CN103913282A - Leakage detection method for closed circulating water system of calcium carbide furnace - Google Patents
Leakage detection method for closed circulating water system of calcium carbide furnace Download PDFInfo
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Abstract
The invention discloses a leakage detection method for a closed circulating water system of a calcium carbide furnace. The method comprises the following steps that flow meters and thermometers are installed on cooling water return branch pipes of all equipment parts of the calcium carbide furnace to collect data in real time, and the change trend of flow and the change trend of temperature of all the branch pipes are recorded; a micro-differential pressure transmitter is arranged on the water supplement position of a high-level surge tank of the system to record the change trend of the liquid level; a dynamic alarm model between the change trend of the flow of the branch pipes and the change trend of the liquid level is established; alarm values of the trend difference of the flow of the branch pipes are synthesized to obtain alarm thresholds of the trend difference of the liquid level of the surge tank of different cycles, and leakage detection and positioning performed on the closed circulating water system of the calcium carbide furnace are completed according to the change trend of the flow and the change trend of the temperature of all the branch pipes. According to the leakage detection method for the closed circulating water system of the calcium carbide furnace, the number of the installed high-accuracy flow meters is greatly reduced, the leakage detection accuracy of the system is improved, the response speed is increased, and meanwhile system cost is effectively lowered. In this way, the leakage detection method provides a reliable guarantee for stable and safe production of calcium carbide furnaces.
Description
Technical field
The present invention relates to chemical industry technical field of smelting, relate in particular to a kind of for furnace of calcium carbide sealing and circulating water system leakage detection method.
Background technology
China is calcium carbide big producing country in the world at present, from 2002, in northwest, Xinjiang and Inner Mongol area successively established many large-scale calcium carbide production lines, in recent years, calcium carbide production technology is gradually from semi-hermetic type to closed transition, especially introduce super large closed calcium carbide furnace from Norway and Germany, the max cap. of the Inner Mongol of just having put into operation and Ningxia furnace of calcium carbide project reaches 81000kVA.Closed circle water system is with its less energy consumption, the features such as water stabilization are also along with the technology upgrading of calcium carbide industry, in the application of furnace of calcium carbide cooling system, obtain application gradually, but also there are at present many problems, wherein, what user was concerned about most is exactly closed calcium carbide furnace recirculated water cooling cover easy minute leakage in process of production, causes water to enter in furnace of calcium carbide, cause that in stove, Hydrogen Vapor Pressure increases, cause blast.
Existing furnace of calcium carbide closed circle water system, all installs high precision flow in the return branch of entering of every chilled water loop, enters the mode of circling water flow rate difference comparison by arm, carries out Leak Detection.This scheme is due to a large amount of high-precision meters that use, cost costliness, and in application, due to operating mode more complicated in furnace of calcium carbide operational process, furnace pressure, the control shakiness of temperature and gas all can cause part of appliance local temperature suddenly to raise, cause that arm partial water is vaporized, affect the reading value of instrument, due to position and the asynchronism(-nization) of vaporization generation, cause site error further to be expanded, and produce many false alarms, for reducing wrong report, alarm threshold value is set the often accumulation precision much larger than two instrument, and the monitoring of little leakage is difficult to realize, major safety risks while becoming furnace of calcium carbide operation.
Summary of the invention
The technical problem to be solved in the present invention is for defect of the prior art, provide a kind of for furnace of calcium carbide sealing and circulating water system leakage detection method, the method realizes the detection of system tiny leakage by detecting the SEA LEVEL VARIATION of buffer tank, can carry out the quick location of leakage point.
The technical solution adopted for the present invention to solve the technical problems is:
A kind of for furnace of calcium carbide sealing and circulating water system leakage detection method, the method comprises the following steps:
Step (1): each needs, in the chilled water return branch of cooling device parts, flowmeter and thermometer real-time data collection are installed at furnace of calcium carbide, and records the trend of each arm flow and temperature variation;
Step (2): the moisturizing position at the high-order buffer tank of system arranges differential pressure transmitter, records liquid level variation tendency; Remain between high liquid level and moisturizing water level by level switch control buffer tank liquid level;
Step (3): set up the dynamic warning model between arm fluctuations in discharge trend and liquid level variation tendency; Described dynamic warning model, with the poor associated buffer tank liquid level variation tendency of fluctuations in discharge trend, dynamically updates arm traffic trends difference alarming value;
Step (4): comprehensive arm traffic trends difference alarming value, obtains the buffer tank liquid level trend difference alarming threshold value of different cycles, and completes detection and location that furnace of calcium carbide closed circle water system is leaked according to the trend of each arm flow and temperature variation.
