技术领域Technical Field
本发明涉及工艺生产监测技术领域，更具体地说，本发明涉及一种精馏塔安全运行监测系统。The present invention relates to the technical field of process production monitoring, and more specifically, to a distillation tower safe operation monitoring system.
背景技术Background Art
精馏塔是化工过程中常用的设备，用于通过蒸馏过程分离混合物中的组分，在传统的精馏塔操作中，操作人员通常依赖经验和定期的手动检测来监控塔内的运行情况，这种方法存在效率低下和反应迟缓的问题，随着工业自动化的发展，自动化监控系统逐渐被应用到了精馏塔运行中。Distillation towers are commonly used equipment in chemical processes, used to separate components in a mixture through a distillation process. In traditional distillation tower operations, operators usually rely on experience and regular manual inspections to monitor the operation of the tower. This method has problems of low efficiency and slow response. With the development of industrial automation, automated monitoring systems have gradually been applied to distillation tower operations.
现有的精馏塔运行自动化控制系统设置温度传感器和压力传感器实时监测精馏塔运行中的塔顶温度、塔底温度、塔顶压力，以及塔底压力，在精馏塔温度和压力脱离生产方案规定的温度和压力时自动报警，由专业技术人员进行检验维护，在一定程度上解放了人力资源，实现了智能化监测，降低了精馏塔运行过程中危险事件的发生频率。The existing distillation tower operation automation control system is equipped with temperature sensors and pressure sensors to monitor the top temperature, bottom temperature, top pressure, and bottom pressure of the distillation tower in real time. When the temperature and pressure of the distillation tower deviate from the temperature and pressure specified in the production plan, it will automatically alarm and be inspected and maintained by professional technicians. This has liberated human resources to a certain extent, realized intelligent monitoring, and reduced the frequency of dangerous events during the operation of the distillation tower.
然而上述系统仍存在一些问题：上述系统仅仅对精馏塔中的温度和压力进行监测，监测角度并不全面，并不能完全展现精馏塔运行时的参数偏离情况，且在精馏塔温度和压力脱离生产方案规定的温度和压力时自动报警，并不能保证精馏塔此时一定存在运行异常，此时由专业技术人员进行检验维护，可能会出现不必要的停工检修情况，拖慢生产进度。However, the above system still has some problems: the above system only monitors the temperature and pressure in the distillation tower, the monitoring angle is not comprehensive, and cannot fully display the parameter deviation during the operation of the distillation tower. In addition, it automatically alarms when the temperature and pressure of the distillation tower deviate from the temperature and pressure specified in the production plan, and cannot guarantee that the distillation tower must have operating abnormalities at this time. At this time, inspection and maintenance by professional technicians may result in unnecessary shutdowns for maintenance, slowing down production progress.
发明内容Summary of the invention
为了克服现有技术的上述缺陷，本发明的实施例提供一种精馏塔安全运行监测系统，以解决上述背景技术中提出的问题。In order to overcome the above-mentioned defects of the prior art, an embodiment of the present invention provides a distillation tower safe operation monitoring system to solve the problems raised in the above-mentioned background technology.
为实现上述目的，本发明提供如下技术方案：一种精馏塔安全运行监测系统，包括：To achieve the above object, the present invention provides the following technical solution: a distillation tower safe operation monitoring system, comprising:
传感器布置模块：用于布置流量传感器、压力传感器、液位传感器、温度传感器，以及料液成分检测计对应的流量检测位点、压力检测位点、液位检测位点、温度检测位点，以及料液成分检测位点；Sensor arrangement module: used to arrange flow sensors, pressure sensors, liquid level sensors, temperature sensors, and flow detection sites, pressure detection sites, liquid level detection sites, temperature detection sites, and liquid composition detection sites corresponding to the liquid composition detector;
精馏塔运行实时监测模块：通过布置的传感器实时监测精馏塔的运行并将检测出的精馏塔实时运行数据发送至基础运行参数对照检验模块和塔内运行数据分析模块；Real-time monitoring module for distillation tower operation: monitors the operation of the distillation tower in real time through the arranged sensors and sends the detected real-time operation data of the distillation tower to the basic operation parameter comparison and inspection module and the tower operation data analysis module;
基础运行参数对照检验模块：将接收到的精馏塔运行压力、温度以及液位数据与工艺生产方案中规定的精馏塔运行压力、温度以及液位进行对照检验基础运行参数是否偏离并计算基础运行参数综合偏移率；Basic operating parameter comparison and inspection module: compare the received distillation tower operating pressure, temperature and liquid level data with the distillation tower operating pressure, temperature and liquid level specified in the process production plan to check whether the basic operating parameters deviate and calculate the comprehensive deviation rate of the basic operating parameters;
塔内运行数据分析模块：基于接收到的数据分别计算实际回流比、实际全塔效率、全塔物料损失系数、易挥发组分损失系数，将计算出的实际回流比、实际全塔效率与工艺生产方案中设计的回流比和全塔效率进行对比计算回流比偏移率和全塔效率匹配度，基于全塔物料丢失系数、易挥发组分丢失系数、回流比偏移率，以及全塔效率匹配度计算运行工艺偏移率；Tower operation data analysis module: based on the received data, the actual reflux ratio, actual full-tower efficiency, full-tower material loss coefficient, and volatile component loss coefficient are calculated respectively; the calculated actual reflux ratio and actual full-tower efficiency are compared with the reflux ratio and full-tower efficiency designed in the process production plan to calculate the reflux ratio deviation rate and full-tower efficiency matching degree; the operation process deviation rate is calculated based on the full-tower material loss coefficient, volatile component loss coefficient, reflux ratio deviation rate, and full-tower efficiency matching degree;
精馏塔运行危险预测模块：基于基础运行参数综合偏移率和运行工艺偏移率预测精馏塔运行的运行危险系数；Distillation tower operation hazard prediction module: predicts the operation hazard coefficient of the distillation tower based on the comprehensive deviation rate of basic operation parameters and the operation process deviation rate;
自动报警模块：将预测出的运行危险系数与预设报警临界值进行比较，预测值大于或等于预设报警临界值时发出警报并自动对精馏塔进行调控，在连续三次报警后自动启动危险清除方案，待危险清除完毕后向精馏塔维护部门发送检修请求；Automatic alarm module: compares the predicted operation risk factor with the preset alarm threshold value. When the predicted value is greater than or equal to the preset alarm threshold value, an alarm is issued and the distillation tower is automatically regulated. After three consecutive alarms, the risk elimination plan is automatically started. After the risk is eliminated, a maintenance request is sent to the distillation tower maintenance department.
