CN115907060A - Safety production early warning device and method for petrochemical enterprises - Google Patents

Abstract

The invention provides a safety production early warning device and a safety production early warning method for petrochemical enterprises, wherein the device acquires influence parameters of different channels through different acquisition units of a data acquisition module, and the influence parameters not only comprise production process parameters, but also give consideration to inherent danger data and enterprise management data; and then, a set operation strategy is utilized to determine comprehensive production state evaluation indexes and decide early warning instructions of different levels so as to transmit early warning information to a user and/or a control terminal, and meanwhile, a production prediction module is utilized to predict production state data of a future required time period based on a set production prediction model and decide future production management and control measures. By adopting the device, the defects of insufficient data acquisition depth and low data input intelligence in the conventional production management system are overcome, different processing logics are respectively designed for parameters of different channels, the calculation accuracy of the production state is improved, the real-time production state is truly embodied, and the production state of a future required time period is reliably predicted.

Description

Safety production early warning device and method for petrochemical enterprises

Technical Field

The invention relates to the technical field of petrochemical engineering reliability test and evaluation, in particular to a safety production early warning device and method for petrochemical enterprises.

Background

The petroleum and chemical fields belong to the field with higher professional requirements on practitioners, once faults or construction abnormalities occur, the personal safety of workers is directly influenced, in recent years, a plurality of major safety accidents continuously occur in the petroleum and chemical fields, general attention of the whole society is drawn, and in addition, the establishment of a safety production prediction early warning mechanism reflecting the safety production condition and the development trend of enterprises belongs to one of necessary conditions of benchmarking demonstration enterprises. However, in view of the existing safety production early warning and forecasting technologies, a manual entry mode is generally used, and a petrochemical enterprise generates a large amount of data, such as management data, process data, inherent danger data and the like, along with daily operation during daily operation, and the data is dispersed. Moreover, in the process of establishing a safety production early warning and forecasting system, the data mining means is single, comprehensive data elements cannot be effectively combined and are only input into a certain part one by one, and the safety analysis result cannot truly reflect the safety production state of an enterprise and cannot accurately predict the future development trend.

The information disclosed in this background section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art that is already known to a person skilled in the art.

Disclosure of Invention

In order to solve the problems, the invention provides a safety production early warning device for petrochemical enterprises, which automatically acquires enterprise management data, process data, inherent danger data and the like through a data acquisition function module, solves the problem of large workload of manual logging, transmits the data to an early warning terminal through a wireless 5G network for matching analysis and operation, realizes the functions of large-scale data acquisition, integrated management, analysis and processing and the like in reasonable time, can comprehensively reflect the safety production condition of the enterprise, predicts the future trend, effectively eliminates potential safety hazards and prevents accidents. In one embodiment, the apparatus comprises:

the data acquisition module is configured to acquire influence parameters related to petrochemical safety production states in different channels by adopting a matched acquisition mode respectively, and manage and store the influence parameters; the different channels comprise production process parameters, inherent danger data and enterprise management data;

the analysis operation module is configured to receive the collected various influence parameters, design corresponding analysis strategies according to the sources of the influence parameters, perform comprehensive analysis and operation and generate production state evaluation indexes;

the early warning decision-making module is connected with the analysis operation module and is configured to divide early warning grades according to a set grading standard based on the calculated production state evaluation index and decide an early warning instruction;

the early warning display module is configured to respond to the decided early warning instruction and transmit early warning information to a user and/or a control terminal, and synchronously display related production state data;

and the production prediction module is configured to establish a production prediction model by combining the evaluation indexes and the statistical analysis, and decide safety production management and control measures in a future requirement time period based on a prediction result of the model.

Preferably, in one embodiment, the data acquisition module includes:

the production device data acquisition unit is connected with a production device DCS system of the current petrochemical enterprise through an OPC interface, and acquires production device data of the petrochemical enterprise based on a wireless high-speed channel, wherein the production device data comprises the following production process parameters: temperature, flow, pressure, liquid level, interlock number of times, combustible gas, toxic gas's real-time recording data and corresponding warning number of times and warning duration.

Further, in one embodiment, the device further comprises an electronic tag which is arranged on the set risk production device and used for recording the corresponding property, the operation characteristic and the production environment risk data of the production device;

the data acquisition module acquires inherent danger information recorded in the electronic tag by using an inherent danger data acquisition unit arranged in the data acquisition module through a radio frequency identification technology, wherein the inherent danger information comprises: the inherent danger grade of the current production device is evaluated by the required fire explosion characteristic danger parameters of the production materials and the inherent danger parameters related to the process, equipment, factory buildings and environment.

In a specific embodiment, the apparatus is connected to a security management information system of a petrochemical enterprise, the data acquisition module includes a production information data acquisition unit that acquires enterprise management data of an HSE information management system of the petrochemical enterprise through a high-speed data channel, and the enterprise management data includes one or more of the following: enterprise safety education data, enterprise emergency measure status, contractor safety education data, and occupational hazard record data.

Further, in an embodiment, a data storage unit is arranged inside the data acquisition module, and different acquired influence parameters are stored in a partition storage mode by using a data type as a tag.

