CN115239039A - Chemical device risk correction early warning method and device based on process safety indexes - Google Patents
Chemical device risk correction early warning method and device based on process safety indexes Download PDFInfo
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Abstract
The invention provides a chemical device risk correction early warning method based on process safety indexes and a chemical device risk correction early warning device based on process safety indexes, which comprise the following steps: acquiring a process safety index of a chemical device and a static risk grade of the chemical device in real time; determining a weight coefficient of each process safety index; determining the grade level corresponding to each process safety index according to the preset grade interval of the process safety index; based on the weight coefficient and the grade level of each process safety index, correcting the determined static risk grade of the chemical device, and determining the dynamic early warning grade of the chemical device; and executing corresponding risk early warning according to the dynamic early warning grade of the chemical device. The method has the advantages of realizing dynamic representation of the risk of the chemical device, realizing dynamic early warning of the device, monitoring and early warning the risk in the operation of the device according to the dynamic early warning, and improving the early warning effect of the safety risk.
Description
Technical Field
The invention relates to the technical field of risk early warning and management and control of chemical devices, in particular to a chemical device risk correction early warning method based on process safety indexes and a chemical device risk correction early warning device based on process safety indexes.
Background
Chemical devices are increasingly developed towards large-scale, complex and integrated development, and once the devices are abnormal in operation, serious accidents such as fire, explosion, poisoning and the like can be caused, so that the life and property safety is threatened. Therefore, the risk assessment and control method is widely applied to the processes of research, development, design, operation, maintenance and the like of chemical devices. In the research and development and design stages, engineering control measures are formulated through risk assessment to ensure that the device meets the requirements of risk standards. In the operation and maintenance stage, risk assessment is performed regularly to check the risk level of the device, and project control measures and operation methods are perfected. Through the measures, the accident occurrence probability is reduced to a certain extent. However, in the operation process of the chemical device, the risk changes due to the operation state of the equipment, the personnel operation level and the personnel consciousness change, and the periodic risk assessment in the unit of year and month cannot meet the requirement of risk control, so that dynamic risk early warning needs to be performed on the chemical device.
In the prior art, process safety indexes of a device are generally obtained, tools of methods such as risk identification, diagnosis and evaluation are deeply integrated, static safety risk early warning in various fields such as enterprise production and public safety is realized, safety countermeasures are provided after safety evaluation and risk evaluation, real-time dynamic risks are not associated with static risks, a real-time dynamic risk correction early warning method is not provided, real-time dynamic changes of device risks cannot be reflected, and early warning is realized but real-time dynamic risks of the device cannot be comprehensively reflected.
Disclosure of Invention
The embodiment of the invention aims to provide a chemical device risk correction early warning method and device based on process safety indexes, and at least solves the problems that the real-time dynamic risk is not associated with the static risk and cannot be comprehensively reflected.
In order to achieve the above object, a first aspect of the present invention provides a chemical plant risk correction early warning method based on process safety indicators, where the method includes:
acquiring a process safety index of a chemical device and a static risk grade of the chemical device in real time;
determining a weight coefficient of each process safety index;
determining a grade level corresponding to each process safety index according to a preset grade interval of the process safety indexes;
correcting the static risk level of the chemical device based on the weight coefficient and the level grade of each process safety index, and determining the dynamic early warning level of the chemical device;
and executing corresponding risk early warning according to the dynamic early warning grade of the chemical device.
Optionally, the process safety index is collected by a distributed control system, a laboratory information management system, and a manufacturing enterprise production process execution system.
Optionally, the preset grade interval of the process safety index is from low to high: a normal interval, a low deviation grade interval and a high deviation grade interval;
the grade levels are from low to high: a normal grade, a low deviation grade and a high deviation grade;
the static risk level is from low to high: static low risk, static general risk, static high risk and static major risk;
the dynamic early warning grade is from low to high: dynamic low risk, dynamic general risk, dynamic high risk, and dynamic major risk.
Optionally, the process safety index at least includes: average alarm number, continuous alarm number for 24 hours, process index qualification rate, raw material quality qualification rate, automatic control rate, equipment integrity rate and equipment leakage rate.
Optionally, the method further includes:
acquiring risk factors of a chemical device;
and determining the static risk grade and the static risk score of the chemical device based on the preset risk matrix of the risk factors.
