CN106959018B - The method of controlling security for preventing tubular heater boiler tube from burning - Google Patents
The method of controlling security for preventing tubular heater boiler tube from burning Download PDFInfo
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- CN106959018B CN106959018B CN201710245063.7A CN201710245063A CN106959018B CN 106959018 B CN106959018 B CN 106959018B CN 201710245063 A CN201710245063 A CN 201710245063A CN 106959018 B CN106959018 B CN 106959018B
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- tubular heater
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D19/00—Arrangements of controlling devices
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Control Of Steam Boilers And Waste-Gas Boilers (AREA)
Abstract
The present invention relates to a kind of method of controlling security for preventing tubular heater boiler tube from burning, and mainly solve the problems, such as that safety is poor in the prior art.The present invention includes the following steps: the low risk analysis of (1) heating furnace tube flow by using a kind of method of controlling security for preventing tubular heater boiler tube from burning；(2) the SIL grade for determining safety instrument function, has recognized safety instrument function on the basis of risk analysis, and the safety integrity level of the low interlock circuit of boiler tube flow is determined using the Layer of Protection Analysis of sxemiquantitative；(3) technical solution of safety interlock system design preferably solves the above problem, can be used in tubular heater security control.
Description
Technical field
The present invention relates to a kind of method of controlling security for preventing tubular heater boiler tube from burning.
Background technique
Common heating furnace is tubular heater in oil-refining chemical production.For heating furnace, the heated heating of processing medium
While be vaporized, the height of temperature will have a direct impact on the operation operating condition and product quality of later procedure.Work as heating-furnace
When pipe flow is too low, it may cause boiler tube dry combustion method and damage, in material leakage to burner hearth, it may occur however that fire, cause heating furnace
Damage, casualties etc..
Heating furnace tube is generally provided with the low alarm of flow interlocking low with flow.But there are probelem in two aspects: one
It is that security control scheme is unreasonable.The control program of common safety interlocking is: respective flow pick-up is installed on each branch road
Device closes fuel gas when any two boiler tube flows are lower than interlocking setting value.Such safety interlocking method is not examined at all
Considering accidentally to close because of situations such as coking, regulating valve causes single branch boiler tube flow low/no, and boiler tube is burnt, and the operating condition of material leakage adds
There is potential danger in hot stove, security control scheme is unreasonable.Second is that safety interlock system design is unreasonable.Design a safety
When interlock system, it should make the safety interlock system that there is correct security function.Further, it is necessary to consider safety instrument function energy
More than enough good is performed, and what safety integrity level (SIL) was concerned about is exactly that security function more than enough good can be executed.Currently,
Designer usually configures sensing unit, logic controller and the executing agency of safety interlock system by rule of thumb, without abundant
Danger and risk analysis, cause safety interlock system to there are problems that " excessively interlocking " and " interlocking deficiency ".
CN201010577606 is related to a kind of functional safety appraisal procedure of safety instrumented systems, for safety instrumented systems
Carry out authentic simulation, monitoring and functional safety assessment, and the situation of change of research safety instrument system common cause failure, method packet
Include: safety instrumented systems carry out functional safety control to controlled system；Initial risks analysis is carried out to safety instrumented systems, is determined
Safety integrity level；Whether verifying safety instrumented systems reach identified safety integrity level；Change safety instrument system
The composed structure or component devices of system.
Therefore, it is necessary to develop a kind of method of controlling security for preventing tubular heater boiler tube from burning, boiler tube flow is studied
When low, heating furnace is imported into predetermined safe condition, prevents boiler tube from burning, protection heating furnace safe operation.
Summary of the invention
The technical problem to be solved by the present invention is to the problems that safety in the prior art is poor, provide a kind of new prevent
The method of controlling security that tubular heater boiler tube is burnt.This method has the advantages that safety is preferable.
