CN116414086A - Device for integrating safety control system based on FMEDA failure prediction technology - Google Patents
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Abstract
The invention provides a device for integrating a safety control system based on an FMEDA failure prediction technology, which comprises: the system comprises a structure organization module, a functional model construction module, a failure prediction module and a target system selection module, wherein a corresponding functional module relation model is constructed for the complete architecture of a planned safety control system based on a 1oo1 model; and further, the failure prediction module analyzes the failure probability of the operation function module around different available structures corresponding to each function module, and the target structure of each function module is optimized according to the calculation result of the failure probability, so that the integrated safety control system which is formally put into use is obtained through integration, clear reliability basis can be provided for early design decision of system products, the failure probability of the designed integrated safety control system is controlled to be the lowest, and the optimal safety control service is provided for equipment to be protected by enterprises.
Description
Technical Field
The invention relates to the technical field of system safety control and optimization, in particular to a device for integrating a safety control system based on an FMEDA failure prediction technology, which is mainly applied to industries such as petrochemical industry and the like.
Background
In the actual production process, in order to prevent and reduce the practitioner risk of the petrochemical enterprise factory field or device, a safety control system (SIS) is required to be arranged, and the reasonable design and stable operation of the system can directly provide guarantee for the safe operation of the field or device and control the influence of the practitioner risk on the safety of business, manpower and material resources. The safety control system can monitor potential danger in the industrial process, timely send alarm information or automatically execute preset protection functions, and the last protection layer positioned on the active protection layer is the most critical protection layer. When the device breaks down, the safety control system can enable the whole device to enter a safe state and give an alarm, timely remind related personnel to carry out fault detection and eliminate the fault, finally avoid accidents, reduce life and property loss caused to personnel and equipment, and furthest reduce adverse effects on the environment.
In recent years, the emerging small-sized green chemical devices or equipment are widely applied, and typical devices comprise an electrolytic water hydrogen production device, a methane cracking hydrogen production device, a hydrogen storage and transportation device, a compressor, a heating furnace (an exhaust gas treatment RTO furnace), an oil gas recovery device, an exhaust gas treatment device, a small-sized oil gas storage and transportation device (an oil delivery station), and the like. The management technical field of the small-sized safety control system is still blank at present, the product of the domestic and foreign safety control system is mainly used for medium-sized and large-sized chemical devices with safety control points above 100 points, and the management strategy is blindly and forcedly arranged on the small-sized chemical devices, so that the problems of excessive investment and arrangement exist, the stability of system operation cannot be ensured, and the problem is also the main reason that the safety instrument system arrangement is not carried out by the small-sized chemical enterprises at present.
Aiming at multi-link safety control business of an integral enterprise, a multi-level small-sized modularized safety control assembly is needed to meet the actual protection requirement of the small-sized device, but as the conditions of manufacturers of components adopted in the integration, whether the components are authenticated by safety functions, authentication level and the like are different, how to calculate the operation reliability of the modularized integrated safety control system is a problem to be solved urgently.
Currently researchers have proposed methods in part to estimate the probability of system failure, such as in the orea industry database published by norwegian class company in 2015, where the probability of failure is characterized as a maximum likelihood estimate (i.e., the total number of faults divided by the total time of operation). Meanwhile, the technician should consider the system-specific operating environment and conditions due to the estimation of the failure rate, so that it is necessary to analyze the influence of various operating conditions in different environments using different models. Foucher and Ratkowsky et al propose that a physical model based on physical laws such as Arrhenius's law, voltage acceleration, and Gangen's law is used to estimate the probability of failure. Failure analysis functions of parameters are presented in standard IEC 6170-2017, where temperature, humidity, stress, voltage or electrical strength are involved. In addition, the trend of the failure probability change can also be predicted by a statistical model using specific operation data, such as a Cox model (proportional hazard model) and a bayesian model. Brissaud proposes a method for predicting failure rate taking into account the influence of design, manufacturing or installation factors, vatn is based on a similar method, while taking into account the implementation effect of predictive assessment risk reduction measures.
Most of the above statistical models are dependent on a large amount of equipment and large-scale sample data, are not suitable for petrochemical enterprise equipment requiring small-scale safety control systems, and for new integrated safety control systems with small application range and short time, no large amount of data can be used as reference in the design stage or the initial operation stage.
The information disclosed in the background section of the invention 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 already known to a person skilled in the art.