精馏塔检修模块：在接收到检修请求后安排维护人员对精馏塔进行异常检验，记录检验结果并在确定异常时执行异常修复任务，基于检修结果计算运行周期内危险预测准确率和平均异常修复效率；Distillation tower maintenance module: After receiving the maintenance request, the maintenance personnel are arranged to perform abnormal inspection on the distillation tower, record the inspection results and perform abnormal repair tasks when abnormalities are confirmed. Based on the maintenance results, the hazard prediction accuracy and average abnormal repair efficiency within the operation cycle are calculated;
精馏塔运行质量评估模块：统计精馏塔运行周期内精馏塔危险事件的发生次数计算危险事件发生率，基于精馏塔运行周期内危险预测准确率、维护效率以及危险事件发生率计算运行质量指数；Distillation tower operation quality assessment module: Count the number of dangerous events in the distillation tower during the operation cycle of the distillation tower and calculate the dangerous event incidence rate, and calculate the operation quality index based on the hazard prediction accuracy, maintenance efficiency and dangerous event incidence rate during the operation cycle of the distillation tower;
数据库：用于储存系统中所有模块的数据信息。Database: used to store data information of all modules in the system.
优选的，精馏塔运行实时监测模块包括多点数据检测单元、数据波动时间线整合单元以及检测数据输出单元，多点数据检测单元通过布置的流量传感器检测原料液的摩尔流量Fma、回流液的摩尔流量Lma、馏出液的摩尔流量Dma，以及釜残液的摩尔流量Wma，通过布置的压力传感器检测塔顶压力Pda和塔底压力Pfa，通过布置的液位传感器检测塔底液位Zda和回流罐处液位Zha，通过布置的温度传感器检测塔顶温度Tda和塔底温度Tfa，通过设置的料液成分检测计检测原料液中易挥发组分的摩尔分数XFa、馏出液中易挥发组分的摩尔分数XDa以及釜残液中易挥发组分的摩尔分数XWa；数据波动时间线整合单元将数据波动时间按照顺序进行排列，将每一个波动时间点同时刻的多点数据检测单元检测出的数据标记为同时间点数据；检测数据输出单元将检测出的精馏塔实时运行数据发送至基础运行参数对照检验模块和塔内运行数据分析模块。Preferably, the real-time monitoring module for the operation of the distillation tower includes a multi-point data detection unit, a data fluctuation timeline integration unit and a detection data output unit. The multi-point data detection unit detects the molar flow rate Fma of the raw liquid, the molar flow rate Lma of the reflux liquid, the molar flow rate Dma of the distillate, and the molar flow rate Wma of the residual liquid through the arranged flow sensors, detects the tower top pressure Pda and the tower bottom pressure Pfa through the arranged pressure sensors, detects the tower bottom liquid level Zda and the liquid level Zha at the reflux tank through the arranged liquid level sensors, detects the tower top temperature Tda and the tower bottom temperature Tfa through the arranged temperature sensors, and detects the molar fraction XFa of the volatile component in the raw liquid, the molar fraction XDa of the volatile component in the distillate, and the molar fraction XWa of the volatile component in the residual liquid through the arranged feed liquid component detector. The data fluctuation timeline integration unit arranges the data fluctuation time in sequence, and marks the data detected by the multi-point data detection unit at each fluctuation time point as data at the same time point; the detection data output unit sends the detected real-time operation data of the distillation tower to the basic operation parameter comparison and inspection module and the in-tower operation data analysis module.
优选的，基础运行参数对照检验模块包括实时运行数据接收单元、标准基础运行参数调取单元、压力对照单元、温度对照单元、液位对照单元、基础运行参数综合偏移率计算单元，以及计算结果输出单元，实时运行数据接收单元用于接收检测出的精馏塔实时运行数据；标准基础运行参数调取单元用于调取工艺生产方案中规定的精馏塔塔顶压力Pdb、塔底压力Pfb、塔顶温度Tdb、塔底温度Tfb、塔底液位Zdb，以及回流罐液位Zhb；压力对照单元将精馏塔实时压力与规定压力进行对照计算运行压力偏移率θP，具体公式为：温度对照单元将精馏塔实时温度与规定温度进行对照计算运行温度偏移率θT，具体公式为：液位对照单元将精馏塔实时液位与规定液位进行对照计算运行液位偏移率θZ，具体公式为：基础运行参数综合偏移率计算单元计算基础运行参数综合偏移率θYC的具体公式为：θYC＝θP+θT+θZ；计算结果输出单元将计算出的基础运行参数综合偏移率发送至精馏塔运行危险预测模块。Preferably, the basic operation parameter comparison and inspection module includes a real-time operation data receiving unit, a standard basic operation parameter retrieval unit, a pressure comparison unit, a temperature comparison unit, a liquid level comparison unit, a basic operation parameter comprehensive deviation rate calculation unit, and a calculation result output unit. The real-time operation data receiving unit is used to receive the detected real-time operation data of the distillation tower; the standard basic operation parameter retrieval unit is used to retrieve the distillation tower top pressure Pdb , tower bottom pressure Pfb , tower top temperature Tdb , tower bottom temperature Tfb , tower bottom liquid level Zdb , and reflux tank liquid level Zhb specified in the process production plan; the pressure comparison unit compares the real-time pressure of the distillation tower with the specified pressure to calculate the operation pressure deviation rate θP , and the specific formula is: The temperature control unit compares the real-time temperature of the distillation tower with the specified temperature to calculate the operating temperature deviation rate θT . The specific formula is: The liquid level control unit compares the real-time liquid level of the distillation tower with the specified liquid level to calculate the operating liquid level deviation rate θZ . The specific formula is: The basic operation parameter comprehensive deviation rate calculation unit calculates the basic operation parameter comprehensive deviation rate θYC using the specific formula: θYC =θP +θT +θZ ; the calculation result output unit sends the calculated basic operation parameter comprehensive deviation rate to the distillation tower operation risk prediction module.
