CN118072495A - Chemical industry reation kettle operation alarm system based on data analysis - Google Patents
Chemical industry reation kettle operation alarm system based on data analysis Download PDFInfo
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Abstract
The invention belongs to the technical field of chemical reaction kettle operation supervision, in particular to a chemical reaction kettle operation alarm system based on data analysis, which comprises a server, a reaction kettle internal condition monitoring module, a reaction kettle external condition monitoring module, a reaction kettle line management module and an operation alarm module; according to the invention, the internal condition of the chemical reaction kettle is monitored and analyzed through the reaction kettle internal condition monitoring module, the internal condition normal signal or the internal condition abnormal signal is generated, the reaction kettle external condition monitoring module monitors and analyzes the control area on the periphery of the chemical reaction kettle in real time, the external condition normal signal or the external condition abnormal signal is generated, the reaction kettle line management module monitors all power lines of the chemical reaction kettle to judge the operation risk of the power lines, and the operation alarm module sends out corresponding early warning when the internal condition abnormal signal, the external condition normal signal or the line risk signal is generated, so that the safety and stable operation of the chemical reaction kettle is guaranteed, the intelligent degree is high, and the operation supervision difficulty is low.
Description
Technical Field
The invention relates to the technical field of chemical reaction kettle operation supervision, in particular to a chemical reaction kettle operation alarm system based on data analysis.
Background
The chemical reaction kettle is a comprehensive reaction container widely applied to the fields of petroleum, chemical industry, rubber, pesticides, dyes, medicines, foods and the like, is mainly used for completing the technological processes of vulcanization, nitration, hydrogenation, alkylation, polymerization, condensation and the like, and can realize the heating, evaporation, cooling and low-speed and high-speed mixing functions of technological requirements through structural design and parameter configuration of the container;
In the chemical production process, the reaction kettle is used as key equipment, the running state of the reaction kettle directly relates to the safety and efficiency of production, the safety conditions of the inner area, the peripheral area and the circuit of the reaction kettle cannot be monitored in real time and fed back accurately in the running process of the chemical reaction kettle at present, the running risk of the reaction kettle is difficult to comprehensively judge and early warn in time, reasonable improvement and regulation measures are not facilitated for management staff, the intelligent degree is low, and the running supervision difficulty is high;
In view of the above technical drawbacks, a solution is now proposed.
Disclosure of Invention
The invention aims to provide a chemical reaction kettle operation alarm system based on data analysis, which solves the problems that the safety conditions of the inside, the peripheral area and a circuit of the chemical reaction kettle cannot be monitored in real time and fed back accurately in the operation process of the chemical reaction kettle in the prior art, the operation risk of the chemical reaction kettle is difficult to comprehensively judge and early warn in time, the intelligent degree is low, and the operation supervision difficulty is high.
In order to achieve the above purpose, the present invention provides the following technical solutions:
The chemical reaction kettle operation alarm system based on data analysis comprises a server, a reaction kettle internal condition monitoring module, a reaction kettle external condition monitoring module, a reaction kettle line management module and an operation alarm module; the internal condition monitoring module of the reaction kettle is used for monitoring the internal condition of the reaction kettle in the operation process of the chemical reaction kettle, generating an internal condition normal signal or an internal condition abnormal signal through analysis, and sending the internal condition normal signal or the internal condition abnormal signal to the operation alarm module through the server, and sending out corresponding early warning when the operation alarm module receives the internal condition abnormal signal;
the external condition monitoring module of the reaction kettle marks an area which is within 1 meter from the peripheral outline L of the chemical reaction kettle as a management and control area, monitors the management and control area in real time in the operation process of the chemical reaction kettle, generates an external condition normal signal or an external condition abnormal signal through analysis, sends the external condition normal signal or the external condition abnormal signal to the operation alarm module through a server, and sends corresponding early warning when the operation alarm module receives the external condition abnormal signal;
The method comprises the steps that a reaction kettle line management module obtains a power line required to be managed by a chemical reaction kettle, the corresponding power line is marked as a target line e, and e is a natural number larger than 1; and monitoring all the electric power lines in the operation process of the chemical reaction kettle to judge the operation risk of the electric power lines, determining a risk line and a safety line according to the risk line and the safety line, generating a line stability signal or a line risk signal, transmitting the line stability signal or the line risk signal to an operation alarm module through a server, and sending out corresponding early warning when the operation alarm module receives the line risk signal.
Further, the specific operation process of the condition monitoring module in the reaction kettle comprises the following steps:
The method comprises the steps of collecting real-time temperatures of a plurality of positions in a chemical reaction kettle, carrying out variance calculation on the real-time temperatures of the plurality of positions to obtain temperature uniformity coefficients, marking the number occupation ratio of the temperature uniformity coefficients exceeding a preset temperature uniformity coefficient threshold value in unit time as a temperature non-uniformity number occupation value, carrying out mean calculation on all the temperature uniformity coefficients in unit time to obtain a temperature cloth condition value, respectively carrying out numerical comparison on the temperature non-uniformity number occupation value and the temperature cloth condition value and the preset temperature non-uniformity number occupation threshold value and the preset temperature cloth Kuang Yuzhi, and generating an internal condition abnormal signal if the temperature non-uniformity number occupation value or the temperature cloth condition value exceeds the corresponding preset threshold value.