In an optional embodiment, the analysis and operation module includes a parameter rating unit configured to, after receiving the influence parameters transmitted through the 4G/5G wireless network, perform rating division on the influence parameters related to the production process parameters and the production management data according to a set rule and assign a rating matching the rating to the influence parameters.

Further, in an embodiment, the analysis and operation module further includes an inherent risk analysis module configured to analyze the inherent risk level of the current petrochemical enterprise by integrating the collected inherent risk parameters and the weight corresponding to each inherent risk coefficient, and decide the operation correction coefficient matched with the current petrochemical enterprise based on the inherent risk level.

In an optional embodiment, the analysis operation module further includes a state index calculation unit, connected to the parameter ranking unit, and configured to calculate the current security state index value of the petrochemical enterprise by introducing an operation correction coefficient obtained by a decision, using an operation model established based on each influence parameter and the scoring data.

Further, in one embodiment, the production prediction module comprises a prediction map generation unit and a production management planning unit;

the prediction map generation unit is configured to form a safety state prediction map of a required period based on an input time-series safety state index value using a gray prediction model;

the production management planning unit is connected with the prediction graph generating unit and is configured to analyze the safety state prediction graph, extract data related to petrochemical enterprise production process and enterprise management, generate safety production management and control measures based on the data, and transmit the safety production management and control measures to a user and/or a control terminal.

Based on other aspects of the apparatus in any one or more of the embodiments, the present invention further provides a safety production early warning method for petrochemical enterprises, including:

acquiring data, namely acquiring influence parameters related to petrochemical safety production states in different channels by a data acquisition module in a matched acquisition mode respectively, and managing and storing the influence parameters; the different channels comprise production process parameters, inherent danger data and enterprise management data;

analyzing and calculating, namely after receiving the collected various influence parameters, designing a corresponding analysis strategy by a set analysis and calculation module according to the source of each influence parameter, and carrying out comprehensive analysis and calculation to generate a production state evaluation index;

an early warning decision step, dividing early warning grades according to a set grading standard based on the calculated production state evaluation index and deciding an early warning instruction;

the early warning display step is to respond to the early warning instruction of the decision and transmit early warning information to a user and/or a control terminal through an early warning display module, and synchronously display related production state data;

and a production prediction step, establishing a production prediction model by adopting a mode of combining evaluation indexes and statistical analysis, and deciding a safety production control measure in a future required time period based on a prediction result of the model.

Compared with the closest prior art, the invention also has the following beneficial effects:

the invention provides a safety production early warning device and a safety production early warning method for petrochemical enterprises, wherein the device acquires influence parameters of different channels through different acquisition units of a data acquisition module, and the influence parameters comprise production process parameters, inherent danger data and enterprise management data; the defects of insufficient data acquisition depth and low data input intelligence in the existing production management system are overcome, the functions of large-scale data acquisition, integrated management, analysis and processing and the like are completed within reasonable time, the safety production condition of an enterprise can be comprehensively reflected, and the future trend can be predicted;

furthermore, the comprehensive production state evaluation index is determined by utilizing the set operation strategy, and the early warning instructions of different levels are decided so as to convey the early warning information to the user and/or the control terminal, different processing logics are respectively designed according to the influence parameters of different channels, and the accuracy of the production state index calculation is improved;

meanwhile, a production prediction module is used for predicting production state data of a future requirement time interval based on a set production prediction model, and making decisions on future production management and control measures, so that the real-time production state is truly embodied, the production state of the future requirement time interval is reliably predicted, production risks can be prevented in advance on the basis of finding potential safety hazards in production in time, and the method is beneficial to promoting the optimization of a hazardous chemical safety management system and the modernized development of management capacity.

Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.

Drawings

The accompanying drawings, which are included to provide a further understanding 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 principles of the invention and not to limit the invention. In the drawings:

fig. 1 is a schematic structural diagram of a safety production early warning apparatus for a petrochemical enterprise according to an embodiment of the present invention;

FIG. 2 is a structural integration setting diagram of a safety production early warning device in an embodiment of the invention;

fig. 3 is a schematic diagram illustrating data processing in the warning terminal in the safety production warning apparatus according to another embodiment of the present invention;

FIG. 4 is a diagram illustrating an example of production prediction data of a safety production early warning device according to an embodiment of the present invention;

fig. 5 is a distribution diagram of index scores of an example enterprise 2020 in a month related to a safety precaution device according to another embodiment of the present invention;

FIG. 6 is a graph illustrating a production index prediction curve for an exemplary enterprise to which a safety precaution device provided by an embodiment of the present invention relates;

fig. 7 is a flowchart illustrating a safety production warning method for a petrochemical enterprise according to yet another embodiment of the present invention.

Detailed Description

The following detailed description will be provided for the embodiments of the present invention with reference to the accompanying drawings and examples, so that the practitioner of the present invention can fully understand how to apply the technical means to solve the technical problems, achieve the technical effects, and implement the present invention according to the implementation procedures. It should be noted that, unless otherwise conflicting, the embodiments and features of the embodiments of the present invention may be combined with each other, and the technical solutions formed are all within the scope of the present invention.

Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel, concurrently, or simultaneously. The order of the operations may be rearranged. A process may be terminated when its operations are completed, but may have additional steps not included in the figure. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc.

The computer equipment comprises user equipment and network equipment. The user equipment or the client includes but is not limited to a computer, a smart phone, a PDA, and the like; network devices include, but are not limited to, a single network server, a server group of multiple network servers, or a cloud based on cloud computing consisting of a large number of computers or network servers. The computer devices may operate individually to implement the invention or may be networked and interoperate with other computer devices in the network to implement the invention. The network in which the computer device is located includes, but is not limited to, the internet, a wide area network, a metropolitan area network, a local area network, a VPN network, and the like.

The terms "first," "second," and the like may be used herein to describe various elements, but these elements should not be limited by these terms, which are used merely to distinguish one element from another. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items. When an element is referred to as being "connected" or "coupled" to another element, it can be directly connected or coupled to the other element or intervening elements may be present.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

In recent years, a plurality of major safety accidents continuously occur in the fields of petroleum and chemical industry, and the general attention of the whole society is attracted. The establishment of a prediction and early warning mechanism for safety production, which reflects the safety production condition and development trend of enterprises, belongs to one of the necessary conditions for being benchmarked enterprises. However, only a few petrochemical enterprises have established the safety production early warning and forecasting system, and in the process of establishing the safety production early warning and forecasting system, a manual entry mode is usually used, while in daily operation of the petrochemical enterprises, a large amount of data, such as management data, process data, inherent danger data and the like, generated along with the daily operation are scattered, and if the manual entry mode is adopted, the workload is huge if all the data are entered. Moreover, the existing mining means is single, in the prior art, only raw material input data and finished product generation data or intermediate material production and discharge data in the construction process of a petrochemical enterprise are usually obtained, the data cannot be effectively combined but are only recorded into a certain part on one side, and an analysis result cannot truly reflect the safe production state of the enterprise and cannot accurately predict the future development trend.

In order to solve the problems, the invention provides a safety production early warning device and a safety production early warning method for petrochemical enterprises, which automatically acquire influence parameters in the aspects of enterprise management, production process, inherent dangerous conditions and the like through different types of data acquisition units, solve the problem of large workload of manual input, realize operation and decision through transmitting the parameters to an early warning terminal through a wireless 5G network, and perform production state early warning and management and control optimization in current and future required time periods based on operation results.

The safety production early warning device provided by the invention can be reliably applied to the petrochemical field and other dangerous chemical industries, the current emergency management department has printed a test point construction scheme of industrial Internet + dangerous safety production, the digitization of enterprises and the accuracy of risk early warning are promoted by informatization, the predictable and controllable level of safety production management is improved, and advanced early warning is an important strategic selection for promoting the modernization of a safety management system and management capability of dangerous chemicals, so the technology has very wide application prospect.

The particular architecture and operational principles of the apparatus of embodiments of the present invention are described in detail below with reference to the accompanying drawings, where the operations illustrated in the schematic flow charts of the drawings may be implemented in a computer system containing, for example, a set of computer-executable instructions. Although a logical order of operations is illustrated in the flowcharts, in some cases, the steps illustrated or described may be performed in a different order than presented herein.

Example one

Fig. 1 is a schematic structural diagram illustrating a safety production early warning apparatus for a petrochemical enterprise according to an embodiment of the present invention, and as can be seen from fig. 1, the apparatus includes:

the data acquisition module is configured to acquire influence parameters related to petrochemical safety production states in different channels by adopting a matched acquisition mode respectively, and manage and store the influence parameters; the different channels comprise production process parameters, inherent danger data and enterprise management data;

the analysis operation module is configured to receive the collected various influence parameters, design corresponding analysis strategies according to the sources of the influence parameters, and carry out comprehensive analysis and operation to generate production state evaluation indexes;

the early warning decision-making module is connected with the analysis operation module and is configured to divide early warning grades according to set grading standards based on the calculated production state evaluation indexes and decide early warning instructions;

the early warning display module is configured to respond to the early warning instruction of the decision to transmit early warning information to a user and/or a control terminal and synchronously display related production state data;

and the production prediction module is configured to establish a production prediction model by combining the evaluation indexes and the statistical analysis, and decide safety production management and control measures in a future requirement time period based on a prediction result of the model.

By adopting the production early warning device shown in the embodiment, based on the automatic data acquisition technology, the data generated in the enterprise safety production process can be accurately and timely acquired, the complex workload of manual input is avoided, and the collection efficiency of system data is greatly improved. The acquired data are comprehensive, and the data are received and output on the early warning terminal through a plurality of databases.

Specifically, in one embodiment, the data acquisition module includes:

the production device data acquisition unit is connected with a production device DCS system of the current petrochemical enterprise through an OPC interface, and acquires production device data of the petrochemical enterprise based on a wireless high-speed channel, wherein the production device data comprises the following production process parameters: temperature, flow, pressure, liquid level, interlock number of times, combustible gas, toxic gas's real-time recording data and corresponding warning number of times and warning duration.