优选的，塔内运行数据分析模块包括实时运行数据接收单元、工艺设计参数调取单元、实时工艺计算单元、工艺设计参数对照单元、运行工艺偏移率计算单元，以及数据输出单元，实时运行数据接收单元用于接收检测出的精馏塔实时运行数据；工艺设计参数调取单元用于调取工艺生产方案中设计的回流比Rb与全塔效率Nb；实时工艺计算单元基于回流液的摩尔流量和馏出液的摩尔流量计算实际回流比Ra，具体公式为：基于原料液中易挥发组分的摩尔分数、馏出液中易挥发组分的摩尔分数以及釜残液中易挥发组分的摩尔分数计算实际全塔效率Na，具体公式为：基于原料液的摩尔流量、馏出液的摩尔流量，以及釜残液的摩尔流量计算全塔物料损失系数αm，具体公式为：基于原料液的摩尔流量、馏出液的摩尔流量，以及釜残液的摩尔流量、原料液中易挥发组分的摩尔分数、馏出液中易挥发组分的摩尔分数以及釜残液中易挥发组分的摩尔分数计算易挥发组分损失系数αX，具体公式为：工艺设计参数对照单元将计算出的实际回流比和实际全塔效率与工艺生产方案中设计的回流比和全塔效率进行对比计算回流比偏移率θR和全塔效率匹配度γN，具体公式如下：运行工艺偏移率计算单元计算运行工艺偏移率θGY的具体公式为：数据输出单元将计算出的运行工艺偏移率发送至精馏塔运行危险预测模块。Preferably, the tower operation data analysis module includes a real-time operation data receiving unit, a process design parameter retrieval unit, a real-time process calculation unit, a process design parameter comparison unit, an operation process deviation rate calculation unit, and a data output unit. The real-time operation data receiving unit is used to receive the detected real-time operation data of the distillation tower; the process design parameter retrieval unit is used to retrieve the reflux ratio Rb and the whole tower efficiency Nb designed in the process production plan; the real-time process calculation unit calculates the actual reflux ratio Ra based on the molar flow rate of the reflux liquid and the molar flow rate of the distillate. The specific formula is: The actual total tower efficiencyNa is calculated based on the mole fraction of the volatile components in the raw liquid, the mole fraction of the volatile components in the distillate, and the mole fraction of the volatile components in the kettle residue. The specific formula is: The material loss coefficient αm of the whole tower is calculated based on the molar flow rate of the raw liquid, the molar flow rate of the distillate, and the molar flow rate of the residual liquid in the kettle. The specific formula is: The volatile component loss coefficient α X is calculated based on the molar flow rate of the raw liquid, the molar flow rate of the distillate, the molar flow rate of the still residue, the molar fraction of the volatile component in the raw liquid, the molar fraction of the volatile component in the distillate, and the molarfraction of the volatile component in the still residue. The specific formula is: The process design parameter comparison unit compares the calculated actual reflux ratio and actual full-tower efficiency with the reflux ratio and full-tower efficiency designed in the process production plan to calculate the reflux ratio deviation rate θR and the full-tower efficiency matching degree γN . The specific formula is as follows: The specific formula for calculating the operating process deviation rate θGY by the operating process deviation rate calculation unit is: The data output unit sends the calculated operation process deviation rate to the distillation tower operation risk prediction module.
优选的，精馏塔运行危险预测模块基于基础运行参数综合偏移率和运行工艺偏移率预测精馏塔运行的运行危险系数αYW的具体公式为：a1、a2分别为基础运行参数综合偏移率和运行工艺偏移率的权重，a2>a1>0。Preferably, the specific formula for the distillation tower operation risk prediction module to predict the operation risk coefficient αYW of the distillation tower operation based on the basic operation parameter comprehensive deviation rate and the operation process deviation rate is: a1 and a2 are the weights of the comprehensive deviation rate of basic operating parameters and the deviation rate of operating process, respectively, and a2 >a1 >0.
优选的，精馏塔检修模块包括检修请求信息接收单元、精馏塔异常检验单元、检验结果记录单元、精馏塔异常修复单元、异常修复数据记录单元、检修数据处理单元，以及计算结果输出单元，检修请求信息接收单元用于接收检修请求信息；精馏塔异常检验单元用于检验精馏塔是否存在异常，存在异常则危险预测正确，反之则危险预测错误；检验结果记录单元用于记录检验出的异常源头位置、异常源头的数量、危险预测正确次数，以及危险预测错误次数；精馏塔异常修复单元在确定异常源头位置后对异常源头进行修复；异常修复数据记录单元用于记录异常修复所需时长；检修数据处理单元基于运行周期内危险预测正确次数myz和危险预测错误次数myc计算危险预测准确率βwy，具体公式为：基于运行周期内第i次异常修复时异常源头的数量myai和异常修复时长tyxi计算平均异常修复效率βyxe，具体公式为：nyx为运行周期内异常修复次数；计算结果输出单元将计算出的危险预测准确率和平均异常修复效率发送至精馏塔运行质量评估模块。Preferably, the distillation tower maintenance module includes a maintenance request information receiving unit, a distillation tower abnormality inspection unit, a inspection result recording unit, a distillation tower abnormality repair unit, an abnormality repair data recording unit, a maintenance data processing unit, and a calculation result output unit. The maintenance request information receiving unit is used to receive maintenance request information; the distillation tower abnormality inspection unit is used to inspect whether the distillation tower has an abnormality. If there is an abnormality, the hazard prediction is correct, otherwise the hazard prediction is wrong; the inspection result recording unit is used to record the detected abnormal source location, the number of abnormal sources, the number of correct hazard predictions, and the number of incorrect hazard predictions; the distillation tower abnormality repair unit repairs the abnormal source after determining the location of the abnormal source; the abnormality repair data recording unit is used to record the time required for abnormal repair; the maintenance data processing unit calculates the hazard prediction accuracy βwy based on the number of correct hazard predictionsmyz and the number of incorrect hazard predictionsmyc during the operation cycle, and the specific formula is: The average anomaly repair efficiency βyxe is calculated based on the number of anomaly sources myai and the anomaly repair time tyxi during the i-th anomaly repair in the operation cycle. The specific formula is: nyx is the number of abnormal repairs within the operation cycle; the calculation result output unit sends the calculated danger prediction accuracy and average abnormal repair efficiency to the distillation tower operation quality evaluation module.