To solve the above problems, The technical solution adopted by the invention is as follows: a kind of prevent tubular heater boiler tube from burning
Method of controlling security includes the following steps:
(1) the low risk analysis of heating furnace tube flow, using Process hazard analysis or dangerous acupoint side
Method, according to heating furnace technique technical regulation and pipeline and instrument flow chart, the reason of identification low with boiler tube flow is analyzed generation and
The consequence that this deviation generates, finds out existing safeguard measure and determines whether independent protection layer meets risk and lower the requirement, and combs
Manage it is existing or it is recommended to increase safety instrument functional loop；
(2) the SIL grade for determining safety instrument function, has recognized safety instrument function on the basis of risk analysis,
The safety integrity level that the low interlock circuit of boiler tube flow is determined using the Layer of Protection Analysis of sxemiquantitative, is specifically included:
1) primary event frequency is determined；2) damage sequence and target risk are determined, mainly includes personal injury risk, environment influence wind
Three aspects in danger and property loss risk；3) scene frequency calculates, and using primary event frequency, the PFD value of IPLs, calculating slows down
Scene frequency afterwards；
(3) safety interlock system designs, and the safety interlock system is by sensing unit, logic controller and finally executes machine
Structure composition, the sensing unit can experience measured information, and the information that can will be experienced, be for conversion into telecommunications by rule
Number sending logic controller to, when the logic controller judgement reaches interlocking value, final executing agency executes scheduled movement,
Device is set to enter predetermined safe condition.
In above-mentioned technical proposal, it is preferable that each scene of LOPA has single primary event, and primary event frequency is logical
It is often indicated with etesian number, primary event is divided into three types: external event, equipment fault, the failure of people；For determination
Consistent primary event frequency, fail data source specifically include that 1) industry data；2) experience of company, company have abundance
Historical data be used to carry out significant statistical analysis；3) data of supplier.
In above-mentioned technical proposal, it is preferable that in LOPA, for consequence, the size order of its seriousness will be assessed；
In LOPA analytic process, what analysis team should determine that each accident scene slows down event in terms of safety, environment and property can
Energy property determines that risk reduces target according to business risk matrix.
In above-mentioned technical proposal, it is preferable that the calculating of scene frequency is carried out, it is also contemplated that shadow of the enabled event to consequence frequency
It rings, by the frequency for discharging scene multiplied by the probability of concern result, calculation formula is modified.
In above-mentioned technical proposal, it is preferable that required according to IEC61511, for safety instrument function, sensor is patrolled
Minimum hardware fault nargin should be had by collecting controller and executing agency.
In above-mentioned technical proposal, it is preferable that configuration safety instrument functional loop should take into account reliabilty and availability, protect
While hindering safe, the probability of safety interlock system malfunction is reduced.
In above-mentioned technical proposal, it is preferable that sensor structure safety: 1oo2 > 2oo3 > 1oo1 > 2oo2, sensor
Configuration process availability: 2oo2 > 2oo3 > 1oo1 > 1oo2；Valve mechanism safety: 1oo2 > 2oo4 > 1oo1 > 2oo2,
Valve mechanism process availability: 2oo2 > 2oo4 > 1oo1 > 1oo2.
This patent is avoided that the low operating condition of heating furnace list boiler tube flow, helps avoid the control of boiler tube boiler tube flow lower security
Scheme is unreasonable to cause safety interlock system that can not be correctly completed its security function；Facilitate reasonable disposition safety interlock system biography
The redundancy structure for feeling unit, logic unit and final element meets SIL class requirement, and has good reliability and can be used
Property, it avoids ensureing heating furnace safe operation due to the low issuable dangerous consequences of heating furnace tube flow, achieve preferable
Technical effect.
Detailed description of the invention
Fig. 1 is the flow diagram of the method for the invention.
Fig. 2 is heating furnace crosslinking lock scheme figure.
The low interlock safety instrument function loop diagram of Fig. 3 boiler tube flow.
In Fig. 2,1 heating furnace body；2 heating furnace tubes；3 flow transmitters；4 safe interlocking circuits；5 regulating valves.
The present invention will be further described below by way of examples, but is not limited only to the present embodiment.