Disclosure of Invention
In order to solve the problems, the invention provides a device for integrating a safety control system based on an FMEDA failure prediction technology, which can accurately integrate a small modularized safety control system, wherein the integrated system is used for identifying the fault state of enterprise equipment and automatically protecting the device. In one embodiment, the apparatus comprises:
The structure organization module is configured to draw the architecture of the target safety control system according to the protection requirements of all devices in the enterprise, and organize all available structures of all target functional modules of the preset safety control system based on the drawn architecture; the useable structure includes a stand-alone device and/or a mature component;
the function model building module is configured to build a corresponding function module relation model for the complete framework of the planned safety control system based on the 1oo1 model;
the failure prediction module is configured to analyze and calculate the failure probability of the functional module in operation around different available structures corresponding to each functional module according to the constructed functional module relation model;
and the target system selection module optimizes the target structure of each functional module according to the calculation result of the failure probability, and integrates the target structure to obtain the formally used integrated safety control system.
Preferably, in one embodiment, the configuration organization module sets a target function module of the safety control system, including:
the information acquisition module is configured to acquire the operation information of the protected equipment in the enterprise in real time;
the logic control module is in communication connection with the information acquisition module and is configured to receive the acquired equipment operation information, perform operation and analysis according to matched program logic and generate a control instruction;
The input end of the safety relay is connected with the logic control module, and the output end of the safety relay is connected with the target control component, so that the automatic adjustment and conversion of the control component circuit are realized;
further, in one embodiment, the safety control system further includes a safety barrier function module connected between the information acquisition module and the logic control module, to limit the electrical signal supplied to the logic control module to a set safety range.
Specifically, in one embodiment, the logic control module adopts a programmable redundancy logic controller, which includes at least two internal control units, each internal control unit respectively performs operation on the equipment operation information according to the same program, if the error of the obtained multiple operation results meets the set condition, a final operation result is generated and output, otherwise, the set operation parameters are output.
In an alternative embodiment, the logic control module further includes an input safety card and an output safety card, where the input safety card is connected to the downstream end of the safety barrier function module and is used for receiving the transmitted signal, and the output safety card is connected to the upstream end of the safety relay and is used for outputting the control signal.
Further, in one embodiment, the logic control module further includes a behavior monitoring circuit electrically connected to each internal control unit, and configured to cross check the operation state of the processor circuit of each internal control unit using a plurality of different oscillators, and each internal control unit checks whether another internal control unit is operated using a clock, and if it is detected that there is no operation within a set period of the internal control unit, the logic control module is put into a safe state.
On the other hand, in one embodiment, the logic control module further includes a clock monitoring unit, configured to monitor the action time of each internal control unit and the time of executing the program logic, and output a corresponding safety parameter if the condition that the set condition is exceeded exists.
In application, in one embodiment, the failure prediction module is configured to predict the failure probability of the operation function module by:
step A1, referring to corresponding product manuals for all available structures of different types and models respectively to obtain operation failure parameters of the product manuals relative to the whole safety control system, wherein the operation failure parameters comprise: the detected security failure probability, the undetected security failure probability, the sensed abnormality information ratio, and the undetected sensed abnormality information ratio;
A2, aiming at each functional module of the system, adopting a fault tree analysis method, and sequentially introducing each operation failure parameter of the structure to calculate the comprehensive failure probability of the functional module;
and step A3, integrating to obtain a high-quality safety control system according to the comprehensive failure probability of the functional module and the optimal organization scheme.
Specifically, in one embodiment, the failure prediction module further calculates the comprehensive failure probability of each functional module according to the following operations:
a2-1, taking each functional module in the system as an analysis object, taking each available structure as a sub-analysis object, introducing each operation failure parameter of the sub-analysis object, and calculating the corresponding instantaneous failure probability of the available structure;
step A2-2, further determining the average failure probability corresponding to each available structure according to a set strategy based on the instantaneous failure probability;
step A2-3, introducing a detection period parameter to determine the failure probability of each available structure in unit time based on the average failure probability;
and step A2-4, calculating the comprehensive failure probability of the whole functional module by using the logic of the fault tree analysis method by taking the failure probability of unit time as a lower analysis basis.
In an alternative embodiment, the failure prediction module, prior to performing steps A2-4, is further configured to: and comparing the failure probability of each available structure in unit time with a set probability threshold, and if the failure probability exceeds the threshold, moving the structure out of the available structure list, and only putting the rest available structures into the operation of the step A2-4.