Optionally, each process safety indicator has a corresponding weight coefficient, and the method further includes:
and classifying all the process safety indexes based on the weight coefficients of the process safety indexes, wherein the sum of the weight coefficients of all the process safety indexes in each class of process safety indexes is 1.
Optionally, each grade level has a corresponding grade level score, and the method corrects the static risk level of the chemical device and determines the dynamic early warning level of the chemical device based on the weight coefficient and the grade level of each process safety index, and includes:
determining the grade score of each process safety index;
respectively correcting the static risk value of the chemical device based on the weight coefficient and the grade value of each process safety index in each type of process safety index to obtain the dynamic early warning value of each type of process safety index;
summing the dynamic early warning values of all the classes of process safety indexes to obtain a total dynamic early warning value of the chemical device;
and obtaining the dynamic early warning grade of the chemical device according to a preset risk classification standard based on the dynamic early warning total value of the chemical device.
Optionally, the calculation formula of the dynamic early warning score of each type of process safety index is as follows:
wherein R is Static state A static risk score for the chemical plant; c i For each process safety index in the process safety indexesA rank-level score of; w i Is the weight coefficient of each process safety index in the process safety indexes, and sigma W i ＝1。
The invention provides a risk correction early warning device for a chemical device based on process safety indexes, which comprises:
the acquisition module is used for acquiring the process safety index of the chemical device and the static risk level of the chemical device in real time;
the weight coefficient determining module is used for determining the weight coefficient of each process safety index;
the grade determining module is used for determining the grade corresponding to each process safety index according to the preset grade interval of the process safety indexes;
the dynamic risk determining module is used for correcting the static risk level of the chemical engineering device based on the weight coefficient and the level grade of each process safety index, and determining the dynamic early warning level of the chemical engineering device;
and the early warning execution module is used for executing corresponding risk early warning according to the dynamic early warning grade of the chemical device.
Optionally, the obtaining module is further configured to:
acquiring risk factors of a chemical device;
and determining the static risk grade and the static risk value of the chemical device based on the preset risk matrix of the risk factors.
Optionally, each process safety indicator has a corresponding weight coefficient, and the apparatus further includes:
a parameter classification module: the method is used for classifying all the process safety indexes based on the weight coefficients of the process safety indexes, wherein the sum of the weight coefficients of all the process safety indexes in each class of process safety indexes is 1.
Optionally, each level has a corresponding level score, and the dynamic early warning determination module is specifically configured to:
determining the grade score of each process safety index;
respectively correcting the static risk value of the chemical device based on the weight coefficient and the grade value of each process safety index in each type of process safety index to obtain the dynamic early warning value of each type of process safety index;
summing the dynamic early warning scores of all the classes of process safety indexes to obtain the total dynamic early warning score of the chemical device;
and obtaining the dynamic early warning grade of the chemical device according to a preset risk classification standard based on the dynamic early warning total value of the chemical device.
Optionally, the calculation formula of the dynamic early warning score of each type of process safety index is as follows:
wherein R is Static state A static risk score for the chemical plant; c i The grade value of each process safety index in the process safety indexes is given; w i Is the weight coefficient of each process safety index in the process safety indexes, and sigma W i ＝1。。
In another aspect, the present invention provides a machine-readable storage medium having instructions stored thereon, where the instructions are used to enable a machine to execute any one of the above-mentioned chemical plant risk correction early warning methods based on process safety indexes.
According to the technical scheme, the process safety indexes of the chemical device are obtained, the static risk levels are obtained based on the danger factors of the device, the weight coefficient is set for each process safety index, the level of each process safety index is determined according to the preset level interval, the static risk levels are corrected through the level levels and the weight coefficients of the process safety indexes, the dynamic representation of the risk of the chemical device is realized, the dynamic early warning of the chemical device is realized, the risk in the operation process of the chemical device is monitored and early warned according to the dynamic early warning, the safety risk early warning effect is improved, and the safe operation of the chemical device is ensured.
Additional features and advantages of embodiments of the present invention will be described in detail in the detailed description which follows.
