CN110009876A - On-line monitoring and alarming device and method for heat exchanger operation status - Google Patents
On-line monitoring and alarming device and method for heat exchanger operation status Download PDFInfo
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Abstract
Description
技术领域technical field
本发明属于承压类特种设备领域，尤其涉及换热器安全可靠运行的测试装置及测试方法，具体涉及一种换热器运行状况在线监测报警装置及方法。The invention belongs to the field of pressure-bearing special equipment, in particular to a test device and a test method for the safe and reliable operation of a heat exchanger, in particular to an on-line monitoring and alarm device and method for the operation status of a heat exchanger.
背景技术Background technique
换热器是将热流体热量传递给冷流体的设备，作为一种能量交换型特种设备，其常以冷却器、冷凝器、蒸发器和再沸器等型式在石油、化工、冶金、电力及其它许多高耗能行业中得到广泛应用,在化工生产和石油加工工艺中其投资甚至超过总投资的三分之一。换热器是能源节约和能源再利用的有效设备，生产过程中单位产品的能耗直接受换热器换热效率的影响。在全球节能减排的大背景下，安全与经济并重、安全与资源节约并重的发展理念正逐渐成为共识。换热器运行状态的好坏直接影响整个生产链的运行效率和生产质量。换热器在长期运行后常常出现压降增大、介质内漏、泄漏、结垢等现象，这些情况的出现均会降低换热器的使用效率。尤其是对于温度或压力要求较高的生产系统，换热器运行状况异常甚至影响到系统的安全和正常运行，造成经济损失。因此对换热器运行状况的监测是一个不可忽略的环节。传统的在线监测手段主要通过操作人员通过仪表观察单一压力、温度或流量传感器的数据用于判断系统状态，且各种仪表通常为物理仪表，而非电子仪表，这就造成使用者难以从系统层面对换热器运行状况进行在线监测，发生问题时往往情节已较严重。A heat exchanger is a device that transfers heat from a hot fluid to a cold fluid. As a special type of energy exchange equipment, it is often used in petroleum, chemical, metallurgy, electric power and other types of coolers, condensers, evaporators and reboilers. It is widely used in many other high-energy-consuming industries, and its investment in chemical production and petroleum processing technology even exceeds one third of the total investment. The heat exchanger is an effective device for energy saving and energy reuse. The energy consumption per unit product in the production process is directly affected by the heat exchange efficiency of the heat exchanger. In the context of global energy conservation and emission reduction, the development concept of equal emphasis on safety and economy, and equal emphasis on safety and resource conservation is gradually becoming a consensus. The operating state of the heat exchanger directly affects the operating efficiency and production quality of the entire production chain. After long-term operation of the heat exchanger, the phenomenon of increased pressure drop, internal leakage of the medium, leakage, scaling, etc., will often reduce the efficiency of the heat exchanger. Especially for production systems with high temperature or pressure requirements, the abnormal operation of the heat exchanger even affects the safety and normal operation of the system, resulting in economic losses. Therefore, the monitoring of the operating condition of the heat exchanger is a link that cannot be ignored. Traditional online monitoring methods mainly use the operator to observe the data of a single pressure, temperature or flow sensor through the instrument to judge the system status, and various instruments are usually physical instruments rather than electronic instruments, which makes it difficult for users to analyze the system level. Online monitoring of the operating conditions of the heat exchanger is carried out, and when problems occur, the situation is often serious.
发明内容SUMMARY OF THE INVENTION
本发明针对现有换热器运行状况诊断方法和技术的不足，提供了一种换热器运行状况在线监测报警装置及方法，通过监测并计算出换热器运行过程中温度、压力、流量及流量差等各个状态参数，可对换热器运行状况进行在线诊断和异常声光报警，具有很好的实用价值。Aiming at the deficiencies of the existing methods and technologies for diagnosing the operating conditions of heat exchangers, the present invention provides an on-line monitoring and alarming device and method for operating conditions of heat exchangers. Various state parameters such as flow difference can carry out online diagnosis and abnormal sound and light alarm for the operation of the heat exchanger, which has good practical value.