Specific embodiment
[embodiment 1]
A kind of method of controlling security for preventing tubular heater boiler tube from burning, as shown in Figure 1, including the following steps:
1, the low risk analysis of heating furnace tube flow
Using Process hazard analysis (PHA) or dangerous acupoint (HAZOP) method, according to heating furnace technique skill
Art regulation and pipeline and instrument flow chart, identification with the reason of analysis boiler tube flow low generation and the consequence of this deviation generation,
It finds out existing safeguard measure and determines whether independent protection layer (IPL) meets risk and lower the requirement, comb existing or suggest
Increased safety instrument functional loop.
2, the SIL grade of safety instrument function is determined
Safety instrument function is recognized on the basis of risk analysis, using layer of protection analysis (LOPA) side of sxemiquantitative
Method determines the safety integrity level of the low interlock circuit of boiler tube flow.
1) primary event frequency is determined
Each scene of LOPA has single primary event, and primary event frequency is usually with etesian frequency table
Show.Primary event is generally divided into three types: external event, equipment fault, the failure of people.
For the consistent primary event frequency of determination, there are many fail data source, specifically include that 1) industry data, such as
" chemical process quantitative risk analysis guide, the second edition " (CCPS, 2000) etc.；2) experience of company, company have sufficient go through
History data can be utilized for significant statistical analysis；3) data of supplier.
2) damage sequence and target risk are determined
It mainly include three personal injury risk, environment influence risk and property loss risk aspects.In LOPA, for
Consequence will assess the size order of its seriousness.In LOPA analytic process, analysis team should determine that each accident scene exists
A possibility that slowing down event in terms of safety, environment and property.According to business risk matrix, determine that risk reduces target (TMEL).
3) scene frequency calculates
Using primary event frequency, the PFD value of IPLs, the scene frequency after slowing down is calculated.The following are specific consequence terminals
The common method that scene frequency calculates is discharged, sees formula 1.
In formula:--- primary event i causes the frequency of C consequence；
--- the primary event frequency of primary event i；
PFDij--- the failure probability (PFD) when the independent protection layer of j-th of prevention consequence C requires in primary event i.
The calculating of scene frequency is carried out, it is also contemplated that enabled event (ignition probability, personnel's exposure probability etc.) is to consequence frequency
Influence, the frequency of scene will be discharged multiplied by the probability of concern result, equation 1 is modified.By taking personal injury consequence as an example,
The frequency that the consequence obtained occurs is reduced target with risk to compare, can obtain the PFD value of SIFs, and then determine SIFs
Target SIL.
In formula: Pig--- ignition probability；
Pex--- personnel appear in the probability of the zone of influence；
Ps--- the probability that injury occurs.
PFD, RRF and SIL grade corresponding relationship are as shown in table 1.
1 safety integrity level of table divides table
3, safety interlock system designs
The safety interlock system is made of sensing unit, logic controller and final executing agency, the sensing unit
Measured information, and the information that can will be experienced can be experienced, electric signal is for conversion by rule and sends logic controller to,
When the logic controller judgement reaches interlocking value, final executing agency executes scheduled movement, and device is made to enter predetermined safety
State.
It is required according to IEC61511, for safety instrument function, sensor, logic controller and executing agency should have
There is minimum hardware fault nargin, as shown in table 2 and table 3.
The minimum hardware failure nargin of 2 PE logic solver of table
3 sensor of table, final element and non-PE logic solver minimum hardware failure nargin
| SIL | Minimum hardware failure nargin |
| 1 | 0 |
| 2 | 1 |
| 3 | 2 |
| 4 | Using particular/special requirement (see IEC61508-2010) |
Safety instrument functional loop is configured, reliabilty and availability should be taken into account, while ensureing safe, reduces safety connection
The probability of lock system malfunction can choose redundancy structure by table 4 for sensor.
The comparison of certain the differential pressure transmitter difference redundancy structure of table 4
Note: by taking certain differential pressure transmitter as an example, λ is calculatedDU、λSU, requirement in the case of the identical parameters such as TI, MTTR when mistake
It imitates probability (PFD) and misses parking rate (STR), provide theoretical foundation for the design of the circuit SIF.
Therefore, sensor structure safety: 1oo2 > 2oo3 > 1oo1 > 2oo2, sensor structure process availability:
2oo2 > 2oo3 > 1oo1 > 1oo2.
