Automation in Petro-Chemical Industry

The overall framework design of the Shaanxi Beijing gas pipeline from "automatic distribution" to "intelligent distribution"

2024, 60(5): 0-0.

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Natural gas distribution control technology is key to ensuring the safe, smooth, and efficient operation of oil and gas pipelines. Under the background of digital transformation, the construction of smart pipeline networks provides strong support for the updating and upgrading traditional automatic distribution control technology. The research status of automatic distribution control technology is introduced based on briefly describing the concept of a smart pipeline network. The principle and main methods of the ShanJing pipeline distribution control technology were elaborated based on the actual site conditions. In response to the shortcomings of the current automatic distribution control technology for the Shanjing pipeline, a plan has been proposed to transform from "automatic distribution" to "intelligent distribution" around the perception layer, control layer, and maintenance layer, providing a solution for improving the construction of smart oil and gas pipeline networks and the development of automatic distribution.

Analysis of the influence of oxygen flow temperature and pressure compensation on the chemical efficiency of ethylene oxide unit

2024, 60(5): 0-0.

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Oxygen is the main reaction material in ethylene oxide unit, and it is also an important calculation factor involved in the selectivity of ethylene oxide unit, and its measurement accuracy directly affects the judgment of catalyst selectivity. In this paper, two methods of calculating catalyst selectivity in ethylene oxide plant using analytical instrument and ethylene/oxygen mass flow rate were introduced, and the reasons for the large error in calculating catalyst selectivity with the latter were found out. The reasons for the error in the temperature and pressure compensation formula of oxygen flow rate were determined. After correction, the two selectivity calculation methods showed similar amplitude and trend. It is proved that the two methods have good reference significance in calculating catalyst selectivity.

Application of OCS in Synthetic Ammonia Urea Production Project

2024, 60(5): 0-0.

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Synthetic ammonia and urea are important fertilizers and industrial raw materials with extensive applications in modern agriculture and chemical industry. In traditional ammonia urea production projects, DCS systems based on copper core cables are generally used as signal transmission media. However, the use of copper core cables makes signal interaction between the control system and the device area susceptible to interference from external electrical signals, and the cost of copper core cables is high. This traditional approach will significantly increase the project cost and spare parts cost for users, affecting the rapid delivery of the project. This article combines industrial optical bus technology with synthetic ammonia urea production projects, which can not only solve the problem of interference in copper core cable signal transmission, but also significantly reduce the installation cost of control systems, save time, and improve the reliability and stability of system operation in synthetic ammonia urea production projects.

On the Hazards and Governance Measures of Single Point Safety Interlocking

2024, 60(5): 0-0.

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Abstract：The interlocking protection system is an important equipment to ensure the smooth operation of the device. Single point interlocking refers to the instrument function where one measuring instrument or a pair of contacts can trigger interlocking action. This article analyzes the main reasons for the serious consequences caused by multiple single point interlocking fault cases. Through induction and summary, it is found that the problems mainly focus on shared instrument pressure points, shared system cards, inadequate instrument maintenance, failure to do seasonal maintenance work, and failure to replace expired equipment according to its service life. And explore and develop single point interlocking governance and rectification plans one by one based on the causes of the case. Through single point interlocking governance, the reliability of the interlocking protection system will be comprehensively improved in terms of source design, compliance rectification, daily maintenance, etc., to ensure the smooth operation of the device.

Discussion on Long Cycle Operation of Instrument and Control System for Ethylene Cracking Gas Compressor

2024, 60(5): 0-0.

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Analysis and suggestions for unplanned shutdown caused by furnace pressure measurement in heater

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With the large-scale development of petrochemicals, the application of heater with furnaces as heat sources is becoming increasingly used. This article study and research on the reasons for the frequent abnormal working conditions of "furnace pressure interlocking", and issued some solutions and suggestions from different perspectives to prevent unnecessary spurious trip and unplanned shutdown caused of process unit by furnace pressure

Research on the Modbus RTU communication between Honeywell and Hollysys distributed control system

2024, 60(5): 0-0.