优选的，精馏塔运行质量评估模块包括数据接收单元、精馏塔危险事件统计单元、危险事件发生率计算单元，以及运行质量指数计算单元，数据接收单元用于接收危险预测准确率和平均异常修复效率；精馏塔危险事件统计单元用于统计精馏塔运行周期内危险事件的发生次数；危险事件发生率计算单元基于精馏塔运行周期内危险事件的发生次数mwf和精馏塔运行周期ty计算危险事件发生率βwf的具体公式为：运行质量指数计算单元基于精馏塔运行周期内危险预测准确率、维护效率以及危险事件发生率计算运行质量指数QYZ的具体公式为：e为自然常数。Preferably, the distillation tower operation quality assessment module includes a data receiving unit, a distillation tower dangerous event statistics unit, a dangerous event occurrence rate calculation unit, and an operation quality index calculation unit. The data receiving unit is used to receive the danger prediction accuracy and the average abnormal repair efficiency; the distillation tower dangerous event statistics unit is used to count the number of dangerous events in the distillation tower operation cycle; the dangerous event occurrence rate calculation unit calculates the dangerous event occurrence rate βwf based on the number of dangerous events in the distillation tower operation cycle mwf and the distillation tower operation cyclety. The specific formula is: The specific formula for calculating the operation quality index QYZ by the operation quality index calculation unit based on the hazard prediction accuracy, maintenance efficiency and the occurrence rate of dangerous events during the operation cycle of the distillation tower is: e is a natural constant.
本发明的技术效果和优点：Technical effects and advantages of the present invention:
1、本发明设置基础运行参数对照检验模块将接收到的精馏塔运行压力、温度以及液位数据与工艺生产方案中规定的精馏塔运行压力、温度以及液位进行对照检验基础运行参数是否偏离并计算基础运行参数综合偏移率，能够直观展现基础运行参数的偏离情况，为后续精馏塔的运行危险预测提供了数据支撑；设置塔内运行数据分析模块基于接收到的数据分别计算实际回流比、实际全塔效率、全塔物料损失系数、易挥发组分损失系数，将计算出的实际回流比、实际全塔效率与工艺生产方案中设计的回流比和全塔效率进行对比计算回流比偏移率和全塔效率匹配度，基于全塔物料丢失系数、易挥发组分丢失系数、回流比偏移率，以及全塔效率匹配度计算运行工艺偏移率，直观展现了运行工艺参数的偏离情况，扩大了监测范围，有利于提高精馏塔运行安全监测的可靠性、全面性，同时也为后续精馏塔的运行危险预测提供了数据支撑。1. The present invention sets a basic operating parameter comparison and inspection module to compare the received distillation tower operating pressure, temperature and liquid level data with the distillation tower operating pressure, temperature and liquid level specified in the process production plan to check whether the basic operating parameters deviate and calculate the comprehensive deviation rate of the basic operating parameters, which can intuitively display the deviation of the basic operating parameters and provide data support for the subsequent operation risk prediction of the distillation tower; the tower operation data analysis module is set to calculate the actual reflux ratio, the actual full tower efficiency, the full tower material loss coefficient, and the volatile component loss coefficient based on the received data, and compare the calculated actual reflux ratio and the actual full tower efficiency with the reflux ratio and the full tower efficiency designed in the process production plan to calculate the reflux ratio deviation rate and the full tower efficiency matching degree, and calculate the operation process deviation rate based on the full tower material loss coefficient, the volatile component loss coefficient, the reflux ratio deviation rate, and the full tower efficiency matching degree. The deviation of the operation process parameters is intuitively displayed, the monitoring range is expanded, which is conducive to improving the reliability and comprehensiveness of the distillation tower operation safety monitoring, and also provides data support for the subsequent operation risk prediction of the distillation tower.
2、本发明设置精馏塔运行危险预测模块基于基础运行参数综合偏移率和运行工艺偏移率预测精馏塔运行的运行危险系数设置自动报警模块将预测出的运行危险系数与预设报警临界值进行比较，预测值大于或等于预设报警临界值时发出警报并自动对精馏塔进行调控，在连续三次报警后自动启动危险清除方案，待危险清除完毕后向精馏塔维护部门发送检修请求，能够在一定程度上降低精馏塔内偶然性参数波动带来的运行危险系数超限的情况，有利于提高精馏塔检修维护的准确率，在一定程度上降低了精馏塔不必要停工检修情况。2. The present invention sets up a distillation tower operation hazard prediction module, which predicts the operation hazard coefficient of the distillation tower based on the comprehensive deviation rate of basic operation parameters and the operation process deviation rate, and sets an automatic alarm module to compare the predicted operation hazard coefficient with a preset alarm critical value. When the predicted value is greater than or equal to the preset alarm critical value, an alarm is issued and the distillation tower is automatically regulated. After three consecutive alarms, the hazard elimination plan is automatically started, and a maintenance request is sent to the distillation tower maintenance department after the hazard is eliminated. This can reduce the situation of excessive operation hazard coefficient caused by accidental parameter fluctuations in the distillation tower to a certain extent, which is beneficial to improving the accuracy of the overhaul and maintenance of the distillation tower, and reduces the unnecessary shutdown of the distillation tower for maintenance to a certain extent.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
图1为本发明的系统结构框图。FIG1 is a system structure block diagram of the present invention.
图2为本发明的系统运行流程图。FIG. 2 is a flow chart of the system operation of the present invention.
具体实施方式DETAILED DESCRIPTION
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整的描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.