Using identical method, the safety and availability of valve difference redundancy structure are compared, conclusion is as follows, valve mechanism
Safety: 1oo2 > 2oo4 > 1oo1 > 2oo2, valve mechanism process availability: 2oo2 > 2oo4 > 1oo1 > 1oo2.
It is illustrated below with reference to example:
As shown in Fig. 2, every boiler tube is equipped with stream to be divided into for 6 road branch pipes enter heating furnace heating by general pipeline in stokehold
Control loop is measured, heating furnace is equipped with the low alarm of flow interlocking low with flow.
1, the low risk analysis of heating furnace tube flow
Due to tube coking, regulating valve failure and other reasons, occur heating furnace tube flow it is low when, it is dry to may cause boiler tube
It burns, boiler tube is burnt, and in material leakage to burner hearth, be may cause and is fired, cause casualties, property loss.
Six boiler tubes are respectively equipped with flow transmitter, are converted into 4-20mA electric signal by AI card and send logic control to
Device, logic controller determine when any two reach interlocking value (2oo6) that the final structure that executes executes predetermined action.This control
Scheme not can avoid single branch boiler tube since regulating valve accidentally closes the operating condition for causing flow low, use single branch boiler tube flow low
The control program of interlocking is more reasonable.
2, the SIL grade of safety instrument function is determined
Using Layer of Protection Analysis, it is determined whether need to be arranged safety interlock system, LOPA record form is shown in Table 5.
5 LOPA analytical table of table
1, primary event: 1a. control loop failure causes FV1A to turn down or close, 1b. occurrence frequency f=0.1；
2, consequence: boiler tube is burnt, material leakage, may cause heating furnace explosion, 1-2 people is dead, according to " Sinopec wind
Dangerous matrix " (Q/SH0560-2013), it can determine that consequence grade is D；
3, target risk: requiring according to risk Metrics, needs target risk being reduced to TMEL=10-6；
4, facilitate the condition of consequence: personnel are exposed to probability P=0.1 of hazardous environment；
5, the low alarm of flow, PFD independent protection layer: are provided with1=0.1,；In addition to this without other independent protection layers；
6, intermediate event possibility: fi=f × P × PFD1=0.1 × 0.1 × 0.1=10-3；
7、PFDSIF: by formula (2), PFDSIF=target risk reduction/intermediate event possibility=10-6/10-3=10-3；
8, goal gradient: by table 1 it can be concluded that, PFDSIFCorresponding SIL2 grade.
3, safety interlock system designs
Design meets SIL2 class requirement safety instrument functional loop.
Sensor: according to the requirement of table 3, hardware fault nargin is 1；According to table 4, PFD and STR is weighed, it should select 2oo3
Structure.3 flow transmitter detection flows sizes are set and are converted into 4~20mA electric signal and give logic control by AI card
Device.
Logic controller: when logic controller reaches interlocking value according to two from three logic judgment, action signal is passed through into DO
Card gives executive component.
Executive component: according to the requirement of table 3, hardware fault nargin is 1；According to minimum reasonable principle, it should select
1oo2 structure.2 stop valves are set, and when executing predetermined action, system enters predetermined safe condition.
The low interlock safety instrument function loop diagram of heating furnace tube flow is shown in Fig. 3.
In this way, tubular heater boiler tube flow lower security control program is reasonable, can guarantee safety instrument function
The reliabilty and availability in circuit is of great significance for the operation of ensuring equipment safety and steady.
