Triple coordination redundancy based coal gas quick switching valve emergency cut-off system

Abstract

The utility model provides a kind of coal gas fast switching valve emergency shutdown system based on triple coordination redundancy, it is related to coal gas pipeline equipment safety protection field, to solve the existing fast switching valve system power failure operating condition, refuse to move, response delay and single point failure risk and so on problem.The system is replaced by power failure fast closing type through hydraulic system reform module, electrical system reform module and control program optimization module triple coordination architecture, obtains power fast closing type solenoid valve, constructs the emergency power supply loop of UPS power series emergency stop button, optimizes DCS direct tripping mechanism, forms hydraulic automatic control, electrical emergency, control direct trip triple redundant link.Process execution according to fault detection, control response, electrical execution, hydraulic action and valve closure, realize ≤0.4 second's ultrafast emergency shutdown, accident rate reduces more than 90%, adapts steel, chemical industry, natural gas transmission and so on high-risk fluid industrial scene, with remarkable safety benefit and popularization value.

Description

Technical Field

[0001] This utility model relates to the field of safety protection of gas pipeline equipment in steel plants, specifically to an emergency shut-off system for gas quick-cut valves based on triple collaborative redundancy. Background Technology

[0002] Quick-cut valves are core safety devices for gas pipelines, required to rapidly cut off the gas supply within ≤0.5 seconds in the event of a malfunction to prevent leaks and explosions. However, existing quick-cut valve systems suffer from several fatal flaws:

[0003] 1. Defects in quick-closing valve function: Traditional systems use "energized quick-closing" type solenoid valves. When the control system loses power, the solenoid valve cannot conduct oil circuit, causing the valve to fail to operate, and high-pressure gas to continuously flow in and cause an accident; moreover, the total time for protection action is ≥2 seconds, far exceeding the safe time window.

[0004] 2. Significant technical bottlenecks: The hydraulic system relies on a single power source or control logic, which poses a risk of single-point failure; the electrical system lacks an emergency power supply design, and valve operation cannot be guaranteed after power failure; the control logic requires signal relay through multiple links, resulting in severe response delays.

[0005] Existing technologies have not fully addressed the aforementioned issues. For example, some solutions rely on pneumatic control or accumulator actuation, lacking redundancy and emergency backup. Other solutions are only applicable to specific operating conditions, with complex logic and slow response times. Utility Model Content

[0006] This utility model aims to solve the problems of valve failure, response delay and single-point failure risk in existing fast-cut valve systems under power failure conditions. Through triple collaborative transformation, it achieves ultra-fast and highly reliable emergency shut-off in case of failure, meeting the inherent safety requirements of high-risk fluid pipelines.

[0007] To achieve the above objectives, this utility model provides an emergency shut-off system for a gas quick-cut valve based on triple collaborative redundancy, the system comprising:

[0008] The hydraulic system modification module is used to replace the energized fast-closing solenoid valve in the original shut-off system with the de-energized fast-closing solenoid valve. Based on the parallel oil circuit design of the dual de-energized fast-closing solenoid valves, when either de-energized fast-closing solenoid valve loses power, the drain oil circuit can be opened by spring force, so that the pressure in the fast-closing chamber of the hydraulic cylinder is released, and the de-energized fast-closing solenoid valve completes the closing action.

[0009] The electrical system upgrade module is used to construct an emergency power supply circuit for the UPS power supply in series with the emergency stop button, providing emergency power to the fast-closing solenoid valve when any of the fast-closing solenoid valves loses power.

[0010] The control program optimization module is used to eliminate the signal relay module in the original cut-off system. When any power-off fast-closing solenoid valve loses power, a direct connection channel between the fault signal and the trip command is established.

[0011] Preferably, in the hydraulic system modification module, based on the parallel oil circuit design of dual power-off quick-closing solenoid valves, two independent physically isolated oil circuits are led out from the quick-closing chamber of the hydraulic cylinder and connected to the oil inlet of the 1.2DT and 1.3DT power-off quick-closing solenoid valves respectively. When either power-off quick-closing solenoid valve loses power, the drain oil circuit can be opened by spring force, so that the pressure in the quick-closing chamber of the hydraulic cylinder is released, and the power-off quick-closing solenoid valve completes the closing action.

[0012] Preferably, the de-energized quick-closing solenoid valve has an operating pressure of 31.5 MPa and an oil port diameter of [missing information]. Response time ≤ 80ms.