Further, if the temperature non-uniform number occupation value and the temperature cloth Kuang Zhi do not exceed the corresponding preset threshold values, collecting the real-time air pressure and the real-time stirring speed in the chemical reaction kettle, marking the deviation value of the real-time air pressure compared with the preset standard real-time air pressure as a real-time pressure analysis deviation value, and marking the deviation value of the real-time stirring speed compared with the preset standard stirring speed as a real-time stirring analysis deviation value;
the real-time temperatures of a plurality of positions are subjected to mean value calculation to obtain real-temperature detection values, deviation values of the real-temperature detection values compared with preset standard real-temperature detection values are marked as real-temperature deviation detection values, internal condition actual measurement values are obtained through numerical calculation of the real-pressure deviation detection values, the real-mixing deviation detection values and the real-temperature deviation detection values, internal condition analysis values are obtained through mean value calculation of all internal condition actual measurement values in unit time, and the internal condition actual measurement values are compared with preset internal condition actual measurement thresholds in a numerical mode;
Acquiring total duration and maximum duration of a chemical reaction kettle in an internal condition bad state in unit time, respectively marking the total duration and the maximum duration as an internal condition bad total value and an internal condition bad holding value, carrying out numerical calculation on an internal condition measured value, an internal condition bad total value and an internal condition bad holding value to obtain a reaction kettle internal condition evaluation value, carrying out numerical comparison on the reaction kettle internal condition evaluation value and a preset reaction kettle internal condition evaluation threshold, and generating an internal condition abnormal signal if the reaction kettle internal condition evaluation value exceeds the preset reaction kettle internal condition evaluation threshold; if the internal condition evaluation value of the reaction kettle does not exceed the preset internal condition evaluation threshold value of the reaction kettle, generating an internal condition normal signal.
Further, the specific operation process of the reaction kettle external condition monitoring module comprises the following steps:
Arranging a plurality of monitoring points in a management and control area, acquiring temperature data of the corresponding monitoring points, acquiring temperature increase data of the corresponding monitoring points in unit time, analyzing the gas leakage detection to obtain gas leakage detection values of the corresponding monitoring points, calculating the temperature data, the temperature increase data and the gas leakage detection values of the corresponding monitoring points to obtain external condition point analysis values, comparing the external condition point analysis values with a preset external condition point analysis value range in a numerical mode, and marking the corresponding monitoring points as high risk monitoring points if the external condition point analysis values exceed the maximum value of the preset external condition point analysis value range; if the external condition point analysis value is within the preset external condition point analysis value range, marking the corresponding monitoring point as a medium risk monitoring point; if the external condition point analysis value does not exceed the minimum value of the preset external condition point analysis value range, marking the corresponding monitoring point as a low risk monitoring point;
If a high risk monitoring point exists in the chemical reaction kettle, an external condition abnormal signal is generated; if high risk monitoring points exist in the chemical reaction kettle, marking the ratio of the number of medium risk monitoring points to the total number of monitoring points as a medium risk point occupation value, carrying out average calculation on external condition point analysis values of all monitoring points to obtain an external condition evaluation value, carrying out numerical calculation on the medium risk point occupation value and the external condition evaluation value to obtain a reaction kettle external condition evaluation value, carrying out numerical comparison on the reaction kettle external condition evaluation value and a preset reaction kettle external condition evaluation threshold, and if the reaction kettle external condition evaluation value exceeds the preset reaction kettle external condition evaluation threshold, generating an external condition abnormal signal; if the external condition evaluation value of the reaction kettle does not exceed the preset external condition evaluation threshold value of the reaction kettle, generating an external condition normal signal.
Further, the specific analysis procedure of the gas leakage detection analysis is as follows:
acquiring gas required to be monitored at the periphery of the chemical reaction kettle in the operation process of the chemical reaction kettle, acquiring average concentration data of corresponding gas of corresponding monitoring points in unit time, presetting a group of preset hazard weight values corresponding to each type of gas respectively, marking the product of the average concentration data of the corresponding gas and the corresponding preset hazard weight values as gas monitoring values, and calculating all the gas monitoring values of the corresponding monitoring points in a summation mode to obtain a gas leakage detection value.
Further, the analysis process of the reaction kettle line management module comprises the following steps:
Marking the difference value between the electric energy data input into the target line e and the electric energy data output by the target line e in unit time as a line loss value, carrying out average value calculation on the surface temperatures of a plurality of positions on the target line e to obtain a line surface temperature detection value, marking the ratio of the line surface temperature detection value to a preset line surface temperature detection threshold value as a line table Wen Zhankuang value, carrying out numerical calculation on the line loss value and the line table Wen Zhankuang value to obtain a line detection evaluation value, carrying out numerical comparison on the line detection evaluation value and the preset line detection evaluation threshold value, and marking the target line e as a risk line if the line detection evaluation value exceeds the preset line detection evaluation threshold value;
If the line detection evaluation value does not exceed the preset line detection evaluation threshold value, acquiring real-time voltage values and real-time current values of a plurality of positions in the target line e, performing variance calculation on the real-time voltage values of all the positions to obtain voltage wave evaluation values, performing variance calculation on the real-time current values of all the positions to obtain current wave evaluation values, respectively performing numerical comparison on the voltage wave evaluation values and the current wave evaluation values with the preset voltage wave evaluation threshold value and the preset current wave evaluation threshold value, and if the voltage wave evaluation values or the current wave evaluation values exceed the corresponding preset threshold values, marking the target line e as a risk line; and if the voltage wave evaluation value and the current wave evaluation value do not exceed the corresponding preset threshold values, marking the target line e as a safety line.
