Hydrogen Production Safety Control for Gas-Liquid Separator Pressure
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Solution Overview
Problem
Existing hydrogen production systems face risks of explosions due to mixing of hydrogen and oxygen, which conventional safety controllers fail to prevent when the control system fails, despite implementing alarm and interlocking functions.
Innovation Solution
A hydrogen production control system with a safety controller that adjusts pressure and liquid levels in gas-liquid separation apparatuses through dedicated valves, independent of the main control loop, to prevent dangerous mixing by halting production and depressurizing or isolating the systems when thresholds are exceeded.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a DCS and PLC are used to control the hydrogen production system, then the system operation and alarm/interlocking protection functions are implemented, but there is still a probability of failure and liquid mixing between oxygen and hydrogen sides cannot be completely prevented
Solution Approach 1:
The control system is segmented into two independent parts: a hydrogen-production controller for normal operation control and a safety controller for safety-critical functions. This segmentation ensures that failure in one controller does not compromise the other, thereby preventing liquid mixing and explosion risks while maintaining system safety
Solution Approach 2:
A safety controller is introduced as an intermediary between the hydrogen-production controller and the control circuits of critical components (control valve, power supply). This intermediary independently monitors parameters and executes safety actions, preventing harmful liquid mixing and explosion risks even when the primary controller fails
2Reliability
If an SIS safety controller is used to implement alarm and interlocking functions, then the power supply is cut off and valves are placed in default safe positions, but the safety controller does not participate in control execution and cannot completely prevent danger occurrence
Solution Approach 1:
The safety controller is designed with multi-functionality: it not only performs traditional alarm and interlocking functions (cutting off power supply and positioning valves) but also independently executes control actions through dedicated control circuits (first control circuit for pressure, second control circuit for liquid level). This universality allows it to both protect safety and maintain control execution capability, preventing danger while ensuring productivity
3Reliability
If the safety controller adjusts pressure and liquid level independently through dedicated valves, then liquid mixing is prevented and safety is enhanced, but the device complexity increases
Solution Approach 1:
The control system is segmented into two independent parts: a hydrogen-production controller for normal operation control and a safety controller for safety-critical functions. This segmentation ensures that failure in one controller does not compromise the other, thereby preventing liquid mixing and explosion risks while maintaining system safety
Solution Approach 2:
A safety controller is introduced as an intermediary between the hydrogen-production controller and the control circuits of critical components (control valve, power supply). This intermediary independently monitors parameters and executes safety actions, preventing harmful liquid mixing and explosion risks even when the primary controller fails
Data Source
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AI summary
The present disclosure relates to a hydrogen production control system and method, and a storage medium. The hydrogen production control system includes a safety controller, a first valve and a second valve respectively connected to the safety controller, a hydrogen-production controller, a third valve and a fourth valve respectively connected to the hydrogen-production controller, an oxygen-side gas-liquid separation apparatus respectively in communication with the first valve and the third valve, and a hydrogen-side gas-liquid separation apparatus respectively in communication with the second valve and the fourth valve, where the hydrogen-production controller is configured to control a pressure in the oxygen-side gas-liquid separation apparatus through the third valve, and control a liquid level in the hydrogen-side gas-liquid separation apparatus through the fourth valve; and the safety controller is configured to: when a hydrogen production parameter is greater than or equal to a preset parameter alarm threshold, adjust the pressure in the oxygen-side gas-liquid separation apparatus through the first valve, and/or adjust the liquid level in the hydrogen-side gas-liquid separation apparatus through the second valve. In this way, system safety is effectively ensured, and production efficiency is improved.