[0013] Preferably, in the electrical system modification module, when any power failure fast-closing solenoid valve loses power, the electrical system modification module activates the emergency power supply circuit of the UPS power supply connected in series with the emergency stop button to provide 300ms of emergency power supply to the power failure fast-closing solenoid valve.

[0014] Preferably, the normally closed contact of the relay connected in the emergency power supply circuit of the UPS power supply series emergency stop button is replaced with a normally open contact, and the trip circuit is reconfigured as follows: protection signal → intermediate relay KA closes → relay coil is energized → relay normally open contact closes → power failure fast-closing solenoid valve is de-energized → power failure fast-closing solenoid valve closes.

[0015] Compared with the prior art, the gas quick-closing valve emergency shut-off system based on triple collaborative redundancy provided by this utility model has the following beneficial effects: This utility model uses a hydraulic system modification module to replace the energized quick-closing solenoid valve in the original shut-off system with an energized quick-closing solenoid valve. Based on the parallel oil circuit design of the dual energized quick-closing solenoid valves, when either energized quick-closing solenoid valve loses power, the drain oil circuit can be opened by spring force, so that the pressure in the quick-closing chamber of the hydraulic cylinder is released, and the energized quick-closing solenoid valve completes the closing action. With the dual solenoid valve parallel oil circuit design, the valve can still be closed by pressure relief even if either valve fails. When the power is cut off, the spring force automatically drains oil to close the valve, solving the problem of traditional valves failing to operate when power is lost. An emergency power supply circuit with a UPS power supply connected in series with an emergency stop button is constructed using an electrical system modification module. This provides emergency power to any fast-closing solenoid valve in the event of a power failure. A control program optimization module eliminates the signal relay module in the original shut-off system. When any fast-closing solenoid valve loses power, a direct connection channel between the fault signal and the trip command is established, eliminating the need for PLC signal relay and compressing signal transmission to 200ms, improving efficiency by 80%. This invention, through the triple collaborative modification of the hydraulic system modification module, electrical system modification module, and control program optimization module, reduces the emergency shut-off time from ≥2 seconds to ≤0.4 seconds, completely resolving the fatal defect of valve failure under power failure conditions.

[0016] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0017] 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 some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This diagram illustrates the structure of an emergency shut-off system for a gas quick-cut valve based on triple collaborative redundancy, as provided in an embodiment of the present invention.

[0019] Figure 2 The schematic diagram of the fast-switching solenoid valve provided in this embodiment of the present invention is shown.

[0020] Figure 3 The diagram shows the hydraulic circuit schematic of the gas quick-cut valve emergency shut-off system based on triple collaborative redundancy provided in this embodiment of the present invention.

[0021] Figure 4The diagram shows the electrical control principle of the gas quick-cut valve emergency shut-off system based on triple collaborative redundancy provided in this embodiment of the present invention. Detailed Implementation

[0022] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0023] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.

[0024] Figure 1 This diagram illustrates the structure of an emergency shut-off system for a gas quick-cut valve based on triple collaborative redundancy, as provided in an embodiment of the present invention. Figure 1 As shown, the system includes:

[0025] Hydraulic system modification module 1 is used to replace the energized fast-closing solenoid valve in the original shut-off system with the de-energized fast-closing solenoid valve. Based on the parallel oil circuit design of the dual de-energized fast-closing solenoid valves, when either de-energized fast-closing solenoid valve loses power, the drain oil circuit can be opened by spring force, so that the pressure in the fast-closing chamber of the hydraulic cylinder is released, and the de-energized fast-closing solenoid valve completes the closing action.

[0026] It should be noted that, as Figure 2 As shown, the original energized fast-closing solenoid valve is replaced with an energized fast-closing solenoid valve, model 4WE10V33 / CG24N9K4. This modification directly determines the valve's operating characteristics when the power is interrupted, providing a physical execution terminal for the electrical system.

[0027] Specifically, such as Figure 2 As shown, the original energized quick-closing solenoid valve (model 4WE10D33) is disassembled, and an energized quick-closing solenoid valve (model 4WE10V33) is installed. The technical parameters of the energized quick-closing solenoid valve are as follows: working pressure 31.5 MPa, oil port diameter... Response time ≤ 80ms.

[0028] Furthermore, such as Figure 3 As shown, the oil circuit connection scheme is as follows:

[0029] (1) Main oil circuit starting point: The quick-closing chamber of the hydraulic cylinder serves as the hydraulic power output end, forming the starting node of the oil circuit system.