Further, in the process of determining the risk line and the safety line, if the risk line exists in the chemical reaction kettle, generating a line risk signal; if no risk line exists in the chemical reaction kettle, acquiring the adjacent last checking time of the target line e, marking the interval duration between the current time and the adjacent last checking time as an interval duration, comparing the interval duration with a corresponding preset interval duration threshold value, and marking the corresponding target line e as a line to be checked if the interval duration exceeds the preset interval duration threshold value;
The method comprises the steps of obtaining the number of lines to be detected in a chemical reaction kettle, marking the number of lines to be detected as a line table value to be detected, marking the ratio of the detection period of a target line e to a corresponding preset detection period threshold value as a detection occupation condition value, carrying out mean value calculation on detection occupation condition values of all power lines to obtain a detection table analysis value, carrying out numerical calculation on the line table value to be detected and the detection table analysis value to obtain a line total analysis value, carrying out numerical comparison on the line total analysis value and the preset line total analysis threshold value, and generating a line risk signal if the line total analysis value exceeds the preset line total analysis threshold value; and if the line total analysis value does not exceed the preset line total analysis threshold value, generating a line stable signal.
Further, the server is in communication connection with the vibration detection analysis module, the vibration detection analysis module collects vibration data and noise data of the chemical reaction kettle in the operation process through the vibration detection sensor and the noise detection sensor, the vibration data and the noise data are respectively compared with a preset vibration data threshold value and a preset noise data threshold value in numerical values, and if the vibration data or the noise data exceeds the corresponding preset threshold value, the chemical reaction kettle is judged to be in a vibration response non-optimal state;
The method comprises the steps of obtaining total time length of a chemical reaction kettle in a non-optimal state of sound vibration in unit time, marking the total time length as a non-optimal time analysis value of sound vibration, carrying out average calculation on all vibration data in unit time to obtain a vibration condition value of the reaction kettle, carrying out average calculation on all noise data in unit time to obtain a sound condition value of the reaction kettle, carrying out numerical calculation on the non-optimal time analysis value of sound vibration, the vibration condition value of the reaction kettle and the sound condition value of the reaction kettle to obtain an auxiliary abnormal value of the reaction kettle, carrying out numerical comparison on the auxiliary abnormal value of the reaction kettle and a preset auxiliary abnormal threshold value of the reaction kettle, generating a sound vibration disqualification signal of the reaction kettle if the auxiliary abnormal value of the reaction kettle exceeds the auxiliary abnormal threshold value of the preset reaction kettle, sending the sound vibration disqualification signal of the reaction kettle to an operation alarm module through a server, and sending corresponding early warning when the operation alarm module receives the sound vibration disqualification signal of the reaction kettle.
Compared with the prior art, the invention has the beneficial effects that:
1. According to the invention, the internal condition of the chemical reaction kettle is monitored and analyzed through the reaction kettle internal condition monitoring module, the monitoring and analyzing module of the external condition of the reaction kettle monitors and analyzes the control area on the periphery of the chemical reaction kettle in real time, the reaction kettle line management module monitors all power lines of the chemical reaction kettle to judge the operation risk of the power lines, and when an internal condition abnormal signal, an external condition abnormal signal or a line risk-saving signal is generated, the operation alarm module sends out corresponding early warning, so that the operation risk of the chemical reaction kettle can be comprehensively judged and early warned in time, reasonable improvement and regulation measures can be carried out by management personnel, the intelligent degree is high, and the operation supervision difficulty is low;
2. According to the invention, the vibration and noise conditions of the chemical reaction kettle in the operation process are acquired and analyzed through the vibration detection and analysis module, the operation abnormal conditions of the chemical reaction kettle are evaluated in an auxiliary mode, whether the abnormal vibration signals of the reaction kettle are generated or not is judged, and when the abnormal vibration signals of the reaction kettle are generated, the operation alarm module is enabled to send out corresponding early warning so as to remind management staff to timely conduct reason investigation and make reasonable improvement measures, and the operation potential safety hazard of the chemical reaction kettle is further reduced.