Press such scheme, the data acquisition of flowmeter described in step 1) and thermometer Real-time Collection is processed with Glitch Filter algorithm, then record the trend of each arm flow and temperature variation.
Press such scheme, furnace of calcium carbide described in step 1) each need cooling device parts to comprise calcium carbide furnace cover, tremie pipe, electrode brasses, petticoat pipe and fire door.
Press such scheme, adopt median filtering algorithm to process to the real-time data collection of differential pressure transmitter, then record liquid level variation tendency.
Press such scheme, described dynamic warning model is specific as follows:
(3.1): the poor computation period of initialization trend, filtering cycle multiple, arm difference in flow alarm threshold value and liquid level trend difference alarming threshold value; Wherein liquid level trend difference limen value is determined by accuracy of instrument;
(3.2): establishing current time is cycle initial time (0 moment), records current arm flow value and buffer tank level value, as history value;
(3.3): cycle timing arrives, by current arm flow value and buffer tank level value respectively with (3.2) step in history value do difference, preserve arm flow difference, if gained arm flow difference is less than the arm difference in flow alarm threshold value of setting in (3.1) step, jump to (3.2); Otherwise relatively liquid level trend difference, if liquid level difference is less than the liquid level trend difference alarming threshold value that (3.1) step is set this moment, goes to (3.4) step, if liquid level difference is greater than the liquid level trend difference alarming threshold value that (3.1) step is set this moment, jumps to (3.5) step;
Described cycle timing is a poor computation period time of trend;
(3.4): doubly several cycle length in filtering cycle of setting through step (3.1), history value in current buffer tank liquid level and step (3.2) is done to difference, the threshold value that step that if liquid level difference is still less than this moment (3.1) is set, with in (3.3) step the flow difference of preserving replace in (3.1) step and set alarm threshold value, as new difference in flow alarm threshold value, (3.3) in step, flow difference is clear 0, jumps to (3.2) step; Otherwise, go to (3.5) step;
(3.5): send arm leakage alarm signal, in (3.3) step, flow difference is clear 0, jumps to step (3.2).
Press such scheme, described step (4), taking an operation class as unit period, to the moment, is chosen the minimum value in the each arm trend difference alarming value obtaining in dynamic warning model in unit period, calculate and upgrade leakage rate detection reference value, i.e. per minute liquid level decline rate alarm threshold value; Taking reference value as reference, according to the length in poor sampling period of liquid level trend, the threshold value of leakage blowing out signals at different levels is set, and (sampling period is longer, accuracy of detection is higher, response time is longer), when buffer tank liquid level decline rate exceedes threshold value, send system leak blowing out signal.
The beneficial effect that the present invention produces is:
1. the present invention realizes the detection of system tiny leakage by detecting the SEA LEVEL VARIATION of buffer tank, and realizes in conjunction with the flowmeter of each cooling branch road water return pipeline the dynamic filter that operating mode is disturbed, and can carry out the quick location of leakage point.
2. the present invention has greatly reduced the installation quantity of high precision flow, in improving system leak accuracy of detection and response speed, effectively reduce system cost, and by the mode of characteristic model and software filtering, greatly reduce misreport of system rate, produce Reliable guarantee is provided for the stability and safety of furnace of calcium carbide.
Brief description of the drawings
Below in conjunction with drawings and Examples, the invention will be further described, in accompanying drawing:
Fig. 1 is the flow sheet of the embodiment of the present invention;
Fig. 2 is the buffer tank high precision liquid level gauge scheme of installation of the embodiment of the present invention;
Fig. 3 is the differential state warning of the arm traffic trends model process flow diagram of the embodiment of the present invention;
Fig. 4 is method flow diagram of the present invention.
Embodiment
In order to make object of the present invention, technical scheme and advantage clearer, below in conjunction with embodiment, the present invention is further elaborated.Should be appreciated that specific embodiment described herein, only in order to explain the present invention, is not intended to limit the present invention.