[0030] (2) Parallel flow splitting structure: Two independent oil circuit channels are drawn out from the quick-closing chamber of the hydraulic cylinder to form a parallel structure. The first oil circuit channel is connected to the oil inlet of the 1.2DT power failure quick-closing solenoid valve, and the second oil circuit channel is connected to the oil inlet of the 1.3DT power failure quick-closing solenoid valve. The two oil circuits are physically isolated and have no cross connection.

[0031] (3) Solenoid valve operating characteristics: Both the 1.2DT and 1.3DT de-energized quick-closing solenoid valves adopt a de-energized conduction design. In the normal energized state: the drain oil path is blocked, and the valve remains open. In the de-energized state: the valve core automatically switches to the conduction position under the action of the spring force, connecting the drain oil passage.

[0032] (4) Oil drain path: When any de-energized fast-closing solenoid valve is de-energized and turned on, high pressure oil → de-energized fast-closing solenoid valve drain port → oil tank, so that the pressure in the hydraulic cylinder fast-closing chamber is rapidly released, and the de-energized fast-closing solenoid valve completes the closing action.

[0033] In the hydraulic system upgrade module, the energized fast-closing solenoid valve is replaced with an energized fast-closing solenoid valve. This allows for automatic oil release and valve closure via spring force upon power failure, resolving the issue of traditional valves failing to operate when power is lost. The dual-solenoid valve redundancy design eliminates the risk of single-point failure, and the millisecond-level response reduces the accident rate by over 90%. Actual measured energized shut-off time has been optimized from over 15 seconds to 0.4 seconds. In other words, the energized fast-closing solenoid valve is supported by hydraulic pressure when open; however, for rapid closure, the hydraulic oil in the cylinder must be quickly released for the energized fast-closing solenoid valve to complete the closing action.

[0034] Electrical system upgrade module 2 is used to construct an emergency power supply circuit for the UPS power supply in series with the emergency stop button, providing emergency power to the fast-closing solenoid valve when any of the fast-closing solenoid valves loses power.

[0035] It should be noted that in the electrical system modification module, when any power failure fast-closing solenoid valve loses power, the electrical system modification module activates the emergency power supply circuit of the UPS power supply in series with the emergency stop button to provide 300ms of emergency power supply to the power failure fast-closing solenoid valve.

[0036] Figure 4 This invention illustrates the electrical control schematic of an emergency shut-off system for a gas quick-cut valve based on triple collaborative redundancy, as provided in this embodiment. It shows the positions and logical relationships of electrical components such as relays, solenoid valves, etc. Figure 4 As shown, an emergency power supply circuit is constructed by connecting the UPS power supply in series with the emergency stop button to provide emergency power protection for the solenoid valve of the hydraulic system modification module 1, forming a hardware response link with the control program optimization module 3.

[0037] Specifically, the modification process for electrical system upgrade module 2 involves adding an emergency stop button to the UPS power output terminal. The emergency stop button model can be LA39-11, using a 6mm... 2 For flame-retardant cable connections, the flame-retardant cable model can be ZR-YJV.

[0038] Furthermore, such as Figure 4 As shown, the method for modifying the relay in the emergency power supply circuit of the UPS power supply series emergency stop button is to replace the normally closed contact of the relay connected in the circuit with a normally open contact. Previously, the solenoid valve was closed under normal conditions and opened when energized in case of an abnormality. After the modification, the solenoid valve is open under normal conditions and closes when de-energized in case of an abnormality. The trip circuit is reconstructed as follows: protection signal → intermediate relay KA closes → relay coil is energized → relay normally open contact closes → de-energized fast-closing solenoid valve → de-energized fast-closing solenoid valve closes.

[0039] Control program optimization module 3 is used to eliminate the signal relay module in the original cut-off system. When any power failure fast-closing solenoid valve loses power, a direct connection channel between the fault signal and the trip command is established.

[0040] It should be noted that the control program optimization module 3 is used to eliminate the signal relay module in the original cut-off system and realize the fast signal transmission mechanism for direct tripping of the distributed control system DCS. When any power failure fast-closing solenoid valve loses power, a direct connection channel between the fault signal and the trip command is established, and a millisecond-level action command is sent to the electrical system modification module 2 to trigger the hydraulic system modification module 1 to perform emergency shutdown.