Drawings
For the convenience of those skilled in the art, the present invention will be further described with reference to the accompanying drawings;
FIG. 1 is a system block diagram of a first embodiment of the present invention;
Fig. 2 is a system block diagram of a second embodiment of the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Embodiment one: as shown in fig. 1, the chemical reaction kettle operation alarm system based on data analysis provided by the invention comprises a server, a reaction kettle internal condition monitoring module, a reaction kettle external condition monitoring module, a reaction kettle line management module and an operation alarm module, wherein the server is in communication connection with the reaction kettle internal condition monitoring module, the reaction kettle external condition monitoring module, the reaction kettle line management module and the operation alarm module;
The internal condition monitoring module of the reaction kettle is used for monitoring the internal condition of the reaction kettle in the operation process of the chemical reaction kettle, generating an internal condition normal signal or an internal condition abnormal signal through analysis, sending the internal condition normal signal or the internal condition abnormal signal to the operation alarm module through the server, sending out corresponding early warning when the operation alarm module receives the internal condition abnormal signal, reasonably analyzing and accurately feeding back the internal condition of the chemical reaction kettle, and timely reminding a manager to make corresponding regulation and control measures so as to ensure the safe and stable operation of the chemical reaction kettle; the specific operation process of the condition monitoring module in the reaction kettle is as follows:
Acquiring real-time temperatures of a plurality of positions in the chemical reaction kettle, and performing variance calculation on the real-time temperatures of the plurality of positions to obtain a temperature uniformity coefficient, wherein the larger the numerical value of the temperature uniformity coefficient is, the more uneven the internal temperature distribution condition of the chemical reaction kettle at corresponding moments is; marking the number occupation ratio of the temperature uniformity coefficient exceeding a preset temperature uniformity coefficient threshold value in unit time as a temperature non-uniformity number occupation value, carrying out average calculation on all the temperature uniformity coefficients in unit time to obtain a temperature cloth condition value, respectively carrying out numerical comparison on the temperature non-uniformity number occupation value and the temperature cloth condition value and the preset temperature non-uniformity number occupation threshold value and the preset temperature cloth Kuang Yuzhi, and generating an internal condition abnormal signal if the temperature non-uniformity number occupation value or the temperature cloth condition value exceeds the corresponding preset threshold value;
If the temperature non-uniform number occupation value and the temperature cloth Kuang Zhi do not exceed the corresponding preset threshold values, collecting the real-time air pressure and the real-time stirring speed in the chemical reaction kettle, marking the deviation value of the real-time air pressure compared with the preset standard real-time air pressure as a real-time pressure analysis deviation value, and marking the deviation value of the real-time stirring speed compared with the preset standard stirring speed as a real-time stirring analysis deviation value; calculating the average value of the real-time temperatures of a plurality of positions to obtain real-temperature detection values, and marking the deviation value of the real-temperature detection values compared with the preset standard real-temperature detection values as a real-temperature deviation value;
By the formula nx= (ew 1 NK+ew2NS+ew3NF)/3, carrying out numerical calculation on the actual pressure offset value NK, the actual mixing offset value NS and the actual temperature offset value NF to obtain an internal condition actual measurement value NX, wherein, ew1, ew2 and ew3 are preset proportionality coefficients, and the values of the ew1, the ew2 and the ew3 are all larger than zero; and the larger the numerical value of the measured value NX of the internal condition is, the worse the internal performance condition of the chemical reaction kettle is at the corresponding moment;
Carrying out average value calculation on all the internal condition actual measurement values in unit time to obtain an internal condition analysis value, carrying out numerical comparison on the internal condition actual measurement value and a preset internal condition actual measurement threshold value, and judging that the chemical reaction kettle is in an internal condition bad state at the corresponding moment if the internal condition actual measurement value exceeds the preset internal condition actual measurement threshold value; acquiring total duration and maximum duration of a chemical reaction kettle in an internal condition bad state in unit time, and respectively marking the total duration and the maximum duration as an internal condition bad total duration value and an internal condition bad duration value;
By the formula Carrying out numerical calculation on an internal condition analysis value NQ, an internal condition bad total value NY and an internal condition bad holding value NW to obtain an internal condition evaluation value NP of the reaction kettle, wherein kp1, kp2 and kp3 are preset proportionality coefficients, and kp3 is more than kp2 and more than kp1 is more than 0; and, the larger the numerical value of the condition evaluation value NP in the reaction kettle is, the worse the internal condition of the chemical reaction kettle is comprehensively;
Comparing the internal condition evaluation value NP of the reaction kettle with a preset internal condition evaluation threshold value of the reaction kettle, and generating an internal condition abnormal signal if the internal condition evaluation value NP of the reaction kettle exceeds the preset internal condition evaluation threshold value of the reaction kettle, which indicates that the internal condition of the chemical reaction kettle is poor in comprehensive aspect and is not beneficial to ensuring the operation safety and the operation effect of the chemical reaction kettle; if the internal condition evaluation value NP of the reaction kettle does not exceed the preset internal condition evaluation threshold value of the reaction kettle, the internal condition of the chemical reaction kettle is better comprehensively, and then an internal condition normal signal is generated.