为解决上述技术问题，本发明采取的技术方案为：In order to solve the above-mentioned technical problems, the technical scheme adopted in the present invention is:
一种换热器运行状况在线监测报警装置，包括：控制系统、传感器、数据采集模块、通讯模块、触摸显示屏、电路通断控制器和报警器，其中，An on-line monitoring and alarm device for heat exchanger operating conditions, comprising: a control system, a sensor, a data acquisition module, a communication module, a touch display screen, a circuit on-off controller and an alarm, wherein,
所述传感器设置于所述换热器的进出口处，用于检测所述进出口处的流体物理参数数据；The sensor is arranged at the inlet and outlet of the heat exchanger, and is used to detect fluid physical parameter data at the inlet and outlet;
所述数据采集模块与所述传感器相连，所述通讯模块分别与所述数据采集模块和控制系统相连，将采集的流体物理参数数据发送至控制系统；The data acquisition module is connected with the sensor, and the communication module is respectively connected with the data acquisition module and the control system, and sends the collected fluid physical parameter data to the control system;
所述触摸显示屏与所述控制系统相连，用于设定控制系统中的流体物理参数数据的阈值范围；The touch display screen is connected with the control system, and is used for setting the threshold range of the fluid physical parameter data in the control system;
所述控制系统，用于将设定的所述阈值范围与所述采集的流体物理参数数据进行比较，判断数据是否异常；The control system is configured to compare the set threshold range with the collected fluid physical parameter data to determine whether the data is abnormal;
所述报警器经所述电路通断控制器与所述控制系统相连，用于异常数据的报警。The alarm is connected to the control system via the circuit on-off controller, and is used for alarming abnormal data.
进一步的，所述流体物理参数主要包括：温度、压力和流量。Further, the physical parameters of the fluid mainly include: temperature, pressure and flow.
进一步的，还包括：数据存储媒介、报警指示灯组和外部开关按键组，所述数据存储媒介与所述控制系统相连，用于存储控制系统获取的流体物理参数数据，所述报警指示灯组与所述电路通断控制器相连，所述外部开关按键组与所述控制系统相连。Further, it also includes: a data storage medium, an alarm indicator light group and an external switch button group, the data storage medium is connected with the control system, and is used to store the fluid physical parameter data obtained by the control system, and the alarm indicator light group It is connected with the circuit on-off controller, and the external switch button group is connected with the control system.
进一步的，还包括：装置主体，所述装置主体的内部设有所述控制系统、电路通断控制器、通讯模块和数据存储媒介；所述装置主体上设有电源插座；所述装置主体的顶部设有所述报警器；所述装置主体下端装有支腿；所述装置主体上设有操作面板，所述操作面板上设有所述触摸显示屏、报警指示灯组和外部开关按键组。Further, it also includes: a device main body, the control system, the circuit on-off controller, the communication module and the data storage medium are arranged inside the device main body; the device main body is provided with a power socket; The top is provided with the alarm device; the lower end of the device main body is provided with legs; the device main body is provided with an operation panel, and the operation panel is provided with the touch display screen, an alarm indicator light group and an external switch button group .
进一步的，所述外部开关按键组包括：各个流体物理参数对应的报警开关按键，用于控制报警状态的开闭；所述报警指示灯组包括：各个流体物理参数对应的报警指示灯。Further, the external switch button group includes: an alarm switch button corresponding to each fluid physical parameter, which is used to control the opening and closing of the alarm state; the alarm indicator light group includes: an alarm indicator light corresponding to each fluid physical parameter.
进一步的，所述通讯模块与所述数据采集模块通过无线信号方式连接。Further, the communication module and the data acquisition module are connected by means of wireless signals.
