, but it can meet the needs of emergency use. The number of both variable frequency pumps and diesel pumps is not less than two to ensure that the pipeline system can operate normally.

[0045] In this embodiment, after all main pumps or standby pumps have been maintained, repaired, or replaced, the cumulative operating time of the main / standby pumps can be reset to zero. Of course, when resetting the timer for a specific main / standby pump, the timers for other pumps also need to be reset; otherwise, the selector will treat that pump as the one with the shortest operating time. This resetting action can be triggered by the user, who can decide whether to reset the corresponding timer. The timer is equipped with a reset button; when the reset button is triggered, the timer's timer result is reset to zero. When the timer is integrated into the DCS system, the user can reset the timer's timer result by inputting a command.

[0046] In this embodiment, to facilitate the DCS system in understanding the real-time pressure of the pipeline, the above scheme may also include a pressure sensor, which is connected to the DCS system and used to detect the pipeline pressure in the pipeline connected to the standby pump and the main pump.

[0047] In summary, this application provides a design scheme that can quickly start a standby pump in a short time. In this scheme, the standby pump can be selected and started based on the cumulative working time of the standby pump, which effectively prevents the problem of rapid aging and damage of equipment caused by some standby pumps being idle for a long time.

[0048] The various embodiments in this specification are described in a progressive manner. The same or similar parts between the various embodiments can be referred to each other. Each embodiment focuses on describing the differences from other embodiments.

[0049] Those skilled in the art will further recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of both. To clearly illustrate the interchangeability of hardware and software, the components and steps of the various examples have been generally described in terms of functionality in the foregoing description. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this invention.

[0050] It should also be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0051] The above description of the disclosed embodiments enables those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A standby pump starting device based on a DCS system, comprising a DCS system, wherein the DCS system is used to output a start command for starting a standby pump when a main pump trips, characterized in that, Also includes: A timer, which corresponds one-to-one with a standby pump, is used to measure the cumulative working time of the corresponding standby pump, and the number of standby pumps is not less than 2; A standby pump selector has a first input interface, a second input interface, and an output interface. The first input interface is used to acquire the start command, the second input interface is used to input the timing result of a timer, and the output interface is used to send a working command to a target standby pump when the start command is acquired. The target standby pump is the standby pump that is in an idle state and has the shortest corresponding timing result.

2. The standby pump starting device based on a DCS system according to claim 1, characterized in that, Also includes: An alarm device, which is connected to the DCS system, is used to acquire and respond to the activation command to execute an alarm action.

3. The standby pump starting device based on a DCS system according to claim 1, characterized in that, Also includes: Main pump selector, and timers corresponding to each main pump; The first input interface of the main pump selector is connected to the DCS system, and the second input interface is connected to the timer corresponding to each main pump. The output terminal of the main pump selector is connected to the control switch of each main pump. When a main pump power-down command is received, the output terminal of the main pump selector is used to send the main pump power-down command to the main pump with the longest cumulative working time, and when a main pump power-on command is received, the output terminal of the main pump selector is used to send the main pump power-on command to the main pump with the shortest cumulative working time.

4. The standby pump starting device based on a DCS system according to claim 1, characterized in that, The backup pumps include variable frequency pumps and diesel pumps, and the number of each type of pump is not less than two.

5. The standby pump starting device based on a DCS system according to claim 1, characterized in that, The backup pump selector is integrated into the DCS system.

6. The standby pump starting device based on a DCS system according to claim 5, characterized in that, The standby pump selector integrates an ascending sorter, and the output interface of the standby pump selector is used to send a working command to the target standby pump based on the sorting result of the sorter when the start command is received.

7. The standby pump starting device based on a DCS system according to claim 5, characterized in that, The timer is integrated into the DCS system.

8. The standby pump starting device based on a DCS system according to claim 5, characterized in that, The timer is equipped with a reset button. When the reset button is triggered, the timer's timing result is reset to zero.

9. The standby pump starting device based on a DCS system according to claim 5, characterized in that, It also includes a pressure sensor connected to the DCS system, which is used to detect pipeline pressure in the pipelines connected to the standby pump and the main pump.

10. The standby pump starting device based on a DCS system according to claim 1, characterized in that, The target standby pump is a standby pump that matches the main pump group to which the tripped main pump belongs; The main pump group includes at least one main pump, and the DCS system is used to monitor the main pumps in multiple main pump groups.

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