Drawings
The accompanying drawings, which are included to provide a further understanding of the embodiments of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the embodiments of the invention without limiting the embodiments of the invention. In the drawings:
FIG. 1 is a flow chart of a risk correction early warning method for a chemical device based on process safety indexes, provided by the invention;
FIG. 2 is a schematic structural diagram of a risk correction early warning device for a chemical device based on process safety indexes, provided by the invention;
fig. 3 is a schematic diagram of a risk matrix for static risk classification provided by the present invention.
Description of the reference numerals
10-an acquisition module; 20-a weight coefficient determination module; 30-grade determination module
40-dynamic risk determination module, 50-early warning execution module.
Detailed Description
The following detailed description of embodiments of the invention refers to the accompanying drawings. It should be understood that the detailed description and specific examples, while indicating the present invention, are given by way of illustration and explanation only, not limitation.
Fig. 1 is a flowchart of a chemical plant risk correction early warning method based on process safety indexes provided by the invention. As shown in fig. 1, an embodiment of the present invention provides a chemical plant risk correction early warning method based on process safety indicators, where the method includes:
103, determining a grade level corresponding to each process safety index according to a preset grade interval of the process safety indexes;
104, correcting the static risk level of the chemical engineering device based on the weight coefficient and the level grade of each process safety index, and determining the dynamic early warning level of the chemical engineering device;
and 105, executing corresponding risk early warning according to the dynamic early warning level of the chemical device.
Specifically, the real-time acquisition of process safety indexes of the chemical device comprises: the process safety index of the chemical device is directly obtained through the database, or the process safety index corresponding to the embodiment mode can be obtained by obtaining the process parameters of the chemical device in real time and carrying out statistical analysis on the process parameters;
after the process safety indexes are obtained, a weight coefficient is set for each process safety index, the setting of the weight coefficient can be determined according to the importance degree of the process safety indexes and the influence degree generated when the process safety indexes change, and the set weight is larger for the process safety indexes which are more important or have higher influence degree;
after the specific numerical value of the process safety index is obtained, the grade level corresponding to each process safety index can be determined according to the preset grade interval of the process safety index;
determining a static risk grade and a static risk score of a chemical device based on a preset risk matrix of risk factors of the chemical device;
after the static risk level of the chemical device is obtained, the static risk level is only simple integration of each risk factor and cannot reflect the dynamic risk of the chemical device at the moment, so that the static risk level of the chemical device is corrected based on the weight coefficient and the level grade of each process safety index, the dynamic early warning level of the chemical device is determined, the dynamic risk level can reflect the risk state of the chemical device in real time, and the safety performance of the chemical device at the moment is visually shown; and executing corresponding risk early warning according to the dynamic early warning grade of the chemical device.
Furthermore, the process safety index is collected through a distributed control system, a laboratory information management system and a manufacturing enterprise production process execution system.
Specifically, the process parameters including pulverized coal flow, oxygen flow, annular space temperature, annular space pressure difference, slag hole pressure difference, oxygen and gasifier pressure difference, gasifier pressure, gasifier liquid level, chilling water flow, burner cooling water liquid level, burner cooling water flow, oxygen-coal ratio, drum liquid level, coal mill outlet temperature, pulverized coal level and the like can be collected through a Distributed Control System (DCS), the collection period can be set to be 5s-2min, the collected data mainly comprise current values (PV), set values (SP), output values (MV), mode (Mode) and the like of the process parameters of the coal gasification device, and during collection, the collected data are read through OPC A & E interfaces and stored in a system database.
The technological parameters collected by a Laboratory Information Management System (LIMS) are mainly the quality analysis data of the raw materials, and the collection period can be set to be 5s-2min.
Data such as equipment management indexes are collected through a manufacturing enterprise production process execution system (MES system).
In another embodiment, the DCS system can also directly acquire the grade level and event (A & E) data of the chemical engineering device for generating the alarm, and store the acquired data in the system database.
Further, the preset grade interval of the process safety index is from low to high as: a normal interval, a low deviation grade interval and a high deviation grade interval;
the grade level is from low to high: a normal grade, a low deviation grade and a high deviation grade;
the static risk level is from low to high: static low risk, static general risk, static high risk, and static major risk;
the dynamic early warning grade is from low to high: dynamic low risk, dynamic general risk, dynamic high risk, and dynamic significant risk.