Compared with the closest prior art, the invention has the following beneficial effects:
the invention provides a device for integrating a safety control system based on an FMEDA failure prediction technology, which comprises the steps of firstly, constructing a framework of a target safety control system according to the protection requirements of various devices in an enterprise through a structure organization module, and organizing all available structures of various target functional modules of the preset safety control system based on the constructed framework; the whole framework can be designed around the operation target of the safety control system, and the comprehensive functional structures of various models or brands can be formulated, so that the comprehensiveness of the structural sample to be analyzed is ensured on the basis of the complexity of the control operation;
the invention further builds a corresponding functional module relation model for the complete framework of the planned safety control system based on the 1oo1 model, can simulate the real operation process of the safety control system, ensures the authenticity and accuracy of analysis fault data, quantitatively analyzes the failure probability of the functional modules in operation by the failure prediction module around different available structures corresponding to the functional modules, integrates the target structures of the functional modules based on the optimized target structures of the functional modules to obtain the integrated safety control system formally put into use, can provide clear reliability basis for early design decisions of system products, controls the failure probability of the designed integrated safety control system to be the lowest, prolongs the service life of the integrated safety control system, and provides optimal safety control service for equipment to be protected by enterprises.
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 are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification, illustrate the invention and together with the embodiments of the invention, serve to explain the invention, without limitation to the invention. In the drawings:
FIG. 1 is a schematic diagram of an apparatus for integrating a safety control system based on FMEDA failure prediction technology according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of the overall architecture of a safety control system constructed by a device for integrating a safety control system according to another embodiment of the present invention;
FIG. 3 is a schematic diagram illustrating failure tree analysis of an integrated safety control system device for a programmable redundant logic controller in accordance with an embodiment of the present invention.
Detailed Description
The following will explain the embodiments of the present invention in detail with reference to the 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 implementation process of the technical effects, and implement the present invention according to the implementation process. It should be noted that, as long as no conflict is formed, each embodiment of the present invention and each feature of each embodiment may be combined with each other, and the formed technical solutions are all within the protection scope of the present invention.
Although a flowchart depicts operations as a sequential process, many of the operations can be performed in parallel, concurrently, or at the same time. The order of the operations may be rearranged. The process may be terminated when its operations are completed, but may have additional steps not included in the figures. The processes may correspond to methods, functions, procedures, subroutines, and the like.
The computer device includes a user device and a network device. Wherein the user equipment or client includes, but is not limited to, a computer, a smart phone, a PDA, etc.; network devices include, but are not limited to, a single network server, a server group of multiple network servers, or a cloud based cloud computing consisting of a large number of computers or network servers. The computer device may operate alone to implement the invention, or may access a network and implement the invention through interoperation with other computer devices in the network. 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 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 the petrochemical engineering field, a safety control system (SIS) is often arranged to prevent and reduce construction risks of petrochemical industry factory enterprises or devices, and the reasonable design and the operation condition of the system directly influence the safe operation of the devices. The safety control system can be used for monitoring potential dangers in industrial processes, sending alarm information in time or automatically executing preset protection functions, and is the last protection layer of the active protection layer. When the device breaks down, the safety control system can enable the whole device to enter a safe state and give an alarm, timely remind related personnel to carry out fault detection and eliminate the fault, finally avoid accidents, reduce life and property loss caused to personnel and equipment, and furthest reduce adverse effects on the environment.
In recent years, the emerging small-sized green chemical devices or package equipment are widely applied, and typical devices comprise electrolytic water hydrogen production, methane pyrolysis hydrogen production, hydrogen storage and transportation, compressors, heating furnaces (waste gas treatment RTO furnaces), oil gas recovery, waste gas treatment devices, small-sized oil gas storage and transportation devices (oil delivery yards) and the like. The field of the current small-sized safety control system is still blank, and the product of the domestic and foreign safety control system is mainly used for medium-sized and large-sized chemical devices with safety control points above 100 points, and the problem of excessive investment and arrangement exists when the safety control system is forcibly arranged in the small-sized chemical devices, which is also a main reason that the safety instrument system arrangement is not carried out by the current small-sized chemical enterprises. Therefore, the integrated development of the small-sized modularized safety control system with the safety control point within 30 points can well meet the actual requirements of the small-sized device. However, as the manufacturers of the components adopted during the integration and whether the components are authenticated by the security function, the authentication level and the like are different, how to control the failure probability of the designed security control system is a problem to be solved urgently.
Currently workers have studied methods for estimating the probability of system failure, such as in the OREDA industrial database published by norway class 2015, the probability of failure is estimated as a maximum likelihood estimate (i.e., the total number of faults divided by the total time of operation). At the same time, the estimation of failure rate should also take into account system-specific operating environments and conditions, so it is recommended to use different models to analyze the impact of various operating conditions in different environments. Foucher and Ratkowsky et al propose that a physical model based on physical laws such as Arrhenius's law, voltage acceleration, and Gangen's law can be considered for estimating the failure probability. Analytical failure functions for parameters such as temperature, humidity, stress, voltage or electrical strength are presented in standard IEC 6170-2017. In addition, statistical models may also use specific operational data to predict the trend of the failure probability, such as Cox models (proportional hazard models) and bayesian models. Brissaud proposes a method for predicting failure rate in consideration of the influence of factors such as design, manufacture or installation, vatn proposes a similar method while considering the implementation effect of risk reduction measures in prediction. It is noted here that the physical model used to estimate the failure probability should use knowledge of the physical mechanism that caused the relevant failure as a basis, and that this knowledge should be well known, and that the prediction of the failure probability is based only on a statistical model in order to build a generic model.