During practical application, the production device data acquisition unit (collector) can be connected with the DCS system server of the production device through the OPC interface, and also can be connected with an independent SIS system at the same time, automatically acquires relevant process parameters and alarm conditions, and comprises the following steps: the alarm times and alarm duration of temperature, flow, pressure and liquid level, the interlocking times, the alarm times and duration of combustible gas and toxic gas, and the like. The data acquisition module has the functions of real-time acquisition, automatic storage, automatic processing and automatic wireless transmission. The data are stored firstly, and then the analysis and calculation module of the early warning terminal is transmitted through a 4G/5G wireless network.

In an optional embodiment, the data acquisition module performs automatic processing on the collected data by performing the following operations:

setting calculation frequency and calculation rules according to pre-imported data of range, upper limit, lower limit and the like of the process parameters; according to the collected technological parameters, the alarm frequency and the alarm duration are automatically calculated, and key indexes such as the number of repeated alarm points, the number of repeated alarm times, the average alarm duration, the average alarm times of the points, the maximum alarm duration and the like are calculated.

Furthermore, in consideration of the inevitable potential safety hazard of production devices or equipment and production environments, the researchers provided by the invention directly affect the personal safety of workers in the production process, therefore, the RFID electronic tag provided by the invention stores inherent danger data of the production devices or equipment and production environments, is usually attached to a place where the production devices are obvious and convenient for personnel to operate, and mainly stores inherent danger parameters of production materials, such as fire explosion characteristics, processes, equipment, plants, environments and the like, required by evaluation of inherent danger levels of the production devices, and is periodically scanned by equipment with a radio frequency identification function before early warning calculation, so as to acquire information on the electronic tag. Therefore, in one embodiment, the system further comprises an electronic tag which is arranged on the set risk production device and used for recording the attribute and the operating characteristic of the corresponding production device and the risk data of the production environment;

the data acquisition module acquires inherent danger information recorded in the electronic tag by using an inherent danger data acquisition unit arranged in the data acquisition module through a radio frequency identification technology, wherein the inherent danger information comprises: the inherent danger level of the current production device is evaluated by the required fire explosion characteristic danger parameters of the production materials and the inherent danger parameters related to the process, equipment, factory buildings and environment.

In practical applications, in a preferred embodiment, the system is connected to a safety management information system of a petrochemical enterprise, the data acquisition module includes a production information data acquisition unit, which acquires enterprise management data of an HSE information management system of the petrochemical enterprise through a high-speed data channel, where the enterprise management data includes one or more of the following: enterprise safety education data, enterprise emergency measure status, contractor safety education data, and occupational hazard record data.

Based on the above-mentioned setting in the embodiment, the production information data acquisition unit (collector) is connected to the security information management system server commonly used by the petrochemical enterprise, and automatically acquires the relevant enterprise management data managed by the HSE of the petrochemical enterprise, including: enterprise training in the aspect of enterprise safety education data is finished according to plan, the effective rate of enterprise personnel certificates, the training rate of whole members in the last year, the certificate holding rate of safety management personnel, the finishing rate of safety education training of new personnel, the training attendance rate and the implementation rate of major risk control measures; identifying the regional coverage rate, the emergency drilling completion rate and the emergency material completion rate of the last year risk in the aspect of the emergency measure state of the enterprise; the contractor education training qualification rate, the contractor problem rectification rate according to the plan, the contractor inspection coverage rate and the contractor education training completion rate in the aspect of the contractor safety education data; and the plan-based correction rate, the per-person diagnosis extraction rate, the diagnosis suggestion participation rate, the diagnosis problem processing rate, the comprehensive inspection implementation rate, the occupational hazard detection qualification rate, the standard exceeding correction and correction time rate of monitoring points, the protection facility perfection rate, the abnormal physical examination occurrence rate, the abnormal physical examination processing rate, the hidden danger project correction rate and the like of the inspection problems in the aspect of occupational hazard record data.

Compared with the current mode of singly relying on the traditional instrument import monitoring early warning or only depending on the manual experience to input hidden danger investigation data, the method deeply excavates the data of safety management generated by a safety management information system commonly used by petrochemical enterprises, combines the inherent dangerous data condition of the enterprises, decides different operation correction coefficients according to the dangerous data condition with different levels, is used for calculating the safety state evaluation index, enables the evaluation index result to be more accurate, can more truly reflect the safety production state of the enterprises, and provides a reliable prediction data basis for predicting the safety production trend in a period of time in the future.

In addition, after the data acquisition module acquires the influence parameters of different channels through the corresponding data side acquisition units, the data acquisition module has the functions of automatic storage, automatic management and automatic wireless transmission, and the data are sequentially stored and then transmitted to the subsequent analysis and operation module through a 4G/5G wireless network. Specifically, in one embodiment, the data acquisition module is internally provided with a data storage unit, and stores the acquired different influence parameters in a partitioned storage mode by using the data type as a tag.