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PetroChina Jinzhou Petrochemical Company has carried out the work of interconnecting data between various upstream and downstream devices. It requires different brands and models of DCS control systems to communicate with Hollysys MACS 6 control system through Modbus RTU protocol. As the actual work progresses, it is found that only the Honeywell PKS control system could not write data to the Hollysys system. In response to this phenomenon, a deep analysis of the basic principles of Modbus RTU communication protocol was conducted, and a method of studying Modbus RTU communication messages was adopted to analyze the differences between the two systems' messages. By adjusting the configuration of the Honeywell and Hollysys systems, the structure of the messages was made consistent. After connecting the Honeywell and Hollysys systems, it was found that the data from the Honeywell system can be successfully written out, thus solving the last problem in the interconnection project.

Research on Electromagnetic compatibility of control system in Petrochemical Plant

2024, 60(5): 0-0.

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The electromagnetic compatibility of SH 3092-2013 "Design specification for distributed control system in petrochemical industry" requires that DCS equipment does not cause bad electromagnetic interference in other equipment, nor will it be excessively sensitive to external electromagnetic interference. This article uses the concept of electromagnetic compatibility, sorts out the emission requirements and anti-interference requirements of electromagnetic compatibility of the control system, puts forward the electromagnetic protection measures of the distributed control system, and summarizes the electromagnetic compatibility design points of the petrochemical plant control system, which is conducive to engineering design and application of Electromagnetic Compatibility.

Research on the Relationship between the Transient Control Performance of Natural Gas Automatic Distribution System with the Parameters of Connecting Pipeline

2024, 60(5): 0-0.

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With the development of automation and intelligent technology, natural gas distributing stations are gradually popularized for automatic control systems. In this article, the types of gas users in a certain natural gas pipeline company are first studied. Three types of classic users are selected, and their data such as gas components, distribution pressure, and flow rate of each type user are collected as the basis of modeling. Furthermore, the mathematical models of the main devices in the automatic control system are analyzed, thus establishing the relationship between the structural parameters of the connection pipeline and the transient control performance indicators of the automatic control system. By comparison, it is found that the diameter and length of the connection pipeline have a significant impact on the transient control performance of the automatic system. There are critical pipe diameter and critical length, before and after which the transient performance indicators of the automatic control system have different trends.

Discussion on the Current Status and Development Direction of Fracturing Unit Control Technology

2024, 60(5): 0-0.

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The control technology level of the fracturing unit directly determines the quality and efficiency of the fracturing operation. For this purpose, the author conducted research on the technological progress and application status of fracturing unit control systems from mainstream domestic and foreign manufacturers. They compared the level of single machine equipment control and centralized intelligent control of units from various manufacturers, and analyzed the main problems that currently hinder the intelligent development of fracturing unit control systems. The conclusion indicates that there is no significant difference in the control technology of domestic fracturing units compared to similar foreign manufacturers; The overall field is developing towards electrification, hybridization, wireless, visualization, and intelligence. We can start from the aspects of technology, management, and personnel to jointly promote the improvement of China's fracturing unit control technology and meet the needs of unconventional oil and gas high-efficiency and high-quality development.

Design and application of a dual robot batching robot system

2024, 60(5): 0-0.

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In today's society, the application of robots is gradually moving from experimentation to application, from component based unit applications to systematic applications. This is an inevitable trend in technological development and the inevitable path to achieving Industry 4.0; This project is based on the collection of two or more robots with multiple tasks and systems, combined with technologies such as microcontroller programming and PLC programming, to achieve a robot system where multiple robots cooperate, coordinate, and unify to complete a task; This article discusses in detail the importance, working principle, application fields, and their impact on production efficiency and quality of the dual robot batching system in modern industry. Through in-depth analysis of the system, its broad prospects and potential in future industrial development have been revealed.