However, the statistical model in the above cases is mostly dependent on data of a large number of devices, but for a novel integrated SIS system with a small application range and a short time, a large amount of data cannot be used as a reference. Thus, FMEDA theory can be combined with fault tree methods to predict plant faults for new safety control systems at the design stage. FMEDA is used as a system analysis method, and the whole system, subsystems, components and the like are required to be analyzed and developed step by step according to the sequence, so that the relation and the hierarchical block diagram among the systems are drawn. Based on the function of the product, the possible failure mode is used as the basis to analyze the failure result and mechanism, and the failure result and the risk brought by the failure result are scientifically evaluated, so that feasible measures are formulated to prevent the occurrence of the failure mode or reduce the failure risk. FMEDA technology is in a development stage in China, and domestic automation manufacturers such as time of interest, core of interest and the like have been conducting research on FMEDA technology application and related diagnostic measures. Based on the analysis, researchers find that the collection and arrangement of failure data of the finished product are work to be developed urgently in China, and reliability is expected to be carried out in an early product design and development stage so as to support the design flow of the product. Developing reliability is expected to provide clear reliability requirements for early stages of development of the product, and additionally excellent reliability is expected to provide insight into potential product degradation over the life cycle of the product. The result of developing reliability predictions can improve product design, reduce cost, optimize test time, etc.
In order to solve the problems in the prior art, the invention relates to a device and a scheme for integrating a safety control system based on an FMEDA failure prediction technology, wherein the scheme of the invention is set as an integrated small modularized safety control system, can effectively identify the fault state of enterprise equipment and automatically protect the device, and can accurately respond at high speed; furthermore, the method based on the FMEDA theory and combined with the fault tree analysis in the invention predicts and calculates the failure probability of each functional module in the safety control system in the design process, and is used for realizing the optimization and filtration of the integrated system structure.
The detailed flow of the method of embodiments of the present invention is described in detail below based on the attached drawing figures, where the steps shown in the flowchart of the figures may be performed in a computer system containing, for example, a set of computer executable instructions. Although a logical order of steps is depicted in the flowchart, in some cases the steps shown or described may be performed in a different order than presented.
Example 1
The field of small-sized safety control systems is still blank at present, and the existing safety control system products are mainly used for medium-sized and large-sized chemical devices with safety control points above 100 points, and the problems of excessive investment and setting exist when the safety control systems are forcibly arranged in the small-sized chemical devices. And for the calculation method of the failure probability of the system, most of the existing statistical models need to rely on historical data of a large number of devices or systems, but for the novel integrated SIS system with a small application range and short time, a large amount of data cannot be used as a reference.
Fig. 1 shows a schematic structural diagram of an apparatus for integrating a safety control system based on FMEDA failure prediction technology according to an embodiment of the present invention, and referring to fig. 1, it can be known that the apparatus includes:
the structure organization module is configured to draw the architecture of the target safety control system according to the protection requirements of all devices in the enterprise, and organize all available structures of all target functional modules of the preset safety control system based on the drawn architecture; the useable structure includes a stand-alone device and/or a mature component;
the function model building module is configured to build a corresponding function module relation model for the complete framework of the planned safety control system based on the 1oo1 model;
The failure prediction module is configured to analyze and calculate the failure probability of the functional module in operation around different available structures corresponding to each functional module according to the constructed functional module relation model;
and the target system selection module optimizes the target structure of each functional module according to the calculation result of the failure probability, and integrates the target structure to obtain the formally used integrated safety control system.
In practical application, the existing safety control systems (SIS) in the field are large in scale and have no small integrated products. The existing large-scale safety control system in the market comprises a detection unit, an input module, a control module, an output module, an execution unit and the like, wherein the control module and the input and output clamping piece are arranged separately. The invention aims to design a safety control system which is a small-sized modularized safety control system integrated with a plurality of functional modules, wherein the complete integrated safety control system comprises an information acquisition module, a logic controller module, a safety relay module, a safety barrier module and a power supply module.
Operation principle of small integrated safety control system:
logic one: the power module is responsible for supplying power to the whole system.
Logic II: the sensor detects the device field current signal and transmits the signal to the input card (DI card, AI card) in the logic controller via the safety barrier.