Specifically, in this embodiment, the normal fluctuation interval of each process safety index under normal conditions can be obtained according to the historical data of the process safety index, and therefore, the preset grade intervals of the process safety indexes can be set as a normal interval, a low deviation grade interval, and a high deviation grade interval, and are arranged from low to high as: normal interval, low deviation grade interval, high deviation grade interval to, to each grade interval of predetermineeing sets up corresponding grade level, with predetermineeing the grade interval and correspond to be divided into: the method comprises the steps of putting the obtained process safety indexes into a preset grade interval to obtain the grade corresponding to each process safety index, obtaining the grade of each process safety index, and obtaining the static risk grade of the device and the dynamic risk grade based on the static risk by using a preset risk matrix after obtaining the grade of the process safety index, wherein the judgment standards of the static risk and the dynamic risk grade can be set into two standards according to actual conditions and can also be set into a unified standard.
In another embodiment, alarm hierarchical pushing can be set for the dynamic risk level of the chemical device, after the dynamic risk level of the process parameter is obtained, the dynamic low risk and the dynamic general risk are pushed to department level, and the dynamic high risk and the dynamic major risk are pushed to plant level.
Further, the process safety index data at least comprises: average alarm number, continuous alarm number for 24 hours, process index qualification rate, raw material quality qualification rate, automatic control rate, equipment integrity rate and equipment leakage rate.
Specifically, the time-average alarm number is: and analyzing the alarm number of the process parameters of each device DCS per hour within a specified time range, evaluating the alarm frequency of each device, directly reading the alarm from an OPC A & E interface and counting, or comparing the real-time data of the process parameters acquired by the DCS with a preset grade interval and counting, and storing the obtained time average alarm number in a real-time database. The number of continuous alarms in 24 hours is as follows: and analyzing the average alarm frequency of each device with the alarm duration time of more than 24 hours within a specified time range, evaluating whether each device has the condition of long-term continuous alarm, wherein the acquisition method is the same as the method for acquiring the time average alarm frequency, and storing the acquired time average alarm frequency in a real-time database. The process index qualification rate is as follows: and (3) introducing data (specific index names can be read from the process cards) of the process cards of the production process into a risk control platform, taking the data every half hour, counting accumulated unqualified times (namely, the data is judged to be unqualified when the data exceeds an index range), wherein the qualification rate = unqualified times/total statistical times, and storing the obtained time average alarm number in a real-time database. The raw coal quality qualification rate is as follows: introducing the analysis data of the raw material coal of a Laboratory Information Management System (LIMS) into a risk management and control platform, and counting accumulated unqualified times (if the analysis data exceeds an index range, the analysis data is judged to be unqualified), wherein the qualification rate = unqualified times/total statistical times. The automatic control rate is as follows: and in a specified time range, counting the percentage of the number of the control loops in the total control loops, and evaluating the automation level condition of the device. The equipment availability ratio is as follows: the proportion of the perfect production equipment in all the production equipment is an important index for reflecting the technical condition of enterprise equipment and evaluating the working level of equipment management, and is also a basic basis for equipment management. The leakage rate of the equipment is as follows: and (4) the enterprise calculates the ratio of the leakage point to the sealing point according to the sealing point ledger and the leakage point ledger.
Further, the method further comprises:
acquiring risk factors of a chemical device;
and determining the static risk grade and the static risk value of the chemical device based on the preset risk matrix of the risk factors.
Specifically, firstly, identifying and acquiring a risk factor of the chemical device, evaluating the possibility of occurrence of the risk factor and an effect brought by the occurrence of the risk factor, obtaining a possibility grade and an effect grade corresponding to the risk factor, and determining a static risk grade of the chemical device based on a risk matrix combining the possibility grade and the effect grade; furthermore, the higher the possibility of occurrence of the risk factors and the more serious the consequences caused when the risk factors occur, the higher the corresponding static risk grade of the chemical device, and the higher the static risk score corresponding to the static risk grade can be obtained by assigning the possibility grade and the consequence grade, and the higher the static risk grade of the chemical device, the higher the corresponding static risk score is.
Further, the risk factors of the chemical plant include: product leakage, fire explosion, poisoning suffocation, electric shock injury, mechanical injury, burn, lifting injury and the like; generally, the main risk factors with more serious consequences and higher probability grade are selected for analysis.