在本发明的另一方面，提出了一种根据前面所述的换热器运行状况在线监测报警装置的在线监测报警方法，包括以下步骤：In another aspect of the present invention, an on-line monitoring and alarming method according to the above-mentioned on-line monitoring and alarming device for heat exchanger operating conditions is proposed, comprising the following steps:
（1）传感器检测所述换热器的进出口处的流体物理参数数据；(1) The sensor detects the fluid physical parameter data at the inlet and outlet of the heat exchanger;
（2） 数据采集模块经通讯模块将采集的流体物理参数数据发送至控制系统；(2) The data acquisition module sends the collected fluid physical parameter data to the control system through the communication module;
（3）控制系统将所述采集的流体物理参数数据与设定的流体物理参数数据的阈值范围进行比较，判断数据是否异常：当所述采集的流体物理参数数据在所述阈值范围内则正常，否则异常；(3) The control system compares the collected fluid physical parameter data with the set threshold range of fluid physical parameter data to determine whether the data is abnormal: when the collected fluid physical parameter data is within the threshold range, it is normal , otherwise an exception;
（4）异常时，控制系统发送触发信号至电路通断控制器控制报警器进行报警。(4) When abnormal, the control system sends a trigger signal to the circuit on-off controller to control the alarm to give an alarm.
进一步的，所述流体物理参数主要包括：温度、压力和流量。Further, the physical parameters of the fluid mainly include: temperature, pressure and flow.
进一步的，还包括以下具体步骤：通过计算进出口处的流量差值并与设定的流量差阈值范围进行比较，检测换热器是否泄漏。Further, the following specific steps are also included: by calculating the flow difference at the inlet and outlet and comparing it with the set flow difference threshold range, detecting whether the heat exchanger leaks.
与现有技术相比，本发明的有益效果在于：Compared with the prior art, the beneficial effects of the present invention are:
1）本发明采用多个电子式传感器，可同时对换热器进出口处温度、压力和流量的多个物理参数进行在线监测并直观屏幕显示，无需使用者在换热器现场观看仪表读数，减小了劳动强度；1) The invention adopts multiple electronic sensors, which can simultaneously monitor multiple physical parameters of temperature, pressure and flow at the inlet and outlet of the heat exchanger and display them on the screen directly, without the need for users to watch the instrument readings on the heat exchanger site, Reduce labor intensity;
2）本发明可通过人为设置参数报警的上下限阈值范围，换热器运行异常时能够自动声光报警，及时发现隐患，与传统的人工不间断检测方式相比，该装置有利于维持生产过程中温度、压力等工艺参数的稳定，并有利于提高应急状况的处理效率；2) The present invention can manually set the upper and lower threshold ranges of parameter alarms, and can automatically sound and light alarms when the heat exchanger runs abnormally, so as to find hidden dangers in time. Compared with the traditional manual uninterrupted detection method, the device is conducive to maintaining the production process. The stability of process parameters such as medium temperature and pressure is beneficial to improve the processing efficiency of emergency situations;
3）本发明除具备温度、压力和流量的多参数检测外，还具有泄漏监测和泄漏报警功能，可通过流程进出口端的流量差值判断是否发生泄漏。3) In addition to the multi-parameter detection of temperature, pressure and flow, the present invention also has the functions of leakage monitoring and leakage alarm, and can judge whether leakage occurs by the flow difference between the inlet and outlet of the process.
附图说明Description of drawings
图1为本发明在线监测报警装置结构框图。FIG. 1 is a structural block diagram of the online monitoring and alarming device of the present invention.
图2为本发明在线监测报警装置立体外观图。FIG. 2 is a three-dimensional appearance view of the online monitoring and alarming device of the present invention.
图3为本发明在线监测报警装置操作面板结构示意图。FIG. 3 is a schematic structural diagram of the operation panel of the online monitoring and alarming device of the present invention.
图4为本发明一个实施例的温度监测报警运行流程图。FIG. 4 is a flow chart of temperature monitoring and alarm operation according to an embodiment of the present invention.
图5为本发明一个实施例的泄漏监测报警运行流程图。FIG. 5 is a flow chart of the operation of leak monitoring and alarming according to an embodiment of the present invention.