As shown in Figure 1, embodiment furnace of calcium carbide closed cycle water process chart.For the safety that ensures furnace of calcium carbide is normally produced, must carry out cooling to the relevant position of furnace of calcium carbide, cooling arm is divided into some airtight water quench unit 13, each cooling unit 13 is conventionally by 1 water inlet divider, the socket of some quantity connects the chilled water arm of furnace of calcium carbide part of appliance, arm flow and temperature measuring equipment, form with 1 backwater water collector, chilled water is through cooling unit, upper degassed to the degassing tank 12 of a system high position, and via after buffer tank 11, after cooling tower 15 coolings of circulation water station, maintain water circulation by ebullator group 14.That instrument function is installed is as follows:
(1) buffer tank top pressure transmitter 1 is for measuring air pressure, base pressure transmitter 2 is for measuring hydraulic pressure, gas admittance valve 8 and vent valve 9 are for ensureing buffer tank top stable gas pressure, utilize the difference of two transmitters to obtain hydraulic pressure in tank, then obtain actual buffer tank liquid level by hydraulic pressure and liquid level reduction formula;
(2) on voltage stabilizing tank body differing heights, level switch is installed, be superelevation liquid level 3, high liquid level 4, moisturizing liquid level 5, low liquid level 6, ultralow liquid level 7 successively under upper.When system liquid level is below moisturizing liquid level, by starting the small pump 10 of circulating pump room, control buffer tank liquid level and remain between high liquid level and moisturizing water level.
According to the requirement of the present embodiment furnace of calcium carbide operation process, need to be to about 0.2m per hour
3water leakage rate detect and report to the police, being converted into buffer tank liquid level rate of change is 1mm/min.But, the buffer tank liquid level of being calculated by two pressure unit differences in accompanying drawing 1, due to precision and the metering system restriction of instrument, be vulnerable to environment and operating mode impact, the liquid level range of the present embodiment is 5.0m, adopting in filtering algorithm situation, measuring shake also between 0.1m ~ 0.15m, according to tank body floorage 5.0m
2estimation, 0.5m
3water yield fluctuating error, cannot be used for realizing the detection of little leakage rate.Therefore, according to Fig. 2 scheme, increase high precision differential pressure transmitter, realize little leakage measuring instrumentation.
As shown in Figure 2, embodiment high-precision liquid level measurement mechanism is installed schematic diagram.Detect for the little leakage rate of furnace of calcium carbide closed circle water system, differential pressure transmitter need to be installed within the scope of 300 ± 100mm under buffer tank moisturizing level switch level height, differential pressure transmitter, transmitter measurement range: 0 ~ 1000mmH are installed in the present embodiment 200mm position below buffer tank moisturizing level switch level height
2o, measuring accuracy: 0.065%.Consider the sealing of pressure vessel, this transmitter is arranged in buffer tank measuring cylinder, and pressure clicks on taken amount cylinder top and bottom discharge pipe, and PLC control system is carried out filtering processing to the live signal of the differential pressure transmitter collection on buffer tank.
According to the method for the invention, by PLC program, current level gauging value and previous measured value are compared, comparative result judges respectively for every 30 seconds, 1 minute, every 5 minutes, every 10 minutes, and in conjunction with the flowmeter alerting signal of each cooling branch road water return pipeline, suppress the interference of external environment condition to buffer tank level gauging value, realize cooling water pipe booster and reveal judgement fast.As shown in Figure 4,
Specific implementation step is as follows:
Step (1): record the trend of each chilled water return branch flow and temperature variation, realize that the low and temperature of arm flow is high reports to the police;
In each chilled water return branch such as calcium carbide furnace cover, tremie pipe, electrode brasses, petticoat pipe, fire doors, flowmeter and thermometer are set, according to designing requirement, dispensing branch flow.For flow in closed circle water system and temperature changing trend feature slowly, utilize Glitch Filter algorithm to remove instantaneous interference value, record arm flow and temperature changing trend.
Glitch Filter algorithm implementation procedure is as follows:
A filtering counter is set, and this routine N of higher limit N(gets 10 as a comparison), triggering start-stop counter per second;
By each sampled value and current effective value comparison: if sampled value equals current effective value, counter O reset; If sampled value and current effective value are more than or equal to instrument (flowmeter or thermometer) measuring accuracy, counter increases 1 certainly, and judges whether counter is more than or equal to upper limit N(and overflows), if counter overflow, this sub-value is replaced to current effective value, and empty counter;
The cumulative number that is only not equal to currency when sampled value reaches upper limit N, upgrades sampled value, records trend.
Step (2): the precise monitoring of carrying out buffer tank liquid level;
On the differential pressure transmitter basis of buffer tank, by median filtering algorithm, by the suitable filtering cycle, test meet with a response time and measuring accuracy optimal balance point, record SEA LEVEL VARIATION trend.Median filtering algorithm implementation procedure is as follows:
A filtering array is set, and array length is that this routine N of continuous sampling data amount check N(gets 60), triggering start-stop counter per second;
The array of 60 continuous datas, adopts first-in first-out rule to upgrade, and gets 60 data of this array and carries out arithmetic mean computing, removes a maximal value and a minimum value, then calculates the arithmetic mean of N-2 data;
Using this arithmetic mean result as liquid level sampled value, carry out trend record.