[0041] It is understood that the safety redundancy design of this utility model has a triple redundancy protection mechanism to cover different fault scenarios: when the main power supply fails, it relies on the emergency power supply circuit of the UPS power supply series emergency stop button for emergency power supply; when the UPS emergency power supply circuit fails, it relies on the mechanical action of the solenoid valve of the hydraulic system modification module 1; and when the DCS communication fails, it relies on hard wiring triggering to ensure that the failure of any link does not affect the overall disconnection function.

[0042] Specifically, in the main power failure scenario: the electrical system upgrade module 2 starts the UPS series emergency stop circuit, continuously supplying power to the power failure quick-closing valve of the hydraulic system upgrade module 1 for 300 milliseconds; in the UPS failure scenario, the power failure quick-closing valve of the hydraulic system upgrade module 1 is automatically activated, and mechanical closure is achieved by using spring force; in the DCS communication failure scenario, the electrical system upgrade module 2 directly triggers the trip through hard wiring, and the normally open contact of the relay is reconfigured to ensure positive signal transmission.

[0043] Furthermore, the action chain before and after the trip modification in control program optimization module 3 is as follows:

[0044] Action chain before tripping modification: Fault signal → PLC logic processing 800ms → Relay conversion 400ms → Solenoid valve response 800ms → Valve action → Time ≥ 2.0s.

[0045] Post-tripping action chain: Control layer: fault signal → DCS direct trip 200ms; Electrical system upgrade module: UPS activation + emergency stop conduction 150ms; Hydraulic layer: solenoid valve de-energization action 50ms → total time ≤ 0.4 seconds, response efficiency improved to 20% of the original system. In control program optimization module 3, the PLC signal relay link is eliminated, establishing a direct DCS tripping mechanism, compressing the signal transmission time from over 800ms to 200ms, significantly improving response efficiency. Table 1 shows the time optimization verification data before and after the tripping upgrade, and Table 2 shows the time optimization verification data before and after the triple collaborative redundancy upgrade.

[0046] Table 1. Verification data on time optimization before and after tripping modification.

[0047] Before renovation Sensor → PLC → Relay → Actuator 2.0s After renovation Sensor → PLC → Actuator 1.0s

[0048] Table 2. Time optimization verification data before and after triple collaborative redundancy modification.

[0049] Power outage shutdown time >15s (expired) 0.4s Trip response time 2.0s 1.0s Single point of failure tolerance none Dual-valve redundancy protection

[0050] Furthermore, the triple collaborative workflow is as follows:

[0051] (1) Fault detection stage: When the system detects a power failure fault signal.

[0052] (2) Control layer response stage: The optimized DCS control program directly issues a trip command within 1 second, eliminating the signal conversion link of the original system intermediate relay.

[0053] (3) Electrical layer execution stage: The UPS emergency power supply circuit is immediately activated, and the emergency stop button circuit is turned on to form a current path.

[0054] (4) Hydraulic layer operation stage: The power failure quick-closing solenoid valve is automatically triggered due to power interruption, and the valve core opens the oil drain circuit under the action of spring force.

[0055] (5) Valve closing stage: The pressure in the quick-closing chamber of the hydraulic cylinder is released, and the quick-closing valve completes the closing action within 0.4 seconds.

[0056] This invention uses the power failure of the fast-closing solenoid valve as the trigger condition. Through a triple link of hydraulic self-controlled oil discharge, UPS emergency power supply, and DCS direct tripping distributed control system, the emergency shut-off time of the gas fast-closing valve is controlled within 0.4 seconds. This not only greatly improves the shut-off speed and safety, but also avoids failure due to a single fault by relying on multiple links, thus achieving fast, reliable and seamless shut-off.

[0057] Compared with the prior art, the gas quick-cut valve emergency shut-off system based on triple collaborative redundancy provided in this utility model embodiment has the following beneficial effects:

[0058] 1. The hydraulic system upgrade module replaces the energized fast-closing solenoid valve with a de-energized fast-closing type, enabling automatic oil release and valve closure upon power failure. This solves the problem of traditional valves failing to operate when power is lost. A dual-solenoid valve parallel oil circuit is used, ensuring pressure release and valve closure even if either solenoid valve fails. A hard-wired circuit connecting the UPS power supply to the emergency stop button ensures 300ms of emergency power supply, creating redundancy with the hydraulic system upgrade module. The DCS direct-jump mechanism compresses signal transmission to 200ms, improving efficiency by 80%.