Claims (7)
1. a kind of method of controlling security for preventing tubular heater boiler tube from burning, includes the following steps:
(1) the low risk analysis of heating furnace tube flow, using Process hazard analysis or dangerous acupoint method, root
It is the reason of identification low with analysis boiler tube flow generation and this inclined according to heating furnace technique technical regulation and pipeline and instrument flow chart
The consequence that difference generates, finds out existing safeguard measure and determines whether independent protection layer meets risk and lower the requirement, and combs existing
Or it is recommended to increase safety instrument functional loop；
(2) the SIL grade for determining safety instrument function has recognized safety instrument function on the basis of risk analysis, uses
The Layer of Protection Analysis of sxemiquantitative determines the safety integrity level of the low interlock circuit of boiler tube flow, specifically includes: 1) really
Determine primary event frequency；2) damage sequence and target risk are determined, mainly includes personal injury risk, environment influence risk and wealth
Produce three aspects of loss risk；3) scene frequency calculates, and using primary event frequency, the PFD value of IPLs, calculates the field after slowing down
Scape frequency；
(3) safety interlock system designs, and the safety interlock system is by sensing unit, logic controller and final executing agency's group
At the sensing unit can experience measured information, and the information that can will be experienced, and be for conversion into electric signal by rule and pass
Logic controller is given, when the logic controller judgement reaches interlocking value, final executing agency executes scheduled movement, makes to fill
It sets into predetermined safe condition.
2. the method for controlling security for preventing tubular heater boiler tube from burning according to claim 1, it is characterised in that LOPA's
Each scene has single primary event, and primary event frequency usually indicates that primary event is divided into etesian number
Three types: external event, equipment fault, the failure of people；For the consistent primary event frequency of determination, fail data source is main
It include: 1) industry data；2) there is sufficient historical data to be used to carry out significant statistical analysis for the experience of company, company；
3) data of supplier.
3. the method for controlling security for preventing tubular heater boiler tube from burning according to claim 1, it is characterised in that in LOPA
In, for consequence, the size order of its seriousness will be assessed；In LOPA analytic process, analysis team should determine each thing
Therefore scene a possibility that slowing down event in terms of safety, environment and property, determines that risk reduces mesh according to business risk matrix
Mark.
4. the method for controlling security for preventing tubular heater boiler tube from burning according to claim 1, it is characterised in that carry out field
Scape frequency calculates, it is also contemplated that enabled influence of the event to consequence frequency, will discharge the frequency of scene multiplied by the general of concern result
Rate is modified calculation formula.
5. the method for controlling security for preventing tubular heater boiler tube from burning according to claim 1, it is characterised in that according to
IEC61511 requirement, for safety instrument function, sensor, logic controller and executing agency should have minimum hardware
Failure nargin.
6. the method for controlling security for preventing tubular heater boiler tube from burning according to claim 1, it is characterised in that configuration peace
Full instrument function circuit, should take into account reliabilty and availability, while ensureing safe, reduce safety interlock system malfunction
Probability.
7. the method for controlling security for preventing tubular heater boiler tube from burning according to claim 1, it is characterised in that sensor
Safety of structure: 1oo2 > 2oo3 > 1oo1 > 2oo2, sensor structure process availability: 2oo2 > 2oo3 > 1oo1 >
1oo2；Valve mechanism safety: 1oo2 > 2oo4 > 1oo1 > 2oo2, valve mechanism process availability: 2oo2 > 2oo4 >
1oo1 > 1oo2.
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Families Citing this family (4)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN110389563A (en) * | 2018-04-19 | 2019-10-29 | 中国石油化工股份有限公司 | A kind of safe interlocking circuit construction method |
| CN109614800B (en) * | 2018-12-07 | 2023-02-21 | 机械工业仪器仪表综合技术经济研究所 | Safety integrated risk determination system and method based on digital workshop |
| CN111061245A (en) * | 2019-11-21 | 2020-04-24 | 青岛欧赛斯环境与安全技术有限责任公司 | Error action evaluation method of safety instrument system |
| CN113112104A (en) * | 2020-01-13 | 2021-07-13 | 中国石油天然气股份有限公司 | Risk evaluation method and device for town gas business and application thereof |
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| JPS54133408A (en) * | 1978-04-10 | 1979-10-17 | Hitachi Ltd | Furnace temperature setting control method of multizone type heating furnace |
| CN103955181A (en) * | 2014-04-11 | 2014-07-30 | 中国石油化工股份有限公司 | Safety interlocking method reducing spurious trip of compressor |
| CN104678955A (en) * | 2015-01-27 | 2015-06-03 | 中国石油化工股份有限公司 | Risk-based optimization method for safety instrument system of heating furnace |
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