And (3) logic III: the input card transmits signals to a CPU unit of the logic controller, and the controller CPU transmits current control signals to the output card (DO card) after performing logic operation.
Logic four: the current signal is output from the output card, flows through the safety relay and then is transmitted to a final control component (such as an electromagnetic valve).
Preferably, in one embodiment, the setting the target function module of the safety control system includes:
the information acquisition module is configured to acquire the operation information of the protected equipment in the enterprise in real time;
the logic control module is in communication connection with the information acquisition module and is configured to receive the acquired equipment operation information, perform operation and analysis according to matched program logic and generate a control instruction;
the input end of the safety relay is connected with the logic control module, and the output end of the safety relay is connected with the target control component, so that the automatic adjustment and conversion of the control component circuit are realized.
Further, in one embodiment, the safety control system further includes a safety barrier function module connected between the information acquisition module and the logic control module, to limit the electrical signal supplied to the logic control module to a set safety range.
The integrated module type safety control system designed by the invention adopts a programmable redundancy logic controller, and the safety type programmable logic controller module further comprises a power supply unit, a CPU unit, an input/output card interface unit and a memory unit, so that the small integrated safety control system (SIS) is of an integrated structure, and the safety type programmable logic controller comprises a controller and safety cards (DI, DO and AI). The memory is mainly used for storing system programs, user programs and working data. The CPU unit may read the user program from the memory one by one, and execute it after interpretation.
A safety programmable logic controller can read signals from the front-end sensor and perform preprogrammed actions to prevent hazards from occurring. The safety logic controller adopted by the safety control system can execute logic processing and decision making functions and has the input and output capability from the sensor to the final control component, and in addition, it is emphasized that the logic controller needs to be authenticated by the functional safety SIL, is designed to be fault-tolerant, has internal redundancy, has additional internal detection (diagnosis) hardware and software to allow functional faults, and increases safety to ensure accidental configuration change, and can effectively play a role in safety control and protect target equipment when the structure of the safety control system itself fails.
Specifically, in one embodiment, the logic control module is configured to adopt a programmable redundancy logic controller, and the programmable redundancy logic controller includes at least two internal control units, each internal control unit respectively performs operation on equipment operation information according to the same program, and if errors of a plurality of obtained operation results meet a set condition, a final operation result is generated and output, otherwise, set operation parameters are output.
Preferably, in one embodiment, the logic control module further includes an input safety card and an output safety card, where the input safety card is connected to the downstream end of the safety barrier function module and is used for receiving the transmitted signal, and the output safety card is connected to the upstream end of the safety relay and is used for outputting the control signal.
Further, in one embodiment, the logic control module further includes a behavior monitoring circuit electrically connected to each internal control unit, and configured to cross check the operation state of the processor circuit of each internal control unit using a plurality of different oscillators, and each internal control unit checks whether another internal control unit is operated using a clock, and if it is detected that there is no operation within a set period of the internal control unit, the logic control module is put into a safe state.
Optionally, in one embodiment, the logic control module further includes a clock monitoring unit, configured to monitor an action time of each internal control unit and a time of executing the program logic, and output a corresponding safety parameter if a condition exceeding a set condition exists.
In practical application, the number of the internal controllers of the safety programmable logic controller is at least two or more (redundant design), and the functions of the two controllers are as follows: the same functional program logic is executed once respectively, the results are compared together, if the errors among the results meet the set conditions, normal electric signal output is carried out, and if the errors are not met, safe control result output (generally, control parameters in the stop sense are not output or are output) is selected.
In addition, the set logic controller has the following self-detection functions including (behavior monitoring) clock measurement, monitoring clock, sequence checking, memory checking, and the like. Wherein the behavior monitoring (clock measurement) function checks the operation state of the processor circuit of each internal control unit by using a plurality of different oscillators in the processor circuit of each internal processing unit of the controller, each internal control unit checks whether the other internal control unit is operated using one clock, and if it is detected that there is no operation within the set period of the internal control unit, the logic control module is brought into a safe state, and two internal processing units are provided with two different oscillators to check their behavior by crossing, each processor checks whether the other is operated using one clock, for example. If the other party is detected to be not running in a certain period, the controller enters a safe state.
In addition, the logic controller is also provided with corresponding proprietary precision checking firmware for checking the precision of each oscillator per second.
Further, the monitoring clock of the logic controller is used to check the activity practice of the controller and the execution time of executing the user logic through the set monitoring clock of one hardware and one firmware.
In practical applications, the sequence checking functional unit may also be configured to monitor the execution logic and order of different parts of the operating system of the controller in real time.