上述诸图中：1-装置主体，2-报警器，3-电源插座，4-操作面板，5-支腿，6-触摸显示屏，21-温度报警开关按键，22-压力报警开关按键，23-流量报警开关按键，24-报警总开关按键，25-电源开关按键，26-泄漏报警开关按键，31-温度报警指示灯，32-压力报警指示灯，33-流量报警指示灯，34-电源供电指示灯，35-泄漏报警指示灯，36-换热器，37-热流体进口，38-热流体出口，39-冷流体进口，40-冷流体出口。In the above figures: 1- device main body, 2- alarm, 3- power socket, 4- operation panel, 5- leg, 6- touch display screen, 21- temperature alarm switch button, 22- pressure alarm switch button, 23-flow alarm switch button, 24-alarm master switch button, 25-power switch button, 26-leakage alarm switch button, 31-temperature alarm indicator light, 32-pressure alarm indicator light, 33-flow alarm indicator light, 34- Power supply indicator light, 35-leakage alarm indicator light, 36-heat exchanger, 37-hot fluid inlet, 38-hot fluid outlet, 39-cold fluid inlet, 40-cold fluid outlet.
具体实施方式Detailed ways
为了使本领域技术人员更好地理解本发明的技术方案，下面结合具体实施例对本发明作进一步的详细说明。下面描述的实施例是示例性的，仅用于解释本发明，而不能理解为对本发明的限制。实施例中未注明具体技术或条件的，按照本领域内的文献所描述的技术或条件或者按照产品说明书进行。In order to make those skilled in the art better understand the technical solutions of the present invention, the present invention will be further described in detail below with reference to specific embodiments. The embodiments described below are exemplary, only for explaining the present invention, and should not be construed as limiting the present invention. If no specific technique or condition is indicated in the examples, the technique or condition described in the literature in the field or the product specification is used.
根据本发明的实施例，本发明提供了一种换热器运行状况在线监测报警装置，图1为本发明在线监测报警装置结构框图，如图1所示，主要包括：控制系统、传感器、无线数据采集模块、无线通讯模块、触摸显示屏、电路通断控制器、报警器、数据存储媒介、报警指示灯组和外部开关按键组。According to an embodiment of the present invention, the present invention provides an online monitoring and alarming device for the operation status of a heat exchanger. Figure 1 is a structural block diagram of the online monitoring and alarming device of the present invention. Data acquisition module, wireless communication module, touch display screen, circuit on-off controller, alarm, data storage medium, alarm indicator group and external switch button group.
根据本技术领域可知，所述换热器主要包括：热流体进口、热流体出口、冷流体进口和冷流体出口，图3为本发明在线监测报警装置操作面板结构示意图，如图3所示，因此，在所述热流体进口、热流体出口、冷流体进口和冷流体出口分别设有本发明所述传感器，本发明所述传感器为电子式传感器，可对外传输电信号，包括温度传感器、压力传感器和流量计，用于分别检测上述进出口处的流体物理参数数据：温度、压力和流量。可以理解的是，为了提高数据的准确性，在每个进出口处设置的传感器数量可以为多个，本发明为使本领域技术人员更好地理解本发明的技术方案，在线监测报警装置优选为包括：四个温度传感器、四个压力传感器和四个流量计，分别设置在上述四个进出口处，即所述四个温度传感器分别用于检测换热器热流体和冷流体在进出口处的温度，所述四个压力传感器分别用于检测换热器热流体和冷流体在进出口处的压力，所述四个流量计分别用于检测热流体和冷流体流入和流出换热器进出口的流量。According to the technical field, the heat exchanger mainly includes: a hot fluid inlet, a hot fluid outlet, a cold fluid inlet and a cold fluid outlet. FIG. 3 is a schematic structural diagram of the operation panel of the online monitoring and alarm device of the present invention, as shown in FIG. Therefore, the sensors of the present invention are respectively provided at the hot fluid inlet, hot fluid outlet, cold fluid inlet and cold fluid outlet. The sensors of the present invention are electronic sensors that can transmit electrical signals to the outside, including temperature sensors, pressure A sensor and a flowmeter are used to detect the physical parameter data of the fluid at the inlet and outlet: temperature, pressure and flow, respectively. It can be understood that, in order to improve the accuracy of the data, the number of sensors set at each inlet and outlet can be multiple. In the present invention, in order to enable those skilled in the art to better understand the technical solution of the present invention, an online monitoring and alarm device is preferred. In order to include: four temperature sensors, four pressure sensors and four flowmeters, which are respectively arranged at the above four inlets and outlets, that is, the four temperature sensors are respectively used to detect the hot fluid and cold fluid of the heat exchanger at the inlets and outlets. The four pressure sensors are used to detect the pressures of the hot fluid and the cold fluid at the inlet and outlet of the heat exchanger, respectively, and the four flow meters are used to detect the inflow and outflow of the hot fluid and the cold fluid into and out of the heat exchanger respectively. Inbound and outbound traffic.