[0059] 2. The entire process from fault detection to valve closure takes ≤0.4 seconds, with seamless coordination between each step. After a fault signal is triggered, the DCS directly issues a trip command, the electrical system simultaneously activates emergency power supply, and the hydraulic system rapidly depressurizes, ultimately achieving ultra-fast closure of the quick-closing valve.

[0060] 3. The total emergency shutdown time is ≤0.4 seconds, which is 80% more efficient than the traditional system response time of ≥2 seconds, far exceeding the safety time window requirement. Triple safety redundancy design eliminates the risk of single point of failure, achieving a 99.99% UPS emergency power supply success rate and reducing the accident rate by over 90%.

[0061] 4. It can seamlessly retrofit existing quick-cut valves on main gas pipelines, significantly reducing the risk of gas leaks and explosions. It is also suitable for industrial pipeline safety applications involving high-risk fluids, such as chemical, coking, and natural gas transportation, meeting the stringent "intrinsically safe" requirements for critical facilities outlined in the "Industrial Control System Safety Action Plan." This system features a dual-valve redundancy design and millisecond-level response, offering strong retrofit compatibility, controllable implementation costs, and the ability to directly replace outdated equipment. It provides a highly reliable and ultra-fast safety shut-off solution for process industries, effectively protecting personnel and equipment safety, reducing accident risks, and demonstrating significant market potential.

[0062] The above description is merely a specific embodiment of this utility model, but the protection scope of this utility model is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this utility model should be included within the protection scope of this utility model. Therefore, the protection scope of this utility model should be determined by the protection scope of the claims.

Claims

1. An emergency shut-off system for gas quick-cut valves based on triple collaborative redundancy, characterized in that, include: The hydraulic system modification module is used to replace the energized fast-closing solenoid valve in the original shut-off system with the de-energized fast-closing solenoid valve. Based on the parallel oil circuit design of the dual de-energized fast-closing solenoid valves, when either de-energized fast-closing solenoid valve loses power, the drain oil circuit can be opened by spring force, so that the pressure in the fast-closing chamber of the hydraulic cylinder is released, and the de-energized fast-closing solenoid valve completes the closing action. The electrical system upgrade module is used to construct an emergency power supply circuit for the UPS power supply in series with the emergency stop button, providing emergency power to the fast-closing solenoid valve when any of the fast-closing solenoid valves loses power. The control program optimization module is used to eliminate the signal relay module in the original cut-off system. When any power-off fast-closing solenoid valve loses power, a direct connection channel between the fault signal and the trip command is established.

2. The emergency shut-off system for a gas quick-cut valve based on triple collaborative redundancy according to claim 1, characterized in that, In the hydraulic system modification module, based on the parallel oil circuit design of dual power-off fast-closing solenoid valves, two independent physically isolated oil circuits are led out from the fast-closing chamber of the hydraulic cylinder and connected to the oil inlet of the 1.2DT and 1.3DT power-off fast-closing solenoid valves respectively. When either power-off fast-closing solenoid valve loses power, the drain oil circuit can be opened by spring force, so that the pressure in the fast-closing chamber of the hydraulic cylinder is released, and the power-off fast-closing solenoid valve completes the closing action.

3. The emergency shut-off system for a gas quick-cut valve based on triple collaborative redundancy according to claim 1 or 2, characterized in that, The power-off quick-closing solenoid valve has a working pressure of 31.5 MPa and an oil port diameter of [missing information]. Response time ≤ 80ms.

4. The emergency shut-off system for a gas quick-cut valve based on triple collaborative redundancy according to claim 1, characterized in that, In the electrical system upgrade module, when any power failure fast-closing solenoid valve loses power, the electrical system upgrade module activates the emergency power supply circuit of the UPS power supply connected in series with the emergency stop button to provide 300ms of emergency power supply to the power failure fast-closing solenoid valve.

5. A gas quick-cut valve emergency shut-off system based on triple collaborative redundancy according to claim 1 or 4, characterized in that, In the emergency power supply circuit of the UPS power supply series emergency stop button, the normally closed contact of the relay connected to it is replaced with a normally open contact. The trip circuit is reconfigured as follows: protection signal → intermediate relay KA closes → relay coil is energized → relay normally open contact closes → power failure fast-closing solenoid valve is de-energized → power failure fast-closing solenoid valve closes.

Images