In addition, the logic controller of the invention also uses a set memory checking functional unit to detect all static memory areas, including a Flash memory and a RAM, by using Cyclic Redundancy Codes (CRC), and double codes are executed. The dynamic memory area is protected by double code execution and periodically detected. In the actual application process of the safety control system, the monitoring and detecting functional units are initialized again during cold start.
Further, in one embodiment, the safety relay is provided as a combination of a plurality of relays and a circuit, so as to be able to complement each other's abnormal defects, achieving a correct and low malfunction relay complete function. The input end of the controller receives a 24V voltage signal from the controller, and the output end of the controller is connected with a final control component with 220V voltage, such as a solenoid valve and the like. In fact, the automatic switch is an automatic switch which uses small current to control large current operation, thus playing roles of automatic regulation, safety protection, conversion circuit and the like in the circuit.
Taking the example that the safety relay is provided with three internal relays, one of the default relays operates, if the operating relay is detected to be faulty, other relays are called to operate, and a specific control decision function is controlled by the logic degree or the functional circuit structure in the relay module.
Further, the safety barrier function module is connected between the intrinsic safety circuit and the non-intrinsic safety circuit, and limits the voltage or current supplied to the intrinsic safety circuit to a certain safety range. In actual design, one end of the device is connected with equipment to be protected, such as a meter, on the enterprise site, and the other end is connected with a logic controller.
And the power supply module is configured to supply power to the controller module in the safety control system and other integrated modules or devices in the cabinet for 24 hours.
The patent provides a small-sized modularized safety control system with an integrated development safety control point within 30 points, and provides a method for combining an FMEDA theory and a fault tree method on the basis of the small-sized modularized safety control system to predict and calculate the operation failure probability of each functional hardware in the designed system, so that the equipment fault of the safety control system can be effectively predicted in the design stage, and the rationality and the high working quality characteristics of the safety control system structure are standardized.
Based on the above conception, the researcher of the invention also provides a method for predicting and calculating the operation failure probability of each functional hardware in the designed system, and in a preferred embodiment, the invention provides a basis for calculating the failure probability by establishing a functional module relation model inside a safety control system based on a 1oo1 model.
In practical application, the functional model building module can be set up to build a functional module relation model based on 1oo1 among the functional modules in the safety control system as shown in fig. 2 according to the functional structural characteristics of the safety control system;
further, in one embodiment, the failure prediction module is configured to predict the failure probability of the operation function module by:
step A1, referring to corresponding product manuals for all available structures of different types and models respectively to obtain operation failure parameters of the product manuals relative to the whole safety control system, wherein the operation failure parameters comprise: the detected security failure probability, the undetected security failure probability, the sensed abnormality information ratio, and the undetected sensed abnormality information ratio; in practical application, the product manual corresponding to each available structure can be consulted Obtaining failure data lambda of each functional module SD 、λ SU 、λ DD 、λ DU The detected security failure probability, the undetected security failure probability, the sensed abnormality information ratio, and the undetected sensed abnormality information ratio are represented, respectively.
A2, calculating the comprehensive failure probability of each operation failure parameter calculation function module of the structure by adopting a fault tree analysis method aiming at each function module of the system based on the preset requirement;
and step A3, integrating to obtain a high-quality safety control system according to the comprehensive failure probability of the functional module and the optimal organization scheme.
Further, in one embodiment, the failure prediction module further calculates the comprehensive failure probability of each functional module according to the following operations:
a2-1, taking each functional module in the system as an analysis object, taking each available structure as a sub-analysis object, introducing each operation failure parameter of the sub-analysis object, and calculating the corresponding instantaneous failure probability of the available structure;
in practical application, the instantaneous failure probability PFD of each structure of the functional system can be calculated according to the following formula:
PFD＝λ DD ×MTTR+λ DU ×TI(1-1)
step A2-2, further determining the average failure probability corresponding to each available structure according to a set strategy based on the instantaneous failure probability;
Specifically, the average failure probability PFD of each structure can be calculated as follows avg ：
Wherein TI represents the running time of the functional model of the safety control system, t is an integral parameter representing time, and MTTR represents the average fault-free time in the running process of the functional model of the system;
step A2-3, introducing a detection period parameter to determine the failure probability of each available structure in unit time based on the average failure probability;
in practical application, the average failure probability when required is divided by the detection period TI to obtain the dangerous failure probability PFHavg of the corresponding structure in unit time (such as per hour):
PFHavg＝PFDavg(1-3)
and step A2-4, calculating the comprehensive failure probability of the whole functional module by using the logic of the fault tree analysis method by taking the failure probability of each available structure in unit time as a lower analysis basis.