Step (3): detect arm trend difference in flow, report to the police according to testing result;
Set up arm trend difference alarming model, with the poor associated buffer tank liquid level variation tendency of fluctuations in discharge trend, dynamically update arm traffic trends difference alarming value, while eliminating operating mode or environment, cause the flowmeter false alarm that arm water partial vaporization produces.As shown in Figure 3, this model realization process is as follows:
(3.1): the poor computation period of initialization trend (this example is got 1min), filtering cycle multiple (this example gets 5), arm difference in flow alarm threshold value (this example is got 0.01m3/h) and liquid level difference alarm threshold value (this example is got 0.001m), wherein liquid level difference alarm threshold value is determined by accuracy of instrument.
(3.2): establishing current time is cycle initial time, i.e. 0 moment, record current arm flow value and buffer tank level value, as history value;
(3.3): the cycle, timing 1min arrived, by current arm flow value and buffer tank level value respectively with (3.2) step in history value do difference, preserve flow difference this moment, if difference in flow is less than the alarm threshold value of setting in (3.1) step, jump to (3.2); Otherwise, comparison liquid potential difference value, the threshold value that step is set if liquid level difference is less than (3.1) this moment, goes to (3.4) step, the threshold value that step is set if liquid level difference is greater than (3.1) this moment, jumps to (3.5) step
(3.4): from 0 moment of (3.2) step period, the 5min time arrives, history value in current buffer tank liquid level and step (2) is done to difference, if now the calculating liquid level difference of 5min is still less than the threshold value that (3.1) step is set, illustrative system is without leakage, and the flow difference in step (3.3) belongs to false alarm value, institute's flow difference of depositing in (3.3) step is replaced in (3.1) step and set alarm threshold value, as the new value of reporting to the police, in (3.3) step, flow difference is clear 0, jumps to (3.2) step; Otherwise, go to (3.5) step;
(3.5): send arm leakage alarm signal, in (3.3) step, flow difference is clear 0, jumps to step (3.2).
Step (4) realizes the little leakage blowing out interlocking of system;
Taking an operation class as unit period, this example is got 8 hours, and each cycle length, (8 hours) were arrived, minimum value in the each arm trend of selecting step (3) model difference alarming value, calculate buffer tank liquid level decline rate alarming value, upgrade leakage rate detection reference value, i.e. per minute liquid level decline rate.Taking reference value as basis, according to the length in buffer tank liquid level difference sampling period, the threshold value of leakage blowing out signals at different levels is set, and (sampling period is longer, accuracy of detection is higher, response time is longer), when buffer tank liquid level decline rate exceedes threshold value, send system leak blowing out signal.
For example, the minimum value obtaining in arm difference in flow alarming value is 0.2m3/h, according to formula (1), calculate buffer tank and detect that 0.001m/min water level declines, send blowing out signal, be in this example according to the operating mode of one of past operation class, optimum leakage rate reference value is 0.001m/min, the area of this routine buffer tank is about 3.3m2.
（1）
Wherein,
leakage rate detection reference value, i.e. buffer tank liquid level decline rate warning reference value, the m/min of unit;
in unit period to the moment, the minimum value of all arm trend difference alarming values, the m3/h of unit;
the unit interval of propping up flowmeter for pipe, if flowmeter unit is m3/h, this value is 60;
buffer tank floorage, the m2 of unit.
On this basis, system can be according to the operating condition of first 8 hours, configures 4 grades of Leak Detection and blowing out interlocking with regard to blowing out by user:
1 grade: for gross leak fast detecting, 30s carries out a drawdown rate of water level and detects, and exceedes 0.005/30s, under this setting value, if a certain arm difference in flow 0.2 m3/h of system sends blowing out signal.
2 grades: for little Leak Detection, 60s carries out a drawdown rate of water level and detects, and exceedes 0.001/min, and this is under setting value, if a certain arm difference in flow 0.2 m3/h of system sends blowing out signal.
3 grades: for little Leak Detection, 5min carries out a drawdown rate of water level and detects, and exceedes 0.004m/5min, under this setting value, if a certain arm difference in flow of system 0.16m3/h sends blowing out signal.
4 grades: for little Leak Detection, 10min carries out a drawdown rate of water level and detects, and exceedes 0.008m/10min, under this setting value, if a certain arm difference in flow of system 0.15m3/h sends blowing out signal.
Should be understood that, for those of ordinary skills, can be improved according to the above description or convert, and all these improvement and conversion all should belong to the protection domain of claims of the present invention.