Further, each process safety index has a corresponding weight coefficient, the method further comprising:
and classifying all the process safety indexes based on the weight coefficients of the process safety indexes, wherein the sum of the weight coefficients of all the process safety indexes in each class of process safety indexes is 1.
Specifically, in the actual production of the chemical plant, there may be many process safety indexes, and a plurality of process safety indexes, when the weight coefficients are set, if the sum of the weight coefficients exceeds 1, the calculated result may generate a deviation, so that the process safety indexes may be classified according to the value of the preset weight coefficient, so that the sum of the weight coefficients of each process safety index in each class of process safety indexes is 1, and the dynamic early warning score is calculated for each class of process safety indexes.
Further, each grade level has a corresponding grade level score, and the method corrects the static risk level of the chemical device based on the weight coefficient and the grade level of each process safety index, and determines the dynamic early warning level of the chemical device, including:
determining the grade score of each process safety index;
respectively correcting the static risk value of the chemical device based on the weight coefficient and the grade value of each process safety index in each type of process safety index to obtain the dynamic early warning value of each type of process safety index;
summing the dynamic early warning scores of all the classes of process safety indexes to obtain the total dynamic early warning score of the chemical device;
and obtaining the dynamic early warning grade of the chemical device according to a preset risk classification standard based on the dynamic early warning total value of the chemical device.
Specifically, firstly, the dynamic early warning score of each type of process safety index is calculated, during calculation, the grade score of each type of process safety index is determined according to the grade of each type of process safety index, the static risk score of the chemical device is utilized, the dynamic early warning score of each type of process safety index is calculated based on the weight coefficient and the grade score of each type of process safety index in the type of process safety index, then the sum of the dynamic early warning scores of each type of process safety index is obtained, the dynamic early warning total score of the chemical device is obtained, then the dynamic early warning grade of the chemical device is obtained according to a preset risk grading standard, and the preset risk grading standard can also carry out grade division according to a risk matrix.
Further, the calculation formula of the dynamic early warning score of each type of process safety index is as follows:
wherein R is Static state Is the static risk score of the chemical plant; c i The grade value of each process safety index in the process safety indexes is divided; w i Is the weight coefficient of each process safety index in the process safety indexes, and sigma W i ＝1。
Specifically, C i And determining the grade score corresponding to each process safety index according to the grade score of each process safety index in the process safety indexes, multiplying the obtained grade score corresponding to each process safety index by the corresponding weight coefficient, adding the obtained values of the process safety indexes, and calculating the dynamic early warning score of the process safety indexes by using the formula.
In another embodiment, the obtained process safety indexes are divided into two categories, and a calculation formula for obtaining the total dynamic early warning score is as follows:
wherein R is Static state A static risk score for the chemical plant; c i The grade scores are corresponding to the grade grades of the time average alarm number, the 24-hour continuous alarm number, the process index qualification rate and the raw material quality qualification rate; w i The weight coefficients corresponding to the time average alarm number, the 24-hour continuous alarm number, the process index qualification rate and the raw material quality qualification rate are W i ＝1；C j Grade scores corresponding to grade grades of the automatic control rate, the equipment integrity rate and the equipment leakage rate; w j Weight coefficients corresponding to the automatic control rate, the equipment integrity rate and the equipment leakage rate, and W j =1, wherein when the classification level score of the automatic control rate is taken as an example, the classification level scores are in three classification level sections, the weighting coefficients are the same, but the classification level scores in each classification level section are different, and the scores when the automatic control rate is in a normal classification level, a low deviation classification level, and a high deviation classification level are named as follows: c From 1 、C From 2 And C From 3 The corresponding size relationship of the score is as follows: c From 3 >C From 2 >C From 1 。
Fig. 2 is a schematic structural diagram of a chemical device risk correction early warning device based on process safety indexes. As shown in fig. 2, an embodiment of the present invention provides a chemical apparatus risk correction early warning apparatus based on process safety indexes, where the apparatus includes:
the acquiring module 10 is used for acquiring the process safety index of the chemical device and the static risk level of the chemical device in real time;
a weight coefficient determining module 20, configured to determine a weight coefficient of each process safety index;
the grade determining module 30 is configured to determine a grade level corresponding to each process safety index according to a preset grade interval of the process safety indexes, and determine a static risk grade of the chemical plant based on the grade levels of all the process safety indexes;
the dynamic risk determining module 40 is configured to correct a static risk level of the chemical device based on the weight coefficient and the level of each process safety index, and determine a dynamic early warning level of the chemical device;
and the early warning execution module 50 is used for executing corresponding risk early warning according to the dynamic early warning grade of the chemical device.