In practical application, the sub-functional modules of the safety production early warning device can be integrated according to requirements, for example, the analysis operation module, the early warning decision module, the early warning display module and the production prediction module are integrated in an early warning terminal which is in communication connection with the data acquisition module and the remote control system, as shown in fig. 2, the data acquisition module is in communication connection with the integrated early warning terminal, and various influence parameter data acquired by the data acquisition module are transmitted to the early warning terminal through a wireless network.

Further, considering that the scale of a petrochemical enterprise may be large, in order to facilitate a user to obtain early warning display information in time, in an embodiment, a plurality of early warning terminals are provided, for example, early warning terminals integrated with a plurality of functional modules are provided at each production area, office area, plant area gate, and the like. Each early warning terminal is also provided with a touch display screen, and workers can perform man-machine interaction with the early warning terminal through an interaction interface of the touch display screen.

Specifically, fig. 3 shows a schematic diagram of data processing in the warning terminal in the safety production warning device according to the embodiment of the present invention, and as shown in fig. 3, in an embodiment, an analysis operation module in the warning terminal includes a parameter rating unit, which is configured to, after receiving an influence parameter transmitted through a 4G/5G wireless network, perform rating division on the influence parameter related to the production process parameter and the production management data according to a set rule, and assign a rating matching the rating.

During actual application, the analysis operation module analyzes the influence parameters related to the production device and enterprise management transmitted by the data acquisition module through the parameter rating unit, each parameter index is given a score according to a set rating standard, the score is 5 full scores, 5 grades are given, and 1-5 grades are respectively given, and the numerical range of the parameter index corresponding to each grade in the rating standard can be set in a user-defined mode through the early warning terminal system. And an early warning decision module in the early warning terminal is connected with an analysis and operation module, and the analysis and operation module transmits the processed safety state operation result to the early warning decision module.

Further, inherent danger data are obtained by scanning a data acquisition module through a radio frequency identification technology, an analysis operation module of the early warning terminal needs to deeply analyze inherent danger characteristics of a production device and a production environment and divide inherent danger levels of the production device. Therefore, in one embodiment, the analysis and operation module further includes an inherent risk analysis module configured to analyze the inherent risk level of the current petrochemical enterprise by integrating the collected inherent risk parameters and the weight corresponding to each inherent risk coefficient, and to decide the operation correction coefficient matched with the current petrochemical enterprise based on the inherent risk level, as shown in table 1 below:

TABLE 1 inherent hazard level correction factor Table

Inherent hazard level	Correction factor
		First stage	W 1 ＝2
Second stage	W 2 ＝1.2
		Three-stage	W 3 ＝1
Four stages	W 4 ＝0.85
		Five stages	W 5 ＝0.75

Further, the analysis operation module further comprises a state index calculation unit, which is connected with the parameter rating unit and the inherent risk analysis module, and is configured to calculate the current safety state index value of the petrochemical enterprise by using an operation model established based on each influence parameter and the rating data and introducing an operation correction coefficient obtained by decision making. In practical application, after the analysis operation module of the early warning terminal receives the processing data of the analysis operation module and the inherent danger level module, the percentage score calculation is carried out on the production state index, different correction coefficients are given to different inherent danger levels, and the comprehensive safety state index value of the petrochemical enterprise is calculated according to the following operation model:

safety production early warning index = production state index score x correction coefficient

Production state index score = (actual score of multiple indices/total score of indices) × 100

After the safety state index value is obtained through calculation, early warning grade division is carried out according to the set grade standard, when the safety state index value is actually applied, the safety production state of an enterprise can be divided into 4 grades such as safety, attention, warning and danger, and the division threshold value in the grade standard can adopt a defined numerical value among the grades and can be set in a system setting in a user-defined mode.

Further, an early warning decision module of the system ranks the current production state according to a set grading standard based on the calculated production state evaluation index, and decides a matched early warning instruction.

In order to enable a user to more intuitively and clearly identify the safety level of the production state, the early warning display module of the system can generate a curve display image of a set time period according to the calculated production state evaluation index, and set 4 early warning levels with obvious early warning colors.

Combining with an actual application scene, the early warning instruction can comprise acousto-optic early warning, the acousto-optic early warning of the early warning terminal determines whether to trigger acousto-optic early warning according to the area of the production state index number in the curve display image, the acousto-optic early warning is not executed in a safety area, and if the current production state index number is in an attention area, yellow warning light early warning is displayed; if the alarm area is located, an orange alarm lamp is displayed for early warning; if the dangerous area exists, a red warning light is displayed for early warning, and the sent sound alarm has different degrees of sharpness along with different grade areas. In an actual production scene, the components or equipment for executing the acousto-optic early warning instruction can be arranged at positions convenient for workers to find according to requirements, and each acousto-optic warning component or equipment is in communication connection with the early warning decision module of the early warning terminal.