Practice of IoT Technology in the Construction of Intelligent Offshore Oil Fields

2024, 60(5): 0-0.

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The implementation of intelligent oil fields using Internet of Things (IoT) technology has been a major research and application focus in recent years. In the construction project of the QHD32-6 intelligent oil field, IoT technology was introduced and extensively studied and applied. supOS is an industrial operating system software focused on achieving intelligence in the Process Automation (PA) layer for industrial enterprises, and after industry-specific transformation and development, it can be applied to the realization of IoT in offshore oil fields. This paper provides an overall introduction on how to utilize supOS as an IoT platform for real-time data collection and application development, with the hope of offering some reference significance for the intelligent construction of other oil fields.

Research on Natural Gas Pipeline Inspection System Based on Drones

2024, 60(5): 0-0.

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The National Development and Reform Commission and the National Energy Administration have released the "Medium - and Long Term Oil and Gas Pipeline Network Plan", which states that by 2025, the scale of the national oil and gas pipeline network will reach 240000 kilometers. During the inspection process of long-distance natural gas pipelines, there are often problems such as complex terrain, long inspection distances, heavy workload, low efficiency of walking inspections, high costs, inability to quickly reach designated locations in case of emergencies, severe personnel aging, and high management costs. With the increasing mileage of natural gas pipelines year by year, the challenges faced by pipeline inspections will become increasingly severe. This article focuses on the problems encountered during the inspection of natural gas pipelines, and combines drone flight, leak detection technology, surface micro deformation detection technology, image recognition technology, communication technology, etc. to develop a comprehensive management platform for natural gas pipeline inspection based on drones. It realizes the full process management of drone inspection and verifies the feasibility of the comprehensive management platform through on-site application.

Discussion on The Application of SPI Design Verification Rule Setting

2024, 60(5): 0-0.

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Smart Plant Instrumentation (SPI) from Hexagon is a management tool for instrumentation design and full-cycle instrumentation based on public database and rule-driven. After years of development, SPI has been recognized as one of the most versatile software for instrumentation design and management in the industry, and is widely used in domestic and international engineering design fields such as oil and gas, chemical, nuclear and power generation, etc. SPI Rule Manager is an independent module in SPI software, which is mainly used for creating, executing, and managing data checking rules, to realize the design calibration function. Due to the different application environments at home and abroad, domestic engineering companies encountered many difficulties in applying SPI Rule Manager for data checking. To solve the above problems, SPI Expert Rule has been redeveloped and applied to integrate the standard specification and engineering experience into the SPI design check rule setting. This paper mainly introduces the application results of SPI Rule Manager and SPI Expert Rule.

The design and implementation of a fully automated intelligent water quality analysis system throughout the entire process

2024, 60(5): 0-0.

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The traditional water quality analysis laboratory is highly dependent on manual operation, and has some problems such as low detection and analysis efficiency, high safety risk and poor experimental stability. Based on the above problems, a whole process unmanned water quality intelligent analysis system is designed, and the working process, hardware and software Settings of the intelligent analysis system are introduced. The application of the system has realized the automatic analysis of COD (chemical oxygen demand), pH, conductivity, ammonia nitrogen, total nitrogen and other items in the water quality, replacing manual analysis more than 120,000 times a year, and realizing sample separation and delivery according to the single maximum sample flux. Complete the analysis and data upload LIMS (Laboratory Information Management System) system within 3 hours, greatly shortening the experiment cycle. The application of this system provides a reference for various enterprises in the laboratory automation and intelligent construction.

Design and Application of Analyzer Management and Data Acquisition System for Large-Scale Refining and Petrochemical Integration Projects

2024, 60(5): 0-0.