The external condition monitoring module of the reaction kettle marks an area within L1 meters from the peripheral outline of the chemical reaction kettle as a control area, and preferably L1 is 0.5; the management and control area is monitored in real time in the operation process of the chemical reaction kettle, an external condition normal signal or an external condition abnormal signal is generated through analysis, the external condition normal signal or the external condition abnormal signal is sent to the operation alarm module through the server, and the operation alarm module sends out corresponding early warning when receiving the external condition abnormal signal, so that the peripheral risk condition of the chemical reaction kettle can be reasonably analyzed and accurately evaluated, the management personnel can conduct cause investigation in time and make corresponding improvement measures, and the operation safety of the chemical reaction kettle is further ensured; the concrete operation process of the reaction kettle external condition monitoring module is as follows:
arranging a plurality of monitoring points in a management and control area, acquiring temperature data corresponding to the monitoring points and temperature increase data corresponding to the monitoring points in unit time, and analyzing by gas leakage detection to obtain gas leakage detection values corresponding to the monitoring points, wherein the gas leakage detection values specifically comprise: acquiring gas required to be monitored at the periphery of the chemical reaction kettle in the operation process, acquiring average concentration data of corresponding gas of corresponding monitoring points in unit time, and presetting a group of preset hazard weight values corresponding to each type of gas respectively, wherein the values of the preset hazard weight values are all larger than zero, and the greater the hazard degree of the corresponding gas is, the greater the value of the preset hazard weight value matched with the corresponding type of gas is; marking the product of the average concentration data of the corresponding gas and the corresponding preset hazard weight value as a gas monitoring value, and obtaining a gas leakage detection value by carrying out summation calculation on all the gas monitoring values of the corresponding monitoring points;
By the formula wx=fy1 WF/fy2+fy2WY+fy3Carrying out numerical calculation on temperature data WF, temperature increase data WY and gas leakage detection value WP of corresponding monitoring points to obtain an external condition point analysis value WX, wherein fy1, fy2 and fy3 are preset proportionality coefficients, and fy2 is larger than fy3 and larger than fy1 is larger than 0; and, the larger the value of the external condition point analysis value WX is, the worse the safety condition of the corresponding monitoring point is indicated;
Comparing the external condition point analysis value WX with a preset external condition point analysis value range in a numerical mode, and marking the corresponding monitoring point as a high risk monitoring point if the external condition point analysis value WX exceeds the maximum value of the preset external condition point analysis value range and the safety condition of the corresponding monitoring point is extremely poor; if the external condition point analysis value WX is in the preset external condition point analysis value range, indicating that the safety condition of the corresponding monitoring point is poor, marking the corresponding monitoring point as a medium risk monitoring point; if the external condition point analysis value WX does not exceed the minimum value of the preset external condition point analysis value range, indicating that the safety condition of the corresponding monitoring point is good, marking the corresponding monitoring point as a low risk monitoring point;
If a high risk monitoring point exists in the chemical reaction kettle, an external condition abnormal signal is generated; if high risk monitoring points exist in the chemical reaction kettle, marking the ratio of the number of medium risk monitoring points to the total number of monitoring points as a medium risk point occupation value, carrying out average calculation on the external condition point analysis values of all the monitoring points to obtain an external condition evaluation value, and obtaining a formula QW=b1 through QK+b2The QS carries out numerical calculation on the medium risk point occupation value QK and the external condition evaluation value QS to obtain an external condition evaluation value QW of the reaction kettle;
Wherein b1 and b2 are preset weight coefficients, and b1 is more than b2 is more than 0; and, the larger the value of QW of the external condition evaluation value of the reaction kettle is, the worse the peripheral safety condition of the chemical reaction kettle is indicated in the comprehensive aspect; comparing the external condition evaluation value QW of the reaction kettle with a preset external condition evaluation threshold value of the reaction kettle, and generating an external condition abnormal signal if the external condition evaluation value QW of the reaction kettle exceeds the preset external condition evaluation threshold value of the reaction kettle, which indicates that the external safety condition of the chemical reaction kettle is poor in comprehensive terms; if the QW (QW) of the external condition evaluation value of the reaction kettle does not exceed the preset external condition evaluation threshold value of the reaction kettle, the external condition normal signal is generated when the external safety condition of the chemical reaction kettle is better.
The method comprises the steps that a reaction kettle line management module obtains a power line required to be managed by a chemical reaction kettle, the corresponding power line is marked as a target line e, and e is a natural number larger than 1; monitoring all power lines in the operation process of the chemical reaction kettle to judge the operation risk of the chemical reaction kettle, determining a risk line and a safety line according to the risk line and the risk line, generating a line stability signal or a line risk signal, transmitting the line stability signal or the line risk signal to an operation alarm module through a server, and sending out corresponding early warning when the operation alarm module receives the line risk signal, so that the comprehensive monitoring of all the power lines of the chemical reaction kettle and the accurate feedback of the risk condition of the power lines are realized, the timely line inspection is facilitated, and the line safety of the chemical reaction kettle is ensured, and the safe and stable operation of the chemical reaction kettle is facilitated; the analysis process of the reaction kettle line management module is as follows:
marking the difference value between the electric energy data input into the target line e and the electric energy data output by the target line e in unit time as a line loss value, carrying out average value calculation on the surface temperatures of a plurality of positions on the target line e to obtain a line surface temperature detection value, marking the ratio of the line surface temperature detection value to a preset line surface temperature detection threshold value as a line surface Wen Zhankuang value, and adopting the formula Performing numerical calculation on the line loss value PYe and the line table Wen Zhankuang value RKe to obtain a line detection evaluation value RPe;
Wherein, hy1 and hy2 are preset proportionality coefficients, the values of hy1 and hy2 are positive numbers, and the larger the value of the line detection evaluation value RPe is, the worse the operation performance of the power line e is indicated; comparing the line detection evaluation value RPe with a preset line detection evaluation threshold value, and marking the target line e as a risk line if the line detection evaluation value RPe exceeds the preset line detection evaluation threshold value, which indicates that the operation performance of the power line e is poor and the safety risk is high;
If the line detection evaluation value RPe does not exceed the preset line detection evaluation threshold, acquiring real-time voltage values and real-time current values of a plurality of positions in the target line e, performing variance calculation on the real-time voltage values of all positions to obtain voltage wave evaluation values, performing variance calculation on the real-time current values of all positions to obtain current wave evaluation values, respectively performing numerical comparison on the voltage wave evaluation values and the current wave evaluation values with the preset voltage wave evaluation threshold and the preset current wave evaluation threshold, and if the voltage wave evaluation values or the current wave evaluation values exceed the corresponding preset thresholds, indicating that the voltage or the current of the power line e is unstable and the potential safety hazard exists is large, marking the target line e as a risk line; if the voltage wave evaluation value and the current wave evaluation value do not exceed the corresponding preset threshold values, the fact that the voltage or the current of the power line e is stable and the potential safety hazard is small is indicated, and the target line e is marked as a safety line.