When the early warning is actually carried out, a touch display screen of the early warning terminal can be used as an early warning display module, and production state data and solution measures related to the real-time early warning are displayed for a user; in the embodiment of the other hand, the early warning display module can be arranged in cooperation with the acousto-optic alarm assembly or the acousto-optic alarm equipment, so that production state data and solution measures corresponding to acousto-optic alarm can be conveniently displayed for a user, the reason for triggering acousto-optic alarm can be known for the first time by the user, the timeliness for solving the abnormal production condition is improved, and fault expansion is avoided.

In addition, the production prediction module of the early warning terminal is connected with the analysis operation module, predicts the production state of a future required time period based on the calculated production state data, and is used for providing guidance for the production management of petrochemical enterprises in the future time period. Specifically, according to the calculation result of the early warning terminal analysis operation module, a production state curve graph is generated every day/week/month (which can be selected by user in the system) and is connected to form a production index curve, further, the production prediction module predicts the production state data of the future required time period through a grey prediction model (for example, the value of 1-6 months in the future from the calculation time point can be selected by user), and fig. 4 shows the result of predicting the production state value of three months in the future in monthly unit.

Therefore, in one embodiment, the production prediction module comprises a prediction graph generation unit and a production management planning unit;

the prediction map generation unit is configured to form a safety state prediction map of a required period based on an input time-series safety state index value using a gray prediction model;

the production management planning unit is connected with the prediction graph generating unit and is configured to analyze the safety state prediction graph, extract data related to petrochemical enterprise production process and enterprise management, generate safety production management and control measures based on the data, and transmit the safety production management and control measures to a user and/or a control terminal.

The method comprises the following steps of automatically calculating the safety production early warning index of a certain historical time period according to a safety production early warning index model, connecting the early warning indexes in multiple periods to form a safety production early warning index curve meeting the requirement on scale, and calculating the future trend of the change of the early warning index by adopting a discrete gray prediction model DGM (1, 1) based on the production early warning index curve, wherein the specific process is as follows:

let X ⁽⁰⁾ Is a non-negative sequence, X ⁽⁰⁾ ＝{x ⁽⁰⁾ (1),x ⁽⁰⁾ (2)，…，x ⁽⁰⁾ (n)}

Calculating X of one accumulation ⁽⁰⁾ Generating a related sequence X ⁽¹⁾

X ⁽¹⁾ ＝{x ⁽¹⁾ (1),x ⁽¹⁾ (2)，…，x ⁽¹⁾ (n) }, wherein

Calculating parameter values, if sets of parameters, by means of least squares

Is a parameter column, and

discrete gray prediction model X ⁽¹⁾ (k+1)＝β ₁ X ⁽¹⁾ (k)+β ₂ Satisfies the least square estimation parameter series

Take x ⁽¹⁾ (1)＝x ⁽⁰⁾ (1) Then the recurrence function is

Or

Finding the reduction value

The data of a certain hazardous chemical enterprise in 2020 and 1-6 months is adopted as follows:

x ⁽⁰⁾ ＝(43.61,48.32,42.82,32.67,37.85,45.64)

x ⁽¹⁾ ＝(43.61,91.93,134.75,167.42,205.27,250.91)

the predicted values of the 3 steps are 37.59,36.40 and 35.24 respectively.

The invention also provides a model testing module which tests the prediction model by calling historical test data, calculates error information of the obtained simulation value and the real data and verifies the accuracy of the prediction model based on the actual error information. In one embodiment, the error checking results are shown in the following table.

TABLE 11 error checking chart

According to the inspection, the error between the simulation value and the original value is less, the accuracy requirement of petrochemical enterprise production is met, and the prediction model can be used.

As shown in fig. 5, the four primary index score distribution graphs displayed by the early warning system of a certain dangerous chemical enterprise 2020 in a month can understand weak links existing in enterprise safety management through the distribution graphs, the early warning system calculates early warning indexes in the current month by using a model, the early warning indexes in each month are connected to form an early warning index curve, and according to the generated early warning index curve, the early warning index value and the development trend curve of the early warning index value in a future period are represented by the system through a gray prediction model, as shown in fig. 6;

in addition, in order to ensure that technicians can know the abnormal condition of the future production state in advance, when the prediction time and the current time meet the set conditions, the early warning signal is output according to the set early warning instruction for the production state prediction data in the attention area, the warning area or the dangerous area.

By adopting the production early warning device provided by the embodiment of the invention, the problem that the enterprise safe production state cannot be really realized due to the fact that a single analysis result is input in a data sheet is solved, the functions of large-scale data acquisition, integrated management, analysis decision and the like can be realized within reasonable time, the enterprise safe production condition can be comprehensively reflected, the future trend can be predicted, the early warning information can be displayed, the attention of related personnel of the enterprise can be timely reminded, effective measures can be taken, the potential safety hazard can be eliminated, and the accident can be prevented.

In the safety production early warning device for petrochemical enterprises, provided by the embodiment of the invention, each module or unit structure can be independently operated or operated in a combined manner according to actual analysis and decision requirements so as to realize corresponding technical effects.

Example two

The structure and the early warning principle of the production early warning device are described in detail in the embodiment disclosed by the invention, and based on the application of the device in any one or more embodiments, the invention also provides a safe production early warning method for petrochemical enterprises, which is applied to the safe production early warning device for petrochemical enterprises in any one or more embodiments. Specific examples are given below for a detailed description.