根据本发明的实施例，所述无线数据采集模块安装于换热器上且与所述传感器相连，用于在线采集传感器数据。所述无线通讯模块通过无线信号方式与无线数据采集模块相连，同时无线通讯模块通过RS485信号方式与控制系统相连，无线通讯模块用于将无线数据采集模块获取的传感器数据，即将采集的流体物理参数数据传输给控制系统。According to an embodiment of the present invention, the wireless data acquisition module is installed on the heat exchanger and connected to the sensor, and is used to collect sensor data online. The wireless communication module is connected to the wireless data acquisition module by means of wireless signals, and at the same time, the wireless communication module is connected to the control system by means of RS485 signals. The wireless communication module is used for the sensor data acquired by the wireless data acquisition module and the fluid physical parameters to be acquired The data is transmitted to the control system.
根据本发明的实施例，所述触摸显示屏与所述控制系统相连，用于通过文本或曲线方式在线显示换热器各部位温度、压力和流量参数，此外使用者可通过触摸显示屏输入设定各个传感器所监测流体物理参数的上下限阈值范围以及泄漏报警的流量差阈值范围，并将各个阈值数据发送至控制系统中，供控制系统计算。According to an embodiment of the present invention, the touch display screen is connected to the control system, and is used to display the temperature, pressure and flow parameters of each part of the heat exchanger online through text or curves. In addition, the user can input settings through the touch screen display. Determine the upper and lower threshold ranges of the physical parameters of the fluid monitored by each sensor and the flow difference threshold range of the leak alarm, and send the data of each threshold to the control system for the control system to calculate.
根据本发明的实施例，本发明所述控制系统优选为PLC，PLC可对在线获得的传感器数据进行分析，通过与用户输入设定的温度、压力和流量上下限阈值范围和泄漏的流量差阈值范围进行比较，判断换热器各部位温度、压力和流量是否异常，计算热流体和冷流体的进出口处流量差，并与流量差阈值进行比较，判断换热器是否发生泄漏。PLC判断出换热器参数异常时对外输出开关量信号给所述电路通断控制器，所述电路通断控制器从而控制报警指示灯和报警器的通断，实现换热器运行异常报警。根据本发明的一些实施例，本发明所述电路通断控制器优选为继电器。According to an embodiment of the present invention, the control system of the present invention is preferably a PLC, and the PLC can analyze the sensor data obtained online, and set the upper and lower threshold ranges of temperature, pressure and flow rate and the flow rate difference threshold of leakage set by the user. Compare the temperature, pressure and flow rate of each part of the heat exchanger, calculate the flow difference between the inlet and outlet of the hot fluid and the cold fluid, and compare it with the flow difference threshold to determine whether the heat exchanger leaks. When the PLC judges that the parameters of the heat exchanger are abnormal, it outputs a digital signal to the circuit on-off controller, and the circuit on-off controller controls the on-off of the alarm indicator light and the alarm to realize the abnormal operation of the heat exchanger. According to some embodiments of the present invention, the circuit on-off controller of the present invention is preferably a relay.
根据本发明的实施例，本发明所述数据存储媒介与PLC连接，用于将PLC获取的换热器各个参数进行存储，便于用户对数据提取和进一步分析，数据存储媒介可为U盘、SD卡或其他存储媒介。According to the embodiment of the present invention, the data storage medium of the present invention is connected to the PLC, and is used to store various parameters of the heat exchanger obtained by the PLC, which is convenient for users to extract and further analyze the data. The data storage medium can be U disk, SD card or other storage medium.