如图1所示本实施例提供一种精馏塔安全运行监测系统，包括传感器布置模块、精馏塔运行实时监测模块、基础运行参数对照检验模块、塔内运行数据分析模块、精馏塔运行危险预测模块、自动报警模块、精馏塔检修模块、精馏塔运行质量评估模块，以及数据库，传感器布置模块与精馏塔运行实时监测模块连接，精馏塔运行实时监测模块与基础运行参数对照检验模块、塔内运行数据分析模块连接，基础运行参数对照检验模块、塔内运行数据分析模块与精馏塔运行危险预测模块连接，精馏塔运行危险预测模块、自动报警模块、精馏塔检修模块、精馏塔运行质量评估模块顺序连接，系统中所有模块均与数据库连接。As shown in Figure 1, this embodiment provides a distillation tower safe operation monitoring system, including a sensor layout module, a distillation tower operation real-time monitoring module, a basic operation parameter comparison and inspection module, an in-tower operation data analysis module, a distillation tower operation risk prediction module, an automatic alarm module, a distillation tower maintenance module, a distillation tower operation quality assessment module, and a database. The sensor layout module is connected to the distillation tower operation real-time monitoring module, the distillation tower operation real-time monitoring module is connected to the basic operation parameter comparison and inspection module and the in-tower operation data analysis module, the basic operation parameter comparison and inspection module and the in-tower operation data analysis module are connected to the distillation tower operation risk prediction module, the distillation tower operation risk prediction module, the automatic alarm module, the distillation tower maintenance module, and the distillation tower operation quality assessment module are connected in sequence, and all modules in the system are connected to the database.
所述传感器布置模块用于布置流量传感器、压力传感器、液位传感器、温度传感器，以及料液成分检测计对应的流量检测位点、压力检测位点、液位检测位点、温度检测位点，以及料液成分检测位点。The sensor arrangement module is used to arrange flow sensors, pressure sensors, liquid level sensors, temperature sensors, and flow detection sites, pressure detection sites, liquid level detection sites, temperature detection sites, and liquid composition detection sites corresponding to the liquid composition detector.
本实施例中具体需要说明的是，所述传感器布置模块中布置的流量检测位点包括原料液入口、回流液入口、塔顶馏出液出口，以及塔底残液出口；设置的压力检测位点包括塔顶和塔底；设置的液位检测位点为塔底和回流罐处；设置的温度检测位点包括塔顶和塔底；设置的料液成分监测位点包括原料液进口、塔顶馏出液出口以及塔底残液出口。What needs to be specifically explained in this embodiment is that the flow detection sites arranged in the sensor arrangement module include the raw liquid inlet, the reflux liquid inlet, the top distillate outlet, and the bottom residual liquid outlet; the set pressure detection sites include the top and the bottom; the set liquid level detection sites are the bottom and the reflux tank; the set temperature detection sites include the top and the bottom; the set liquid composition monitoring sites include the raw liquid inlet, the top distillate outlet and the bottom residual liquid outlet.
所述精馏塔运行实时监测模块通过布置的传感器实时监测精馏塔的运行并将检测出的精馏塔实时运行数据发送至基础运行参数对照检验模块和塔内运行数据分析模块。The real-time monitoring module for distillation tower operation monitors the operation of the distillation tower in real time through arranged sensors and sends the detected real-time operation data of the distillation tower to the basic operation parameter comparison and inspection module and the in-tower operation data analysis module.
进一步，所述精馏塔运行实时监测模块包括多点数据检测单元、数据波动时间线整合单元以及检测数据输出单元，多点数据检测单元通过布置的流量传感器检测原料液的摩尔流量Fma、回流液的摩尔流量Lma、馏出液的摩尔流量Dma，以及釜残液的摩尔流量Wma，通过布置的压力传感器检测塔顶压力Pda和塔底压力Pfa，通过布置的液位传感器检测塔底液位Zda和回流罐处液位Zha，通过布置的温度传感器检测塔顶温度Tda和塔底温度Tfa，通过设置的料液成分检测计检测原料液中易挥发组分的摩尔分数XFa、馏出液中易挥发组分的摩尔分数XDa以及釜残液中易挥发组分的摩尔分数XWa；数据波动时间线整合单元将数据波动时间按照顺序进行排列，将每一个波动时间点同时刻的多点数据检测单元检测出的数据标记为同时间点数据；检测数据输出单元将检测出的精馏塔实时运行数据发送至基础运行参数对照检验模块和塔内运行数据分析模块。Further, the real-time monitoring module for the operation of the distillation tower includes a multi-point data detection unit, a data fluctuation timeline integration unit and a detection data output unit. The multi-point data detection unit detects the molar flow rate Fma of the raw liquid, the molar flow rate Lma of the reflux liquid, the molar flow rate Dma of the distillate, and the molar flow rate Wma of the residual liquid through the arranged flow sensors, detects the tower top pressure Pda and the tower bottom pressure Pfa through the arranged pressure sensors, detects the tower bottom liquid level Zda and the liquid level Zha at the reflux tank through the arranged liquid level sensors, detects the tower top temperature Tda and the tower bottom temperature Tfa through the arranged temperature sensors, and detects the molar fraction XFa of the volatile component in the raw liquid, the molar fraction XDa of the volatile component in the distillate, and the molar fraction XWa of the volatile component in the residual liquid through the arranged feed liquid component detector. The data fluctuation timeline integration unit arranges the data fluctuation time in sequence, and marks the data detected by the multi-point data detection unit at each fluctuation time point as data at the same time point; the detection data output unit sends the detected real-time operation data of the distillation tower to the basic operation parameter comparison and inspection module and the in-tower operation data analysis module.
所述基础运行参数对照检验模块将接收到的精馏塔运行压力、温度以及液位数据与工艺生产方案中规定的精馏塔运行压力、温度以及液位进行对照检验基础运行参数是否偏离并计算基础运行参数综合偏移率。The basic operating parameter comparison and verification module compares the received distillation tower operating pressure, temperature and liquid level data with the distillation tower operating pressure, temperature and liquid level specified in the process production plan to check whether the basic operating parameters deviate and calculate the comprehensive deviation rate of the basic operating parameters.