Further, according to the fault tree analysis method, the comprehensive failure probability (fault overall occurrence probability) F (T) of the function module to which the fault tree belongs is calculated according to the following formula:
wherein n represents the number of structures contained in the functional module, each structure being regarded as a sub-analysis object, lambda i Failure probability per unit time (failure probability) for the i-th component;
in practical application, in order to timely filter out the clearly unsatisfactory structure, so as to save operation resources and time consumption, in an alternative embodiment, before executing step A2-4, the failure prediction module is further configured to: and comparing the failure probability of each available structure in unit time with a set probability threshold, and if the failure probability exceeds the threshold, moving the structure out of the available structure list, and only putting the rest available structures into the operation of the step A2-4.
The scheme of the embodiment of the patent is mainly applied to enterprise equipment in petrochemical industry and is used for integrated design and failure probability prediction calculation of a safety control system of a small-sized production and storage device. The integrated modularized safety control system can provide safety guarantee for normal operation of a device to be protected, meanwhile, the hardware failure probability calculation method based on FMEDA can effectively predict equipment failure of the safety control system in a design stage, and structural reliability of the integrated safety control system is improved.
Taking a certain brand of structure as an example, acquiring data in a product manual of the structure as an operation failure parameter lambda SD 、λ SU 、λ DD 、λ DU The source, according to the formulas (1-1), (1-2) and (1-3), calculates the failure probability per unit time corresponding to the structure, as shown in Table 2. Further, calculating the comprehensive failure probability of the functional module to which the functional module belongs according to the formula (1-4);
for example, the failure of the module is caused by the failure of a power supply unit, a programmable redundancy logic controller (CPU unit), an input-output card interface and a memory unit, so that a fault tree model of the programmable redundancy logic controller module can be constructed as shown in FIG. 3;
Taking a programmable redundancy logic controller as an example, the method can be calculated according to formulas (1-1) - (1-3),
PFD programmable redundant logic controller = 148.626 x 10 -9 ×8+1361.721×10 -+ ×8760＝1.119×10 -2
PFD avg Programmable redundant logic controller= 148.626 ×10 -9 ×8+1361.721×10 -9 ×8760/2＝5.966×10 -3
PFHavg programmable redundant logic controller=5.966×10 -3 /8760＝0.681×10 -6
Similarly, the average failure probability PFD and the per-hour failure probability PFH value are calculated for the power supply unit, the input/output card interface and the memory unit according to the formulas 1-1 to 1-3 respectively, and then the comprehensive failure probability of the whole functional module of the logic control module is calculated according to the formulas 1-4.
Before the comprehensive failure probability of the functional module is calculated, the failure probability of the structure in unit time calculated is compared with a preset probability threshold value, if the failure probability exceeds the preset probability threshold value, the failure probability of the structure is too high, the operation requirement of the safety control system cannot be met, and the safety control system is moved out of a list of available structures.
Specifically, the standard MTTR which needs to be met by combining the standard average fault-free time parameter in the product manual and the actual operation requirement decision can be introduced, the operation time TI consistent with the actual calculation is introduced, the upper limit of the average failure probability PFD when the requirement of the corresponding structure in the safety control system is obtained based on the logic calculation, and the corresponding failure probability PFH value in unit time is obtained as a preset probability threshold. Wherein the status information can reflect whether the structure is malfunctioning.
Further, in the step of inputting the comprehensive failure probability of the calculation function module into the plurality of structures with the failure probability per unit time smaller than the set probability threshold, if a plurality of available structures exist, the structure with the minimum comprehensive failure probability is selected as a target.
The safety control system based on the logic design can well control the failure probability of the structure adopted in the functional module to be minimum.
In the device for integrating the safety control system based on the FMEDA failure prediction technology provided by the embodiment of the invention, each module or unit structure can independently operate or operate in a combined mode according to actual operation and organization requirements so as to achieve corresponding technical effects.
For the sake of simplicity of description, the foregoing apparatus implementation principle embodiments are all described as a series of combinations of actions, but it should be understood by those skilled in the art that the operation of the apparatus of the present invention is not limited by the described order of actions, as some steps may be performed in other order or simultaneously according to the present invention. Further, those skilled in the art will also appreciate that the embodiments described in the specification are all preferred embodiments, and that the acts and modules referred to are not necessarily required for the present invention.
It is to be understood that the disclosed embodiments are not limited to the specific structures, process steps, or materials disclosed herein, but are intended to extend to equivalents of these features as would be understood by one of ordinary skill 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 "one embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment.
Although the embodiments of the present invention are described above, the embodiments are only used for facilitating understanding of the present invention, and are not intended to limit the present invention. Any person skilled in the art can make any modification and variation in form and detail without departing from the spirit and scope of the present disclosure, but the scope of the present disclosure is still subject to the scope of the appended claims.