Further, the obtaining module 10 is further configured to:
acquiring risk factors of a chemical device;
and determining the static risk grade and the static risk score of the chemical device based on the preset risk matrix of the risk factors.
Further, each process safety index has a corresponding weight coefficient, the apparatus further comprises:
parameter classification module (not shown): the method is used for classifying all the process safety indexes based on the weight coefficients of the process safety indexes, wherein the sum of the weight coefficients of all the process safety indexes in each class of process safety indexes is 1.
Further, each grade has a corresponding grade score, and the dynamic risk determination module 40 is specifically configured to:
determining the grade score of each process safety index;
respectively correcting the static risk value of the chemical device based on the weight coefficient and the grade value of each process safety index in each type of process safety index to obtain the dynamic early warning value of each type of process safety index;
summing the dynamic early warning scores of all the classes of process safety indexes to obtain the total dynamic early warning score of the chemical device;
and obtaining the dynamic early warning grade of the chemical device according to a preset risk grading standard based on the dynamic early warning total value of the chemical device.
Further, the calculation formula of the dynamic early warning score of each type of process safety index is as follows:
wherein R is Static state Is the static risk score of the chemical plant; c i The grade value of each process safety index in the process safety indexes is divided; w is a group of i Is the weight coefficient of each process safety index in the process safety indexes, and sigma W i ＝1。
The invention provides a machine-readable storage medium, wherein instructions are stored on the machine-readable storage medium and used for enabling a machine to execute the chemical device risk correction early warning method based on the process safety index.
Example 1:
in this embodiment, fig. 3 is a schematic view of a risk matrix for static risk classification provided by the present invention, and as shown in fig. 3, the scores of the risk matrix are classified into 1 to 200, where 1 to 8 correspond to static low risk, 9 to 17 correspond to static general risk, 18 to 37 correspond to static high risk, and 38 to 200 correspond to static major risk, after determining the risk factors of the chemical plant, the static risk classification of the chemical plant is determined to be static general risk based on the preset risk matrix of the risk factors, and the static risk score is 15; the division standard of the preset grade interval is shown in table 1, and the process safety indexes listed in the table include: the average alarm number, the continuous alarm number in 24 hours, the process index qualification rate, the raw coal quality qualification rate, the automatic control rate, the equipment perfection rate and the equipment leakage rate are respectively marked as follows: a. b, c, d, e, f and g; the table sequentially lists the source of each process safety index, the unit of each process safety index, the division standard of three preset grade intervals corresponding to each process safety index and the weight coefficient corresponding to each process safety index, the three preset grade intervals are divided into 3 grades, 2 grades and 1 grade from high to low and respectively represent a high deviation grade interval, a low deviation grade interval and a normal interval, and the corresponding scores of the three grades are 1 grade, 2 grades and 3 grades; setting the time average alarm number (a), the 24-hour continuous alarm number (b), the process index qualified rate (c) and the raw coal quality qualified rate (d) as a first group; setting the automatic control rate (e), the equipment integrity rate (f) and the equipment leakage rate (g) as a second group, wherein the sum of the weight coefficients in the two groups is 1; and respectively calculating the dynamic risk values of the two groups, and adding the dynamic risk values of the two groups to serve as the dynamic early warning total value of the chemical device.