Further, in the determination of the risk line and the safety line, if the risk line exists in the chemical reaction kettle, the line risk of the chemical reaction kettle is indicated to be large, and a line risk signal is generated; if no risk line exists in the chemical reaction kettle, acquiring the adjacent last inspection time of the target line e, and marking the interval duration between the current time and the adjacent last inspection time as an inspection interval duration, wherein the larger the value of the inspection interval duration is, the more the corresponding target line e needs to be inspected in time; the detection interval time length is compared with a corresponding preset detection interval time length threshold value in a numerical mode, and if the detection interval time length exceeds the preset detection interval time length threshold value, the corresponding target line e is marked as a line to be detected;
the method comprises the steps of obtaining the number of lines to be detected in a chemical reaction kettle, marking the number of lines to be detected as a line table value to be detected, marking the ratio of the detection period of a target line e to a corresponding preset detection period threshold value as a detection occupation condition value, carrying out average calculation on the detection occupation condition values of all power lines to obtain a detection table analysis value, and obtaining a detection judgment value through a formula LK=tk1 LP+tk2The LW carries out numerical calculation on the to-be-detected risk table value LP and the gauge analysis value LW to obtain a line total analysis value LK; wherein, tk1 and tk2 are preset proportionality coefficients, and tk2 is more than tk1 and more than 0;
And the larger the numerical value of the line total analysis value LK is, the greater the line hidden trouble degree of the chemical reaction kettle is indicated in the comprehensive aspect; the line total analysis value LK is compared with a preset line total analysis threshold value, and if the line total analysis value LK exceeds the preset line total analysis threshold value, a line risk of the chemical reaction kettle is indicated to be large, and a line risk signal is generated; if the line total analysis value LK does not exceed the preset line total analysis threshold, the line risk of the chemical reaction kettle is smaller, and a line stable signal is generated.
Embodiment two: as shown in fig. 2, the difference between the embodiment and embodiment 1 is that the server is in communication connection with the vibration detecting and analyzing module, and the vibration detecting and analyzing module collects vibration data and noise data of the chemical reaction kettle in the operation process through the vibration detecting sensor and the noise detecting sensor, wherein the vibration data is a data value representing the sum of the vibration amplitude and the vibration frequency of the chemical reaction kettle, and the noise data is a data value representing the decibel value of noise generated in the operation process of the chemical reaction kettle;
respectively comparing the vibration data and the noise data with a preset vibration data threshold value and a preset noise data threshold value, and judging that the chemical reaction kettle is in a non-optimal vibration response state if the vibration data or the noise data exceeds the corresponding preset threshold value, which indicates that the vibration and the noise generated by the chemical reaction kettle are abnormal; acquiring the total time length of the chemical reaction kettle in the non-optimal state of sound vibration in unit time, marking the total time length as a non-optimal time analysis value of sound vibration, carrying out average value calculation on all vibration data in unit time to obtain a vibration condition value of the reaction kettle, and carrying out average value calculation on all noise data in unit time to obtain a sound condition value of the reaction kettle;
By the formula fy=a1 FS+（a2FK+a3FR)/a 1 carries out numerical calculation on a sound vibration non-optimal time analysis value FS, a reaction kettle vibration condition value FK and a reaction kettle sound condition value FR to obtain a reaction kettle auxiliary abnormal value FY, wherein a1, a2 and a3 are preset proportionality coefficients, and the values of a1, a2 and a3 are positive numbers; and the larger the numerical value of the auxiliary different value FY of the reaction kettle is, the more abnormal the operation condition of the chemical reaction kettle is;
Numerical comparison is carried out on the auxiliary abnormal value FY of the reaction kettle and the auxiliary abnormal threshold value of the preset reaction kettle, if the auxiliary abnormal value FY of the reaction kettle exceeds the auxiliary abnormal threshold value of the preset reaction kettle, the abnormal operation condition of the chemical reaction kettle is indicated, a reaction kettle vibration failure signal is generated, the reaction kettle vibration failure signal is sent to an operation alarm module through a server, and the operation alarm module sends out corresponding early warning when receiving the reaction kettle vibration failure signal, so that management staff is reminded to timely conduct reason investigation and make reasonable improvement measures, and the operation potential safety hazard of the chemical reaction kettle is reduced.