Claims (10)
1. An apparatus for integrating a safety control system based on FMEDA failure prediction technology, the apparatus comprising:
The structure organization module is configured to draw the architecture of the target safety control system according to the protection requirements of all devices in the enterprise, and organize all available structures of all target functional modules of the preset safety control system based on the drawn architecture; the useable structure includes a stand-alone device and/or a mature component;
the function model building module is configured to build a corresponding function module relation model for the complete framework of the planned safety control system based on the 1oo1 model;
the failure prediction module is configured to analyze and calculate the failure probability of the functional module in operation around different available structures corresponding to each functional module according to the constructed functional module relation model;
and the target system selection module optimizes the target structure of each functional module according to the calculation result of the failure probability, and integrates the target structure to obtain the formally used integrated safety control system.
2. The apparatus of claim 1, wherein the structural organization module to set the target function module of the safety control system comprises:
the information acquisition module is configured to acquire the operation information of the protected equipment in the enterprise in real time;
the logic control module is in communication connection with the information acquisition module and is configured to receive the acquired equipment operation information, perform operation and analysis according to matched program logic and generate a control instruction;
The input end of the safety relay is connected with the logic control module, and the output end of the safety relay is connected with the target control component, so that the automatic adjustment and conversion of the control component circuit are realized.
3. The apparatus of claim 1, wherein the safety control system is further configured to include a safety barrier function module coupled between the information acquisition module and the logic control module to limit the electrical signal provided to the logic control module to within a set safety range.
4. The apparatus of claim 2, wherein the logic control module employs a programmable redundancy logic controller, and the programmable redundancy logic controller includes at least two internal control units, each internal control unit respectively operates on the device operation information according to the same program, and generates and outputs a final operation result if errors of the obtained operation results satisfy a set condition, and otherwise outputs the set operation parameters.
5. The apparatus of claim 2, wherein the logic control module further comprises an input safety card connected to the downstream end of the safety barrier function module for receiving the transmitted signal and an output safety card connected to the upstream end of the safety relay for outputting the control signal.
6. The apparatus of claim 2, wherein the logic control module further comprises a behavior monitoring circuit electrically connected to each of the internal control units for cross checking an operating state of the processor circuit of each of the internal control units using a plurality of different oscillators, each of the internal control units checking whether the other internal control unit is operating using a clock, and if no operation within a set period of the internal control unit is detected, causing the logic control module to enter a safe state.
7. The apparatus of claim 2, wherein the logic control module further comprises a clock monitoring unit for monitoring the operation time of each internal control unit and the time of executing the program logic, and outputting the corresponding safety parameter if the set condition is exceeded.
8. The apparatus of claim 1, wherein the failure prediction module is configured to predict the failure probability of the operational function module by:
step A1, referring to corresponding product manuals for all available structures of different types and models respectively to obtain operation failure parameters of the product manuals relative to the whole safety control system, wherein the operation failure parameters comprise: the detected security failure probability, the undetected security failure probability, the sensed abnormality information ratio, and the undetected sensed abnormality information ratio;
A2, aiming at each functional module of the system, adopting a fault tree analysis method, and sequentially introducing each operation failure parameter of the structure to calculate the comprehensive failure probability of the functional module;
and step A3, integrating to obtain a high-quality safety control system according to the comprehensive failure probability of the functional module and the optimal organization scheme.
9. The apparatus of claim 2, wherein the failure prediction module further calculates the composite failure probability for each functional module according to:
a2-1, taking each functional module in the system as an analysis object, taking each available structure as a sub-analysis object, introducing each operation failure parameter of the sub-analysis object, and calculating the corresponding instantaneous failure probability of the available structure;
step A2-2, further determining the average failure probability corresponding to each available structure according to a set strategy based on the instantaneous failure probability;
step A2-3, introducing a detection period parameter to determine the failure probability of each available structure in unit time based on the average failure probability;
and step A2-4, calculating the comprehensive failure probability of the whole functional module by using the logic of the fault tree analysis method by taking the failure probability of unit time as a lower analysis basis.
10. The apparatus of claim 9, wherein the failure prediction module, prior to performing steps A2-4, is further configured to: and comparing the failure probability of each available structure in unit time with a set probability threshold, and if the failure probability exceeds the threshold, moving the structure out of the available structure list, and only putting the rest available structures into the operation of the step A2-4.
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| CN116821638B (en) * | 2023-08-31 | 2023-12-22 | 北京中电科卫星导航系统有限公司 | Data analysis method and system for AI chip application optimization design |
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