根据本发明的实施例，图2为本发明在线监测报警装置立体外观图，参照图2所示，本发明所述换热器运行状况在线监测报警装置还包括：装置主体，所述装置主体的内部设有PLC、继电器、无线通讯模块和数据存储媒介；所述装置主体上设有电源插座，用于接外部电源，给在线监测报警装置供电；所述装置主体的顶部设有所述报警器，当换热器参数异常时报警器发出声光报警信号；为方便操作，装置主体下端装有支腿。装置主体上装有操作面板，用于用户操作。According to an embodiment of the present invention, FIG. 2 is a three-dimensional appearance view of the online monitoring and alarming device of the present invention. Referring to FIG. 2 , the online monitoring and alarming device for the operation condition of the heat exchanger according to the present invention further includes: a device main body, and the device main body has a PLC, relay, wireless communication module and data storage medium are arranged inside; the main body of the device is provided with a power socket, which is used to connect the external power supply and supply power to the online monitoring and alarm device; the top of the main body of the device is provided with the alarm device , when the parameters of the heat exchanger are abnormal, the alarm will send out an audible and visual alarm signal; for the convenience of operation, the lower end of the main body of the device is equipped with outriggers. An operation panel is installed on the main body of the device for user operation.
根据本发明的实施例，参照图3所示，所述操作面板上设有所述触摸显示屏、报警指示灯组和外部开关按键组，更具体的，触摸显示屏上显示有换热器模型图并标注出各个传感器在换热器上的位置，如压力传感器（P），流量计（V）及温度传感器（T）。According to an embodiment of the present invention, referring to FIG. 3 , the operation panel is provided with the touch display screen, an alarm indicator light group and an external switch button group. More specifically, a heat exchanger model is displayed on the touch screen display. Figure and mark the position of each sensor on the heat exchanger, such as pressure sensor (P), flow meter (V) and temperature sensor (T).
所述报警指示灯组与所述继电器相连，用于报警指示，参照图3所示，具体包括：温度报警指示灯、压力报警指示灯、流量报警指示灯、泄漏报警指示灯。本发明还包括：电源供电指示灯，用于供电指示。所述外部开关按键组与所述控制系统相连，具体包括：报警总开关按键、温度报警开关按键、压力报警开关按键、流量报警开关按键、泄漏报警指示灯。本发明还包括：电源按键、电源按键用于装置的开启和关闭，按下电源按键打开在线监测报警装置后上述电源供电指示灯亮，指示当前装置处于运行状态。The alarm indicator group is connected to the relay and is used for alarm indication, as shown in FIG. 3 , and specifically includes: a temperature alarm indicator, a pressure alarm indicator, a flow alarm indicator, and a leakage alarm indicator. The invention also includes: a power supply indicator light for power supply indication. The external switch button group is connected with the control system, and specifically includes: an alarm master switch button, a temperature alarm switch button, a pressure alarm switch button, a flow alarm switch button, and a leakage alarm indicator light. The invention also includes: a power button and a power button for turning on and off the device, and after pressing the power button to turn on the online monitoring and alarming device, the power supply indicator light is on, indicating that the current device is in a running state.
根据本发明的实施例，上述报警指示灯组和外部开关按键组的具体工作原理如下。According to an embodiment of the present invention, the specific working principles of the above-mentioned alarm indicator light group and external switch key group are as follows.
（1）当PLC监测到换热器热流程和冷流程各自进出口处共4个部位存在温度大于温度上限阈值或小于温度下限阈值时，温度报警指示灯亮，同时报警器发出声光报警。装置开机时温度监测报警功能默认为打开状态，使用过程中按下温度报警开关按键可停止温度监测报警功能，温度报警指示灯熄灭，不可用于温度异常报警，当温度监测报警功能停止时按下温度报警开关按键可开启温度监测报警功能，温度报警指示灯可重新用于温度异常报警。(1) When the PLC detects that the temperature is greater than the upper temperature threshold or lower than the lower temperature threshold in 4 parts at the inlet and outlet of the heat exchanger heat process and the cold process, the temperature alarm indicator lights up, and the alarm emits an audible and visual alarm at the same time. When the device is turned on, the temperature monitoring and alarm function is turned on by default. Press the temperature alarm switch button to stop the temperature monitoring and alarm function during use. The temperature alarm indicator light is off and cannot be used for abnormal temperature alarm. The temperature alarm switch button can turn on the temperature monitoring and alarm function, and the temperature alarm indicator light can be reused for abnormal temperature alarm.