进一步，所述基础运行参数对照检验模块包括实时运行数据接收单元、标准基础运行参数调取单元、压力对照单元、温度对照单元、液位对照单元、基础运行参数综合偏移率计算单元，以及计算结果输出单元，实时运行数据接收单元用于接收检测出的精馏塔实时运行数据；标准基础运行参数调取单元用于调取工艺生产方案中规定的精馏塔塔顶压力Pdb、塔底压力Pfb、塔顶温度Tdb、塔底温度Tfb、塔底液位Zdb，以及回流罐液位Zhb；压力对照单元将精馏塔实时压力与规定压力进行对照计算运行压力偏移率θP，具体公式为：温度对照单元将精馏塔实时温度与规定温度进行对照计算运行温度偏移率θT，具体公式为：液位对照单元将精馏塔实时液位与规定液位进行对照计算运行液位偏移率θZ，具体公式为：基础运行参数综合偏移率计算单元计算基础运行参数综合偏移率θYC的具体公式为：θYC＝θP+θT+θZ；计算结果输出单元将计算出的基础运行参数综合偏移率发送至精馏塔运行危险预测模块。Further, the basic operation parameter comparison and inspection module includes a real-time operation data receiving unit, a standard basic operation parameter retrieval unit, a pressure comparison unit, a temperature comparison unit, a liquid level comparison unit, a basic operation parameter comprehensive deviation rate calculation unit, and a calculation result output unit. The real-time operation data receiving unit is used to receive the detected real-time operation data of the distillation tower; the standard basic operation parameter retrieval unit is used to retrieve the distillation tower top pressure Pdb , tower bottom pressure Pfb , tower top temperature Tdb , tower bottom temperature Tfb , tower bottom liquid level Zdb , and reflux tank liquid level Zhb specified in the process production plan; the pressure comparison unit compares the real-time pressure of the distillation tower with the specified pressure to calculate the operation pressure deviation rate θP , and the specific formula is: The temperature control unit compares the real-time temperature of the distillation tower with the specified temperature to calculate the operating temperature deviation rate θT . The specific formula is: The liquid level control unit compares the real-time liquid level of the distillation tower with the specified liquid level to calculate the operating liquid level deviation rate θZ . The specific formula is: The basic operation parameter comprehensive deviation rate calculation unit calculates the basic operation parameter comprehensive deviation rate θYC using the specific formula: θYC =θP +θT +θZ ; the calculation result output unit sends the calculated basic operation parameter comprehensive deviation rate to the distillation tower operation risk prediction module.
所述塔内运行数据分析模块基于接收到的数据分别计算实际回流比、实际全塔效率、全塔物料损失系数、易挥发组分损失系数，将计算出的实际回流比、实际全塔效率与工艺生产方案中设计的回流比和全塔效率进行对比计算回流比偏移率和全塔效率匹配度，基于全塔物料丢失系数、易挥发组分丢失系数、回流比偏移率，以及全塔效率匹配度计算运行工艺偏移率。The tower operation data analysis module calculates the actual reflux ratio, actual whole-tower efficiency, whole-tower material loss coefficient, and volatile component loss coefficient based on the received data, compares the calculated actual reflux ratio and actual whole-tower efficiency with the reflux ratio and whole-tower efficiency designed in the process production plan, calculates the reflux ratio deviation rate and the whole-tower efficiency matching degree, and calculates the operation process deviation rate based on the whole-tower material loss coefficient, volatile component loss coefficient, reflux ratio deviation rate, and the whole-tower efficiency matching degree.
进一步，所述塔内运行数据分析模块包括实时运行数据接收单元、工艺设计参数调取单元、实时工艺计算单元、工艺设计参数对照单元、运行工艺偏移率计算单元，以及数据输出单元，实时运行数据接收单元用于接收检测出的精馏塔实时运行数据；工艺设计参数调取单元用于调取工艺生产方案中设计的回流比Rb与全塔效率Nb；实时工艺计算单元基于回流液的摩尔流量和馏出液的摩尔流量计算实际回流比Ra，具体公式为：基于原料液中易挥发组分的摩尔分数、馏出液中易挥发组分的摩尔分数以及釜残液中易挥发组分的摩尔分数计算实际全塔效率Na，具体公式为：基于原料液的摩尔流量、馏出液的摩尔流量，以及釜残液的摩尔流量计算全塔物料损失系数αm，具体公式为：基于原料液的摩尔流量、馏出液的摩尔流量，以及釜残液的摩尔流量、原料液中易挥发组分的摩尔分数、馏出液中易挥发组分的摩尔分数以及釜残液中易挥发组分的摩尔分数计算易挥发组分损失系数αX，具体公式为：工艺设计参数对照单元将计算出的实际回流比和实际全塔效率与工艺生产方案中设计的回流比和全塔效率进行对比计算回流比偏移率θR和全塔效率匹配度γN，具体公式如下：运行工艺偏移率计算单元计算运行工艺偏移率θGY的具体公式为：数据输出单元将计算出的运行工艺偏移率发送至精馏塔运行危险预测模块。Furthermore, the tower operation data analysis module includes a real-time operation data receiving unit, a process design parameter retrieval unit, a real-time process calculation unit, a process design parameter comparison unit, an operation process deviation rate calculation unit, and a data output unit. The real-time operation data receiving unit is used to receive the detected real-time operation data of the distillation tower; the process design parameter retrieval unit is used to retrieve the reflux ratio Rb and the whole tower efficiency Nb designed in the process production plan; the real-time process calculation unit calculates the actual reflux ratio Ra based on the molar flow rate of the reflux liquid and the molar flow rate of the distillate. The specific formula is: The actual total tower efficiencyNa is calculated based on the mole fraction of the volatile components in the raw liquid, the mole fraction of the volatile components in the distillate, and the mole fraction of the volatile components in the kettle residue. The specific formula is: The material loss coefficient αm of the whole tower is calculated based on the molar flow rate of the raw liquid, the molar flow rate of the distillate, and the molar flow rate of the residual liquid in the kettle. The specific formula is: The volatile component loss coefficient α X is calculated based on the molar flow rate of the raw liquid, the molar flow rate of the distillate, the molar flow rate of the still residue, the molar fraction of the volatile component in the raw liquid, the molar fraction of the volatile component in the distillate, and the molarfraction of the volatile component in the still residue. The specific formula is: The process design parameter comparison unit compares the calculated actual reflux ratio and actual full-tower efficiency with the reflux ratio and full-tower efficiency designed in the process production plan to calculate the reflux ratio deviation rate θR and the full-tower efficiency matching degree γN . The specific formula is as follows: The specific formula for calculating the operating process deviation rate θGY by the operating process deviation rate calculation unit is: The data output unit sends the calculated operation process deviation rate to the distillation tower operation risk prediction module.