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In large-scale integrated refining and chemical projects, the challenges of managing numerous online analyzers and the high maintenance costs are faced. In order to achieve the goal of digitalization and intelligent management of online analyzers in petrochemical enterprises, this paper conducts research on the design of an analyzer management and data acquisition system(AMADAS), which is based on the requirements of a certain integrated refining and chemical project. The network architecture and functional design of the system have been deeply analyzed. After the actual application of the system, enterprise instrument engineers can achieve remote monitoring and maintenance of the online analyzers through the central control room or the engineer stations of each device, and the practical experience of the system has been summarized. Finally, the direction for continuous optimization of the system is outlined.

Investment Analysis of Bus Control System

2024, 60(5): 0-0.

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Research on optimization technology of combustible gas sensor layout in oil and gas station

2024, 60(5): 0-0.

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Abstract: In order to effectively predict combustible gas leakage in oil and gas station, a scientific, reasonable and economical gas sensor layout scheme was developed. Based on the fusion of the leakage source parameter set and the wind field parameter set, the number of scenarios corresponding to the cumulative leakage probability of 90% was defined as typical scenarios to replace all leakage scenarios. Combined with numerical simulation, the diffusion range and harm area of combustible gas in the station were determined, and the sensor layout schemes of different equipment and stations were optimized through regional block division. The results show that 1320 leakage scenes corresponding to 44 main equipment in the original station and yard can be reduced to 542 by screening, and the number of scenes is reduced by 58.9%, which greatly reduces the difficulty of subsequent calculation. The station requires 45 sensors to ensure coverage of high-risk leakage areas while reducing sensor redundancy. The research results can provide practical reference for the emergency warning of oil and gas station leakage accidents.

Discussion on the Design of Natural Gas Flow Measurement Calibration Process under Complex Gas Source Conditions

2024, 60(5): 0-0.

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This paper examines the simulated water calculation of gas source pressure and flow at a bypass calibration station on a ring natural gas pipeline network, and proposes operational conditions for the pipeline network to comply with calibration regulations；Simultaneously, we propose technical measures to enhance the precision of flowmeter calibration outcomes and provide recommendations for site selection, design, and operation of analogous bypass calibration stations.

Design of an automatic safety risk identification system for offshore drilling and completion operations based on computer vision

2024, 60(5): 0-0.

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Video surveillance on offshore platforms plays a significant role in safety monitoring and accident investigation during drilling and completion operations. Currently, the video surveillance systems on offshore platforms primarily rely on manual observation for safety monitoring and analysis, which leads to issues such as inadequate continuous monitoring, insufficient early warning capabilities, and high labor costs. To address these problems, this study proposes a machine vision-based framework for automatic identification of safety risks in offshore drilling and completion operations. The study utilizes rotation detection techniques to ensure accurate results even in tilted equipment conditions. Additionally, by incorporating object tracking technology, the system enables tracking and distance measurement of personnel and equipment, thus effectively monitoring the operational status of offshore platforms in complex environments. The proposed system was deployed and tested on a specific offshore platform, achieving an accuracy rate of over 90% for all algorithms employed. This significantly enhances the safety and efficiency of drilling and completion operations, reduces potential hazards and safety incidents, and makes a valuable contribution to improving the safety, efficiency, and management level of offshore drilling and completion operations.

Several implementation methods and applicability analysis for the partial stroke test function of the emergency shutdown valve

2024, 60(5): 0-0.

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With the continuous enhancement of petrochemical industry security awareness, the requirements of different local governments for the interlocking evaluation of some major risk sources have also been continuously improved. In the SIL verification stage of the project, there are cases where the verification results do not meet the SIL classification requirements. In order to avoid adding extra independent protective layers to reduce the SIL evaluation level with high cost, the emergency shutdown valve partial stroke test has attracted more and more attention as an effective means to shorten the detection period and improve the detection coverage. This article introduces the origin and specific requirements of the partial stroke test function of the emergency shutdown valve. Three categories with six different forms of implementation methods and some products on the market are thoroughly described. This article made a detailed analysis for the partial stroke test function with practical application, and also made a comprehensive comparison in terms of economy, availability and security. The test plan of airway design with moderate cost and most wide applicability is recommended.

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