| Data | Unit | Grade | 3 | |
|
Weight coefficient | |
| Time-averaged alarm count | Real-time database | Console/h | ≥12 | <12 | <6 | 0.25 | |
| Number of continuous alarms for 24 hours | Real-time database | Console/h | ≥15 | <15 | <10 | 0.25 | |
| Percent of pass of process index | Real-time database | ％ | ≤95 | >95 | >98 | 0.25 | |
| Raw coal quality percent of pass | LIMS system | ％ | <85 | ≥85 | ≥95 | 0.25 | |
| Automatic rate of control | MES system | ％ | <95 | ≥95 | ≥98 | 0.3 | |
| Equipment availability factor | MES system | ％ | <96 | ≥96 | ≥98 | 0.3 | |
| Leakage rate of equipment | MES system | ％ | >0.05 | ≦0.05 | ≦0.03 | 0.4 |
TABLE 1 statistical table of process safety indexes
Reading the process parameters through a DCS (distributed control system) and storing the process parameters in a real-time database, wherein the time average alarm number of the obtained chemical devices is 10 alarms per hour, the continuous alarm number of the chemical devices per 24 hours is 2, the process index qualification rate is 96%, the raw coal quality qualification rate is 96% through a LIMS (laser induced mechanical Spectroscopy) system, the automatic control rate of the chemical devices is 97%, the equipment integrity rate of the chemical devices is 98%, the equipment leakage rate of the chemical devices is 0.04%, and according to the numerical values in the statistical table of the process safety indexes, the grade grades corresponding to the process safety indexes are respectively obtained as follows: c a = 2min, C b =1 min, C c = 2min, C d =3 min, C e = 2min, C f =3 min and C g =2 min; the weight coefficient corresponding to the process safety index is W a ＝0.25、W b ＝0.25、W c ＝0.25、W d ＝0.25、W e ＝0.3、W f =0.3 and W g =0.4; substituting the obtained static risk value of the chemical device, the weight coefficient corresponding to each process safety index data and the grade value of the grade into a calculation formula of the dynamic early warning total value to calculate the dynamic early warning total value, and calculating the dynamic early warning total value according to a second preset risk grading standardObtaining the dynamic early warning grade of the chemical device;
the specific calculation formula is:
after deformation:
substituting the data above:
R dynamic state =53 (minute)
And after the dynamic early warning total score is calculated, the dynamic early warning grade of the chemical device is obtained based on the preset risk grading standard.
Those skilled in the art can understand that all or part of the steps in the method for implementing the above embodiments may be implemented by a program, where the program is stored in a storage medium and includes several instructions to enable a single chip, a chip, or a processor (processor) to execute all or part of the steps in the method according to the embodiments of the present invention. And the aforementioned storage medium includes: a U-disk, a removable hard disk, a Read-Only Memory (ROM), a Random Access Memory (RAM), a magnetic disk, or an optical disk, and various media capable of storing program codes.
While the embodiments of the present invention have been described in detail with reference to the accompanying drawings, the embodiments of the present invention are not limited to the details of the above embodiments, and various simple modifications can be made to the technical solution of the embodiments of the present invention within the technical idea of the embodiments of the present invention, and the simple modifications are within the scope of the embodiments of the present invention. It should be noted that the various features described in the above embodiments may be combined in any suitable manner without departing from the scope of the invention. In order to avoid unnecessary repetition, the embodiments of the present invention will not be described separately for the various possible combinations.
In addition, any combination of the various embodiments of the present invention is also possible, and the same should be considered as disclosed in the embodiments of the present invention as long as it does not depart from the spirit of the embodiments of the present invention.
Claims (14)
1. A chemical device risk correction early warning method based on process safety indexes is characterized by comprising the following steps:
acquiring a process safety index of a chemical device and a static risk level of the chemical device in real time;
determining a weight coefficient of each process safety index;
determining the grade level corresponding to each process safety index according to the preset grade interval of the process safety index;
correcting the static risk level of the chemical device based on the weight coefficient and the level grade of each process safety index, and determining the dynamic early warning level of the chemical device;
and executing corresponding risk early warning according to the dynamic early warning grade of the chemical device.
2. The chemical device risk correction early warning method based on the process safety index as claimed in claim 1, wherein the process safety index is collected through a distributed control system, a laboratory information management system and a manufacturing enterprise production process execution system.
3. The chemical device risk correction early warning method based on process safety indexes as claimed in claim 1, wherein the preset grade interval of the process safety indexes from low to high is as follows: a normal interval, a low deviation grade interval and a high deviation grade interval;
the grade level is from low to high: a normal grade, a low deviation grade and a high deviation grade;
the static risk level is from low to high: static low risk, static general risk, static high risk and static major risk;
the dynamic early warning level is from low to high: dynamic low risk, dynamic general risk, dynamic high risk, and dynamic significant risk.
4. The chemical device risk correction early warning method based on the process safety index as claimed in claim 1, wherein the process safety index at least comprises: average alarm number, continuous alarm number for 24 hours, process index qualification rate, raw material quality qualification rate, automatic control rate, equipment integrity rate and equipment leakage rate.