Claims (6)
1. for a furnace of calcium carbide sealing and circulating water system leakage detection method, it is characterized in that, the method comprises the following steps:
Step (1): each needs, in the chilled water return branch of cooling device parts, flowmeter and thermometer real-time data collection are installed at furnace of calcium carbide, and records the trend of each arm flow and temperature variation;
Step (2): the moisturizing position at the high-order buffer tank of system arranges differential pressure transmitter, records liquid level variation tendency; Remain between high liquid level and moisturizing water level by level switch control buffer tank liquid level;
Step (3): set up the dynamic warning model between arm fluctuations in discharge trend and liquid level variation tendency; Described dynamic warning model, with the poor associated buffer tank liquid level variation tendency of fluctuations in discharge trend, dynamically updates arm traffic trends difference alarming value;
Step (4): comprehensive arm traffic trends difference alarming value, obtains the buffer tank liquid level trend difference alarming threshold value of different cycles, and completes detection and location that furnace of calcium carbide closed circle water system is leaked according to the trend of each arm flow and temperature variation.
2. leakage detection method according to claim 1, is characterized in that, the data acquisition of flowmeter described in step (1) and thermometer Real-time Collection is processed with Glitch Filter algorithm, then records the trend of each arm flow and temperature variation.
3. leakage detection method according to claim 1, is characterized in that, adopts median filtering algorithm to process to the real-time data collection of differential pressure transmitter, then records liquid level variation tendency.
4. leakage detection method according to claim 1, is characterized in that, described dynamic warning model is specific as follows:
(3.1): the poor computation period of initialization trend, filtering cycle multiple, arm difference in flow alarm threshold value and liquid level trend difference alarming threshold value; Wherein liquid level trend difference limen value is determined by accuracy of instrument;
(3.2): establishing current time is cycle initial time (0 moment), records current arm flow value and buffer tank level value, as history value;
(3.3): cycle timing arrives, by current arm flow value and buffer tank level value respectively with (3.2) step in history value do difference, preserve arm flow difference, if gained arm flow difference is less than the arm difference in flow alarm threshold value of setting in (3.1) step, jump to (3.2); Otherwise relatively liquid level trend difference, if liquid level difference is less than the liquid level trend difference alarming threshold value that (3.1) step is set this moment, goes to (3.4) step, if liquid level difference is greater than the liquid level trend difference alarming threshold value that (3.1) step is set this moment, jumps to (3.5) step;
Described cycle timing is a poor computation period time of trend;
(3.4): doubly several cycle length in filtering cycle of setting through step (3.1), history value in current buffer tank liquid level and step (3.2) is done to difference, the threshold value that step that if liquid level difference is still less than this moment (3.1) is set, with in (3.3) step the flow difference of preserving replace in (3.1) step and set alarm threshold value, as new difference in flow alarm threshold value, (3.3) in step, flow difference is clear 0, jumps to (3.2) step; Otherwise, go to (3.5) step;
(3.5): send arm leakage alarm signal, in (3.3) step, flow difference is clear 0, jumps to step (3.2).
5. leakage detection method according to claim 4, it is characterized in that, described step (4) is taking an operation class as unit period, in unit period to the moment, choose the minimum value in the each arm trend difference alarming value obtaining in dynamic warning model, calculate and upgrade leakage rate detection reference value, i.e. per minute liquid level decline rate alarm threshold value; Taking reference value as reference, according to the length in poor sampling period of liquid level trend, the threshold value of leakage blowing out signals at different levels is set, when buffer tank liquid level decline rate exceedes threshold value, send system leak blowing out signal.
6. leakage detection method according to claim 1, is characterized in that, furnace of calcium carbide described in step (1) each need cooling device parts to comprise calcium carbide furnace cover, tremie pipe, electrode brasses, petticoat pipe and fire door.
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| CN109801012A (en) * | 2018-12-20 | 2019-05-24 | 广东宏川科技创新有限公司 | Processing method, device, computer equipment and the storage medium of tank measurements data |
| CN110220266A (en) * | 2019-05-27 | 2019-09-10 | 汪吉平 | One kind being used for central air conditioning water system preventing water leakage automatic water-replenishing device |
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| CN112061330B (en) * | 2020-08-10 | 2021-10-15 | 集美大学 | Automatic alarm technology for leakage of ship cargo tank |
| CN112833067A (en) * | 2021-01-22 | 2021-05-25 | 山信软件股份有限公司 | Method and device for detecting oil leakage of oil tank of hydraulic station |
| CN113303305A (en) * | 2021-05-14 | 2021-08-27 | 北京百瑞盛田环保科技发展有限公司 | Pesticide application monitoring method, device and system |
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