The working principle of the invention is as follows: when the intelligent monitoring system is used, the internal condition of the chemical reaction kettle is monitored in the operation process of the chemical reaction kettle through the reaction kettle internal condition monitoring module, an internal condition normal signal or an internal condition abnormal signal is generated through analysis, the reaction kettle external condition monitoring module marks an area which is within L1 meters from the peripheral outline of the chemical reaction kettle as a management and control area, the management and control area is monitored in real time in the operation process of the chemical reaction kettle, an external condition normal signal or an external condition abnormal signal is generated through analysis, the reaction kettle line management module acquires power lines which are required to be managed by the chemical reaction kettle, monitors all the power lines in the operation process of the chemical reaction kettle to judge the operation risk of the power lines, determines a risk line and a safety line according to the risk line or the internal condition normal signal or the internal condition abnormal signal, the external condition normal signal or the line safety signal, and enables the operation alarm module to send corresponding early warning when the internal condition normal signal, the external condition normal signal or the line safety signal are generated, so that the safety and stable operation of the chemical reaction kettle can be guaranteed.
The above formulas are all formulas with dimensions removed and numerical values calculated, the formulas are formulas with a large amount of data collected for software simulation to obtain the latest real situation, and preset parameters in the formulas are set by those skilled in the art according to the actual situation. The preferred embodiments of the invention disclosed above are intended only to assist in the explanation of the invention. The preferred embodiments are not intended to be exhaustive or to limit the invention to the precise form disclosed. Obviously, many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and the practical application, to thereby enable others skilled in the art to best understand and utilize the invention. The invention is limited only by the claims and the full scope and equivalents thereof.
Claims (8)
1. The chemical reaction kettle operation alarm system based on data analysis is characterized by comprising a server, a reaction kettle internal condition monitoring module, a reaction kettle external condition monitoring module, a reaction kettle line management module and an operation alarm module; the internal condition monitoring module of the reaction kettle is used for monitoring the internal condition of the reaction kettle in the operation process of the chemical reaction kettle, generating an internal condition normal signal or an internal condition abnormal signal through analysis, and sending the internal condition normal signal or the internal condition abnormal signal to the operation alarm module through the server, and sending out corresponding early warning when the operation alarm module receives the internal condition abnormal signal;
the external condition monitoring module of the reaction kettle marks an area which is within 1 meter from the peripheral outline L of the chemical reaction kettle as a management and control area, monitors the management and control area in real time in the operation process of the chemical reaction kettle, generates an external condition normal signal or an external condition abnormal signal through analysis, sends the external condition normal signal or the external condition abnormal signal to the operation alarm module through a server, and sends corresponding early warning when the operation alarm module receives the external condition abnormal signal;
The method comprises the steps that a reaction kettle line management module obtains a power line required to be managed by a chemical reaction kettle, the corresponding power line is marked as a target line e, and e is a natural number larger than 1; and monitoring all the electric power lines in the operation process of the chemical reaction kettle to judge the operation risk of the electric power lines, determining a risk line and a safety line according to the risk line and the safety line, generating a line stability signal or a line risk signal, transmitting the line stability signal or the line risk signal to an operation alarm module through a server, and sending out corresponding early warning when the operation alarm module receives the line risk signal.
2. The chemical reaction kettle operation alarm system based on data analysis according to claim 1, wherein the specific operation process of the reaction kettle internal condition monitoring module comprises:
The method comprises the steps of collecting real-time temperatures of a plurality of positions in a chemical reaction kettle, performing variance calculation on the real-time temperatures of the plurality of positions to obtain temperature uniformity coefficients, marking the number ratio of the temperature uniformity coefficients exceeding a preset temperature uniformity coefficient threshold value in unit time as a temperature non-uniformity number ratio value, performing mean calculation on all the temperature uniformity coefficients in unit time to obtain a temperature distribution condition value, and generating an internal condition abnormal signal if the temperature non-uniformity number ratio value or the temperature distribution condition value exceeds a corresponding preset threshold value.
3. The data analysis-based chemical reaction kettle operation alarm system according to claim 2, wherein if the temperature non-uniform number occupation value and the temperature cloth Kuang Zhi do not exceed the corresponding preset thresholds, the real-time air pressure and the real-time stirring speed inside the chemical reaction kettle are collected, the deviation value of the real-time air pressure compared with the preset standard real-time air pressure is marked as a real-time pressure analysis deviation value, and the deviation value of the real-time stirring speed compared with the preset standard stirring speed is marked as a real-time stirring analysis deviation value;
the real-time temperatures of a plurality of positions are subjected to mean value calculation to obtain real-temperature detection values, deviation values of the real-temperature detection values compared with preset standard real-temperature detection values are marked as real-temperature deviation detection values, internal condition actual measurement values are obtained through numerical calculation of the real-pressure deviation detection values, the real-mixing deviation detection values and the real-temperature deviation detection values, internal condition analysis values are obtained through mean value calculation of all internal condition actual measurement values in unit time, and the internal condition actual measurement values are compared with preset internal condition actual measurement thresholds in a numerical mode;
Acquiring total duration and maximum duration of a chemical reaction kettle in an internal condition bad state in unit time, respectively marking the total duration and the maximum duration as an internal condition bad total value and an internal condition bad holding value, carrying out numerical calculation on an internal condition analysis value, an internal condition bad total value and an internal condition bad holding value to obtain a reaction kettle internal condition evaluation value, and generating an internal condition abnormal signal if the reaction kettle internal condition evaluation value exceeds a preset reaction kettle internal condition evaluation threshold; if the internal condition evaluation value of the reaction kettle does not exceed the preset internal condition evaluation threshold value of the reaction kettle, generating an internal condition normal signal.