5. The chemical plant risk correction early warning method based on process safety indexes as claimed in claim 1, wherein the method further comprises:
acquiring risk factors of a chemical device;
and determining the static risk grade and the static risk value of the chemical device based on the preset risk matrix of the risk factors.
6. The chemical plant risk correction early warning method based on process safety indexes as claimed in claim 5, wherein each process safety index has a corresponding weight coefficient, the method further comprises:
and classifying all the process safety indexes based on the weight coefficients of the process safety indexes, wherein the sum of the weight coefficients of all the process safety indexes in each class of process safety indexes is 1.
7. The chemical plant risk correction early warning method based on process safety indexes as claimed in claim 6, wherein each grade level has a corresponding grade level score, the static risk level of the chemical plant is corrected based on the weight coefficient and grade level of each process safety index, and the dynamic early warning level of the chemical plant is determined, including:
determining the grade score of each process safety index;
respectively correcting the static risk value of the chemical device based on the weight coefficient and the grade value of each process safety index in each type of process safety index to obtain the dynamic early warning value of each type of process safety index;
summing the dynamic early warning scores of all the classes of process safety indexes to obtain the total dynamic early warning score of the chemical device;
and obtaining the dynamic early warning grade of the chemical device according to a preset risk classification standard based on the dynamic early warning total value of the chemical device.
8. The chemical device risk correction early warning method based on process safety indexes as claimed in claim 7, wherein the calculation formula of the dynamic early warning score of each type of process safety indexes is as follows:
wherein R is Static state Is the static risk score of the chemical plant; c i The grade value of each process safety index in the process safety indexes is divided; w i Is the weight coefficient of each process safety index in the process safety indexes, and sigma W i ＝1。
9. The utility model provides a chemical plant device risk correction early warning device based on technology safety index which characterized in that, the device includes:
the acquisition module is used for acquiring the process safety index of the chemical device and the static risk level of the chemical device in real time;
the weight coefficient determining module is used for determining the weight coefficient of each process safety index;
the grade determining module is used for determining the grade corresponding to each process safety index according to the preset grade interval of the process safety index;
the dynamic risk determining module is used for correcting the static risk level of the chemical engineering device based on the weight coefficient and the level grade of each process safety index, and determining the dynamic early warning level of the chemical engineering device;
and the early warning execution module is used for executing corresponding risk early warning according to the dynamic early warning level of the chemical device.
10. The chemical plant risk correction early warning device based on process safety index of claim 9, wherein the obtaining module is further configured to:
acquiring risk factors of a chemical device;
and determining the static risk grade and the static risk value of the chemical device based on the preset risk matrix of the risk factors.
11. The chemical plant risk correction early warning device based on process safety indexes as claimed in claim 10, wherein each process safety index has a corresponding weight coefficient, the device further comprises:
and the parameter classification module is used for classifying all the process safety indexes based on the weight coefficients of the process safety indexes, wherein the sum of the weight coefficients of all the process safety indexes in each class of process safety indexes is 1.
12. The chemical plant risk correction early warning device based on process safety indexes as claimed in claim 11, wherein each grade level has a corresponding grade level score, and the dynamic risk determination module is specifically configured to:
determining the grade score of each process safety index;
respectively correcting the static risk value of the chemical device based on the weight coefficient and the grade value of each process safety index in each type of process safety index to obtain the dynamic early warning value of each type of process safety index;
summing the dynamic early warning scores of all the classes of process safety indexes to obtain the total dynamic early warning score of the chemical device;
and obtaining the dynamic early warning grade of the chemical device according to a preset risk classification standard based on the dynamic early warning total value of the chemical device.
13. The chemical device risk correction early warning device based on process safety indexes as claimed in claim 12, wherein the calculation formula of the dynamic early warning score of each type of process safety indexes is as follows:
wherein R is Static state A static risk score for the chemical plant; c i The grade value of each process safety index in the process safety indexes is divided; w is a group of i Is the weight coefficient of each process safety index in the process safety indexes, and sigma W i ＝1。
14. A machine-readable storage medium having stored thereon instructions for causing a machine to execute the chemical plant risk correction early warning method based on process safety indicators of any one of claims 1-8.
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