Specifically, fig. 7 is a schematic flow chart of a safety production early warning method for a petrochemical enterprise according to an embodiment of the present invention, and as shown in fig. 7, the method includes the following operation steps:

acquiring data, namely acquiring influence parameters related to petrochemical safety production states in different channels by a data acquisition module in a matched acquisition mode respectively, and managing and storing the influence parameters; the different channels comprise production process parameters, inherent danger data and enterprise management data;

analyzing and calculating, namely after receiving the collected various influence parameters, designing a corresponding analysis strategy by a set analysis and calculation module according to the source of each influence parameter, carrying out comprehensive analysis and calculation and generating a production state evaluation index;

an early warning decision step, dividing early warning grades according to set grading standards based on the calculated production state evaluation indexes and deciding an early warning instruction;

the early warning display step is to respond to the early warning instruction of the decision and transmit early warning information to a user and/or a control terminal through an early warning display module, and synchronously display related production state data;

and a production prediction step, establishing a production prediction model by adopting a mode of combining evaluation indexes and statistical analysis, and deciding a safety production control measure in a future required time period based on a prediction result of the model.

In practical applications, in one embodiment, the data obtaining step includes the following operations:

the method comprises the steps of acquiring data of a production device, connecting the data of the production device with a DCS (distributed control System) of the current petrochemical enterprise through an OPC (optical proximity correction) interface, and acquiring data of the production device of the petrochemical enterprise based on a wireless high-speed channel, wherein the data of the production device comprises the following production process parameters: the real-time recording data of temperature, flow, pressure, liquid level, interlocking times, combustible gas and toxic gas, and the corresponding alarm times and alarm duration.

Acquiring inherent danger data, and acquiring inherent danger information recorded in the electronic tag through a radio frequency identification technology, wherein the inherent danger information comprises: the method comprises the following steps of (1) evaluating the inherent danger level of a current production device by using the required fire explosion specific danger parameters of production materials and the inherent danger parameters related to processes, equipment, plants and environments; the electronic tag is an electronic information tag which is arranged on a set dangerous production device by a system to record the self attribute, the operation characteristic and the dangerous data of the production environment of the corresponding production device;

a production information data collection step of collecting enterprise management data of the HSE information management system of the petrochemical enterprise through a high-speed data channel, wherein the enterprise management data comprises one or more of the following aspects: enterprise safety education data, enterprise emergency measure status, contractor safety education data, and occupational hazard record data.

In a preferred embodiment, the method further comprises a data storage step of storing the acquired different influence parameters in a partition storage mode by using the data type as a tag.

Further, in one embodiment, the analyzing operation step includes the following operations:

and a parameter grading step, after receiving the influence parameters transmitted by the 4G/5G wireless network, grading the influence parameters related to the production process parameters and the production management data according to a set rule and assigning grades matched with the grades.

The method comprises the steps of inherent danger analysis, namely integrating acquired inherent danger parameters and weights corresponding to all inherent danger coefficients to evaluate the inherent danger level of the current petrochemical enterprise, and deciding the operation correction coefficient matched with the current petrochemical enterprise based on the inherent danger level;

and calculating the state index, namely calculating the safety state index value of the current petrochemical enterprise by introducing an operation correction coefficient obtained by decision by using an operation model established based on each influence parameter and the scoring data.

Preferably, in one embodiment, the production prediction step includes the following operations:

a prediction graph generation step of forming a safety state prediction graph of a requirement period based on an input time sequence safety state index value by using a gray prediction model;

and the production management planning step is used for analyzing the safety state prediction diagram, extracting data related to the production process and enterprise management of the petrochemical enterprise, and generating a safety production control measure based on the data and transmitting the safety production control measure to a user and/or a control terminal.

While, for purposes of simplicity of explanation, the foregoing method embodiments have been described as a series of acts or combination of acts, it will be appreciated by those skilled in the art that the present invention is not limited by the illustrated ordering of acts, as some steps may occur in other orders or concurrently in accordance with the invention. Further, those skilled in the art should also appreciate that the embodiments described in the specification are preferred embodiments and that the acts and modules referred to are not necessarily required by the invention.

It should be noted that, in other embodiments of the present invention, the method may further obtain a new safety production early warning method by combining one or some of the above embodiments, so as to implement optimization of production management and control of a petrochemical enterprise.

It should be noted that, based on the method in any one or more embodiments of the present invention, the present invention further provides a storage medium having program codes stored thereon, which can implement the method in any one or more embodiments of the present invention, and when the program codes are executed by an operating system, the method for pre-warning safety production in a petrochemical enterprise as described above can be implemented.

It is to be understood that the disclosed embodiments of the invention are not limited to the particular structures, process steps, or materials disclosed herein but are extended to equivalents thereof as would be understood by those ordinarily skilled in the relevant arts. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.

Reference in the specification to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. Thus, the appearances of the phrase "an embodiment" appearing in various places throughout the specification are not necessarily all referring to the same embodiment.