4. The chemical reaction kettle operation alarm system based on data analysis according to claim 2, wherein the specific operation process of the reaction kettle external condition monitoring module comprises:
Arranging a plurality of monitoring points in a management and control area, acquiring temperature data of the corresponding monitoring points, acquiring temperature increase data of the corresponding monitoring points in unit time, analyzing the gas leakage detection to obtain gas leakage detection values of the corresponding monitoring points, calculating the temperature data, the temperature increase data and the gas leakage detection values of the corresponding monitoring points to obtain external condition point analysis values, and marking the corresponding monitoring points as high-risk monitoring points if the external condition point analysis values exceed the maximum value of the preset external condition point analysis value range; if the external condition point analysis value is within the preset external condition point analysis value range, marking the corresponding monitoring point as a medium risk monitoring point; if the external condition point analysis value does not exceed the minimum value of the preset external condition point analysis value range, marking the corresponding monitoring point as a low risk monitoring point;
If a high risk monitoring point exists in the chemical reaction kettle, an external condition abnormal signal is generated; if high-risk monitoring points exist in the chemical reaction kettle, marking the ratio of the number of medium-risk monitoring points to the total number of monitoring points as a medium-risk point occupation value, carrying out average calculation on the external condition point analysis values of all the monitoring points to obtain an external condition evaluation value, carrying out numerical calculation on the medium-risk point occupation value and the external condition evaluation value to obtain a reaction kettle external condition evaluation value, and if the reaction kettle external condition evaluation value exceeds a preset reaction kettle external condition evaluation threshold value, generating an external condition abnormal signal; if the external condition evaluation value of the reaction kettle does not exceed the preset external condition evaluation threshold value of the reaction kettle, generating an external condition normal signal.
5. The chemical reaction kettle operation alarm system based on data analysis according to claim 4, wherein the specific analysis process of the gas leakage detection analysis is as follows:
acquiring gas required to be monitored at the periphery of the chemical reaction kettle in the operation process of the chemical reaction kettle, acquiring average concentration data of corresponding gas of corresponding monitoring points in unit time, presetting a group of preset hazard weight values corresponding to each type of gas respectively, marking the product of the average concentration data of the corresponding gas and the corresponding preset hazard weight values as gas monitoring values, and calculating all the gas monitoring values of the corresponding monitoring points in a summation mode to obtain a gas leakage detection value.
6. The chemical reaction kettle operation alarm system based on data analysis of claim 1, wherein the analysis process of the reaction kettle line management module comprises:
Marking the difference value between the electric energy data input into the target line e and the electric energy data output by the target line e in unit time as a line loss value, carrying out average value calculation on the surface temperatures of a plurality of positions on the target line e to obtain a line surface temperature detection value, marking the ratio of the line surface temperature detection value to a preset line surface temperature detection threshold value as a line table Wen Zhankuang value, carrying out numerical calculation on the line loss value and the line table Wen Zhankuang value to obtain a line detection evaluation value, and marking the target line e as a risk line if the line detection evaluation value exceeds the preset line detection evaluation threshold value;
If the line detection evaluation value does not exceed the preset line detection evaluation threshold value, acquiring real-time voltage values and real-time current values of a plurality of positions in the target line e, performing variance calculation on the real-time voltage values of all the positions to obtain voltage wave evaluation values, performing variance calculation on the real-time current values of all the positions to obtain current wave evaluation values, and if the voltage wave evaluation values or the current wave evaluation values exceed the corresponding preset threshold value, marking the target line e as a risk line; and if the voltage wave evaluation value and the current wave evaluation value do not exceed the corresponding preset threshold values, marking the target line e as a safety line.
7. The data analysis-based chemical reaction kettle operation alarm system according to claim 6, wherein in determining a risk line and a safety line, if a risk line exists in the chemical reaction kettle, a line risk signal is generated; if no risk line exists in the chemical reaction kettle, acquiring the adjacent last checking time of the target line e, marking the interval duration between the current time and the adjacent last checking time as an interval duration, comparing the interval duration with a corresponding preset interval duration threshold value, and marking the corresponding target line e as a line to be checked if the interval duration exceeds the preset interval duration threshold value;
The method comprises the steps of obtaining the number of lines to be detected in a chemical reaction kettle, marking the number of lines to be detected as a line table value to be detected, marking the ratio of the detection period of a target line e to a corresponding preset detection period threshold value as a detection occupation condition value, carrying out mean value calculation on detection occupation condition values of all power lines to obtain a detection table analysis value, carrying out numerical calculation on the line table value to be detected and the detection table analysis value to obtain a line total analysis value, and generating a line risk signal if the line total analysis value exceeds the preset line total analysis threshold value; and if the line total analysis value does not exceed the preset line total analysis threshold value, generating a line stable signal.
8. The chemical reaction kettle operation alarm system based on data analysis according to claim 1, wherein the server is in communication connection with a sound vibration detection analysis module, the sound vibration detection analysis module obtains a reaction kettle auxiliary abnormal value by carrying out numerical calculation on a sound vibration non-optimal time analysis value, a reaction kettle vibration condition value and a reaction kettle sound condition value, if the reaction kettle auxiliary abnormal value exceeds a preset reaction kettle auxiliary abnormal threshold value, a reaction kettle sound vibration disqualification signal is generated, and the reaction kettle sound vibration disqualification signal is sent to the operation alarm module through the server.
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