所述精馏塔运行危险预测模块基于基础运行参数综合偏移率和运行工艺偏移率预测精馏塔运行的运行危险系数。The distillation tower operation risk prediction module predicts the operation risk coefficient of the distillation tower operation based on the comprehensive deviation rate of basic operation parameters and the operation process deviation rate.
进一步，所述精馏塔运行危险预测模块基于基础运行参数综合偏移率和运行工艺偏移率预测精馏塔运行的运行危险系数αYW的具体公式为：a1、a2分别为基础运行参数综合偏移率和运行工艺偏移率的权重，a2>a1>0。Further, the specific formula for the distillation tower operation risk prediction module to predict the operation risk coefficient αYW of the distillation tower operation based on the basic operation parameter comprehensive deviation rate and the operation process deviation rate is: a1 and a2 are the weights of the comprehensive deviation rate of basic operating parameters and the deviation rate of operating process, respectively, and a2 >a1 >0.
所述自动报警模块将预测出的运行危险系数与预设报警临界值进行比较，预测值大于或等于预设报警临界值时发出警报并自动对精馏塔进行调控，在连续三次报警后自动启动危险清除方案，待危险清除完毕后向精馏塔维护部门发送检修请求。The automatic alarm module compares the predicted operating risk factor with the preset alarm critical value. When the predicted value is greater than or equal to the preset alarm critical value, an alarm is issued and the distillation tower is automatically regulated. After three consecutive alarms, the risk elimination plan is automatically started, and a maintenance request is sent to the distillation tower maintenance department after the risk is eliminated.
所述精馏塔检修模块在接收到检修请求后安排维护人员对精馏塔进行异常检验，记录检验结果并在确定异常时执行异常修复任务，基于检修结果计算运行周期内危险预测准确率和平均异常修复效率。After receiving the maintenance request, the distillation tower maintenance module arranges maintenance personnel to perform abnormal inspection on the distillation tower, records the inspection results and executes abnormal repair tasks when abnormalities are determined, and calculates the hazard prediction accuracy and average abnormal repair efficiency within the operation cycle based on the maintenance results.
进一步，所述精馏塔检修模块包括检修请求信息接收单元、精馏塔异常检验单元、检验结果记录单元、精馏塔异常修复单元、异常修复数据记录单元、检修数据处理单元，以及计算结果输出单元，检修请求信息接收单元用于接收检修请求信息；精馏塔异常检验单元用于检验精馏塔是否存在异常，存在异常则危险预测正确，反之则危险预测错误；检验结果记录单元用于记录检验出的异常源头位置、异常源头的数量、危险预测正确次数，以及危险预测错误次数；精馏塔异常修复单元在确定异常源头位置后对异常源头进行修复；异常修复数据记录单元用于记录异常修复所需时长；检修数据处理单元基于运行周期内危险预测正确次数myz和危险预测错误次数myc计算危险预测准确率βwy，具体公式为：基于运行周期内第i次异常修复时异常源头的数量myai和异常修复时长tyxi计算平均异常修复效率βyxe，具体公式为：nyx为运行周期内异常修复次数；计算结果输出单元将计算出的危险预测准确率和平均异常修复效率发送至精馏塔运行质量评估模块。Further, the distillation tower maintenance module includes a maintenance request information receiving unit, a distillation tower abnormality inspection unit, a inspection result recording unit, a distillation tower abnormality repair unit, an abnormality repair data recording unit, a maintenance data processing unit, and a calculation result output unit. The maintenance request information receiving unit is used to receive maintenance request information; the distillation tower abnormality inspection unit is used to inspect whether the distillation tower has an abnormality. If there is an abnormality, the hazard prediction is correct, otherwise the hazard prediction is wrong; the inspection result recording unit is used to record the detected abnormal source location, the number of abnormal sources, the number of correct hazard predictions, and the number of incorrect hazard predictions; the distillation tower abnormality repair unit repairs the abnormal source after determining the abnormal source location; the abnormality repair data recording unit is used to record the time required for abnormal repair; the maintenance data processing unit calculates the hazard prediction accuracy βwy based on the number of correct hazard predictionsmyz and the number of incorrect hazard predictionsmyc in the operation cycle, and the specific formula is: The average anomaly repair efficiency βyxe is calculated based on the number of anomaly sources myai and the anomaly repair time tyxi during the i-th anomaly repair in the operation cycle. The specific formula is: nyx is the number of abnormal repairs within the operation cycle; the calculation result output unit sends the calculated danger prediction accuracy and average abnormal repair efficiency to the distillation tower operation quality evaluation module.
所述精馏塔运行质量评估模块统计精馏塔运行周期内精馏塔危险事件的发生次数计算危险事件发生率，基于精馏塔运行周期内危险预测准确率、维护效率以及危险事件发生率计算运行质量指数。The distillation tower operation quality assessment module calculates the occurrence rate of dangerous events by counting the number of dangerous events during the distillation tower operation cycle, and calculates the operation quality index based on the hazard prediction accuracy, maintenance efficiency and dangerous event occurrence rate during the distillation tower operation cycle.