Although the embodiments of the present invention have been described above, the above descriptions are only for the convenience of understanding the present invention, and are not intended to limit the present invention. It will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.

Claims (10)

1. A safety in production early warning device for petrochemical enterprise, its characterized in that, the device includes:

the data acquisition module is configured to acquire the influence parameters related to the petrochemical safety production state of different channels by adopting a matched acquisition mode respectively, and manage and store the influence parameters; the different channels comprise production process parameters, inherent danger data and enterprise management data;

the analysis operation module is configured to receive the collected various influence parameters, design corresponding analysis strategies according to the sources of the influence parameters, perform comprehensive analysis and operation and generate production state evaluation indexes;

the early warning decision-making module is connected with the analysis operation module and is configured to divide early warning grades according to a set grading standard based on the calculated production state evaluation index and decide an early warning instruction;

the early warning display module is configured to respond to the early warning instruction of the decision and transmit early warning information to the user and/or the control terminal, and synchronously display related production state data;

and the production prediction module is configured to establish a production prediction model by combining the evaluation indexes and the statistical analysis, and decide safety production management and control measures in a future requirement time period based on a prediction result of the model.

2. The apparatus of claim 1, wherein the data acquisition module comprises:

the production device data acquisition unit is connected with a production device DCS system of the current petrochemical enterprise through an OPC interface, and acquires production device data of the petrochemical enterprise based on a wireless high-speed channel, wherein the production device data comprises the following production process parameters: temperature, flow, pressure, liquid level, interlock number of times, combustible gas, toxic gas's real-time recording data and corresponding warning number of times and warning duration.

3. The device of claim 1, further comprising an electronic tag disposed on the set risk production device for recording the corresponding production device's own attributes, operation characteristics and production environment risk data;

the data acquisition module acquires inherent danger information recorded in the electronic tag by using an inherent danger data acquisition unit arranged in the data acquisition module through a radio frequency identification technology, wherein the inherent danger information comprises: the inherent danger level of the current production device is evaluated by the required fire explosion characteristic danger parameters of the production materials and the inherent danger parameters related to the process, equipment, factory buildings and environment.

4. The apparatus of claim 1, wherein the apparatus is connected to a safety management information system of a petrochemical enterprise, and the data acquisition module comprises a production information data acquisition unit which acquires enterprise management data of an HSE information management system of the petrochemical enterprise through a high-speed data channel, wherein the enterprise management data comprises one or more of the following aspects: enterprise safety education data, enterprise emergency measure status, contractor safety education data, and occupational hazard record data.

5. The device of claim 1, wherein the data acquisition module is internally provided with a data storage unit for storing the acquired different influencing parameters in a partition storage mode by taking the data type as a tag.

6. The device of claim 1, wherein the analysis and operation module comprises a parameter grading unit configured to grade the impact parameters related to the production process parameters and the production management data according to a set rule and assign a grade matching the grade after receiving the impact parameters transmitted through the 4G/5G wireless network.

7. The apparatus of claim 1, wherein the analysis and calculation module further comprises an inherent risk analysis module configured to analyze the inherent risk level of the current petrochemical enterprise by integrating the collected inherent risk parameters and the weight corresponding to each inherent risk coefficient, and to decide the calculation and correction coefficient matched with the current petrochemical enterprise based on the inherent risk level.

8. The apparatus according to claim 6 or 7, wherein the analysis and operation module further comprises a state index calculation unit, connected to the parameter ranking unit, configured to calculate the current petrochemical enterprise safety state index value by introducing a decision-making operation modification coefficient using an operation model established based on each impact parameter and the scoring data.

9. The apparatus of claim 1, wherein the production prediction module comprises a prediction graph generation unit and a production management planning unit;

the prediction map generation unit is configured to form a safety state prediction map of a required period based on an input time-series safety state index value using a gray prediction model;

the production management planning unit is connected with the prediction graph generating unit and is configured to analyze the safety state prediction graph, extract data related to petrochemical enterprise production processes and enterprise management, generate safety production management and control measures based on the data and transmit the safety production management and control measures to users and/or control terminals.

10. A safety production early warning method for petrochemical enterprises is characterized by comprising the following steps:

acquiring data, namely acquiring influence parameters related to petrochemical safety production states in different channels by a data acquisition module in a matched acquisition mode respectively, and managing and storing the influence parameters; the different channels comprise production process parameters, inherent danger data and enterprise management data;

analyzing and calculating, namely after receiving the collected various influence parameters, designing a corresponding analysis strategy by a set analysis and calculation module according to the source of each influence parameter, and carrying out comprehensive analysis and calculation to generate a production state evaluation index;

an early warning decision step, dividing early warning grades according to set grading standards based on the calculated production state evaluation indexes and deciding an early warning instruction;

the early warning display step is to respond to the early warning instruction of the decision and transmit early warning information to a user and/or a control terminal through an early warning display module, and synchronously display related production state data;

and a production prediction step, establishing a production prediction model by adopting a mode of combining evaluation indexes and statistical analysis, and deciding a safety production control measure in a future required time period based on a prediction result of the model.

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