进一步，所述精馏塔运行质量评估模块包括数据接收单元、精馏塔危险事件统计单元、危险事件发生率计算单元，以及运行质量指数计算单元，数据接收单元用于接收危险预测准确率和平均异常修复效率；精馏塔危险事件统计单元用于统计精馏塔运行周期内危险事件的发生次数；危险事件发生率计算单元基于精馏塔运行周期内危险事件的发生次数mwf和精馏塔运行周期ty计算危险事件发生率βwf的具体公式为：运行质量指数计算单元基于精馏塔运行周期内危险预测准确率、维护效率以及危险事件发生率计算运行质量指数QYZ的具体公式为：e为自然常数。Further, the distillation tower operation quality assessment module includes a data receiving unit, a distillation tower dangerous event statistics unit, a dangerous event occurrence rate calculation unit, and an operation quality index calculation unit. The data receiving unit is used to receive the danger prediction accuracy and the average abnormal repair efficiency; the distillation tower dangerous event statistics unit is used to count the number of dangerous events in the distillation tower operation cycle; the dangerous event occurrence rate calculation unit calculates the dangerous event occurrence rate βwf based on the number of dangerous events in the distillation tower operation cycle mwf and the distillation tower operation cyclety. The specific formula is: The specific formula for calculating the operation quality index QYZ by the operation quality index calculation unit based on the hazard prediction accuracy, maintenance efficiency and the occurrence rate of dangerous events during the operation cycle of the distillation tower is: e is a natural constant.
本实施例中具体需要说明的是，危险事件包括爆炸、泄漏、烫伤、设备故障、密封失效、设备断裂、操作失误，以及违规操作行为。It should be specifically noted in this embodiment that dangerous events include explosion, leakage, scalding, equipment failure, seal failure, equipment breakage, operating error, and illegal operating behavior.
所述数据库用于储存系统中所有模块的数据信息。The database is used to store data information of all modules in the system.
本实施例中具体需要说明的是，所用预设值、规定值以及权重均基于实际需要选取，不在此做具体取值限定。It should be specifically noted in this embodiment that the preset values, specified values and weights used are all selected based on actual needs and are not limited to specific values here.
如图2本实施例提供一种精馏塔安全运行监测系统的运行流程，包括以下步骤：As shown in FIG2 , this embodiment provides an operation flow of a distillation tower safe operation monitoring system, including the following steps:
S1：布置流量传感器、压力传感器、液位传感器、温度传感器，以及料液成分检测计对应的流量检测位点、压力检测位点、液位检测位点、温度检测位点，以及料液成分检测位点；S1: Arrange flow sensors, pressure sensors, liquid level sensors, temperature sensors, and flow detection sites, pressure detection sites, liquid level detection sites, temperature detection sites, and liquid composition detection sites corresponding to the liquid composition detector;
S2：通过布置的传感器实时监测精馏塔的运行；S2: Real-time monitoring of the operation of the distillation column through arranged sensors;
S3：将精馏塔运行压力、温度以及液位数据与工艺生产方案中规定的精馏塔运行压力、温度以及液位进行对照检验基础运行参数是否偏离并计算基础运行参数综合偏移率；S3: Compare the operating pressure, temperature and liquid level data of the distillation tower with the operating pressure, temperature and liquid level of the distillation tower specified in the process production plan to check whether the basic operating parameters deviate and calculate the comprehensive deviation rate of the basic operating parameters;
S4：分别计算实际回流比、实际全塔效率、全塔物料损失系数、易挥发组分损失系数，将计算出的实际回流比、实际全塔效率与工艺生产方案中设计的回流比和全塔效率进行对比计算回流比偏移率和全塔效率匹配度，基于全塔物料丢失系数、易挥发组分丢失系数、回流比偏移率，以及全塔效率匹配度计算运行工艺偏移率；S4: respectively calculating the actual reflux ratio, the actual whole-tower efficiency, the whole-tower material loss coefficient, and the volatile component loss coefficient, comparing the calculated actual reflux ratio and the actual whole-tower efficiency with the reflux ratio and the whole-tower efficiency designed in the process production plan to calculate the reflux ratio deviation rate and the whole-tower efficiency matching degree, and calculating the operating process deviation rate based on the whole-tower material loss coefficient, the volatile component loss coefficient, the reflux ratio deviation rate, and the whole-tower efficiency matching degree;
S5：基于基础运行参数综合偏移率和运行工艺偏移率预测精馏塔运行的运行危险系数；S5: Predict the operation risk factor of the distillation tower based on the comprehensive deviation rate of basic operation parameters and the deviation rate of operation process;
S6：将预测出的运行危险系数与预设报警临界值进行比较，预测值大于或等于预设报警临界值时发出警报并自动对精馏塔进行调控，在连续三次报警后自动启动危险清除方案，待危险清除完毕后向精馏塔维护部门发送检修请求；S6: Compare the predicted operation risk factor with the preset alarm threshold value. When the predicted value is greater than or equal to the preset alarm threshold value, an alarm is issued and the distillation tower is automatically regulated. After three consecutive alarms, the risk elimination plan is automatically started. After the risk is eliminated, a maintenance request is sent to the distillation tower maintenance department.
S7：在接收到检修请求后安排维护人员对精馏塔进行异常检验，记录检验结果并在确定异常时执行异常修复任务，基于检修结果计算运行周期内危险预测准确率和平均异常修复效率；S7: After receiving the maintenance request, arrange maintenance personnel to perform abnormal inspection on the distillation tower, record the inspection results and perform abnormal repair tasks when abnormalities are determined, and calculate the hazard prediction accuracy and average abnormal repair efficiency within the operation cycle based on the maintenance results;
S8：统计精馏塔运行周期内精馏塔危险事件的发生次数计算危险事件发生率，基于精馏塔运行周期内危险预测准确率、维护效率以及危险事件发生率计算运行质量指数。S8: Calculate the occurrence rate of dangerous events by counting the number of dangerous events that occur during the operation period of the distillation tower, and calculate the operation quality index based on the hazard prediction accuracy, maintenance efficiency and dangerous event occurrence rate during the operation period of the distillation tower.
最后：以上所述仅为本发明的优选实施例而已，并不用于限制本发明，凡在本发明的精神和原则之内，所做的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。Finally: 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, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.
| Application Number | Priority Date | Filing Date | Title |
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| CN202411682097.9ACN119185998B (en) | 2024-11-22 | 2024-11-22 | A distillation tower safe operation monitoring system |
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| CN202411682097.9ACN119185998B (en) | 2024-11-22 | 2024-11-22 | A distillation tower safe operation monitoring system |
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