（2）当PLC监测到换热器热流程和冷流程各自进出口处共4个部位存在流体压力大于压力上限阈值或小于压力下限阈值时，压力报警指示灯亮，同时报警器发出声光报警。装置开机时压力监测报警功能默认为打开状态，使用过程中按下压力报警开关按键可停止压力监测报警功能，压力报警指示灯熄灭，不可用于压力异常报警，当压力监测报警功能停止时按下压力报警开关按键可开启压力监测报警功能，压力报警指示灯可重新用于压力异常报警。(2) When the PLC detects that the fluid pressure is greater than the upper limit of the pressure threshold or less than the lower limit of the pressure in the four parts at the inlet and outlet of the heat exchanger heat process and the cold process, the pressure alarm indicator lights up, and the alarm emits sound and light alarms at the same time. When the device is turned on, the pressure monitoring and alarm function is turned on by default. During use, press the pressure alarm switch button to stop the pressure monitoring and alarm function. The pressure alarm indicator light is off and cannot be used for abnormal pressure alarm. The pressure alarm switch button can open the pressure monitoring and alarm function, and the pressure alarm indicator light can be reused for abnormal pressure alarm.
（3）当PLC监测到换热器热流程和冷流程各自进出口处共4个部位存在流量值大于流量上限阈值或小于流量下限阈值时，流量报警指示灯亮，同时报警器发出声光报警。装置开机时流量监测报警功能默认为打开状态，使用过程中按下流量报警开关按键可停止流量监测报警功能，流量报警指示灯熄灭，不可用于流量异常报警，当流量监测报警功能停止时按下流量报警开关按键可开启流量监测报警功能，流量报警指示灯可用于流量异常报警。(3) When the PLC detects that the flow value is greater than the upper flow limit threshold or smaller than the flow lower limit threshold in 4 parts at the inlet and outlet of the heat exchanger and the cold flow, the flow alarm indicator light will be on, and the alarm will sound and light alarm. When the device is turned on, the flow monitoring and alarm function is turned on by default. Press the flow alarm switch button to stop the flow monitoring and alarm function during use. The flow alarm indicator light is off and cannot be used for abnormal flow alarm. The flow alarm switch button can turn on the flow monitoring and alarm function, and the flow alarm indicator light can be used for abnormal flow alarm.
（4）当PLC监测到换热器热流程或冷流程存在泄漏时，泄漏报警指示灯亮，同时报警器发出声光报警。装置开机时泄漏监测报警功能默认为打开状态，使用过程总按下泄漏报警开关按键可停止泄漏监测报警功能，泄漏报警指示灯熄灭，不可用于泄漏异常报警，当泄漏监测报警功能停止时按下泄漏报警开关按键可开启泄漏监测报警功能，泄漏报警指示灯可用于泄漏异常报警。(4) When the PLC detects that there is leakage in the heat process or cold process of the heat exchanger, the leakage alarm indicator light is on, and the alarm device emits a sound and light alarm at the same time. When the device is turned on, the leakage monitoring and alarm function is turned on by default. Always press the leakage alarm switch button during use to stop the leakage monitoring and alarm function. The leakage alarm indicator light is off and cannot be used for abnormal leakage alarm. The leakage alarm switch button can turn on the leakage monitoring and alarm function, and the leakage alarm indicator light can be used for abnormal leakage alarm.
（5）报警总开关按键用于对所有温度、压力、流量和泄漏在线监测报警功能进行开启和关闭。装置开机时所有监测报警功能默认为开启状态，按下报警总开关按键后，温度报警指示灯、压力报警指示灯、流量报警指示灯、泄漏报警指示灯和图2中报警器都不可用于异常报警。所有在线监测报警功能关闭后再次按下报警总开关按键将打开所有的温度、压力、流量和泄漏在线监测报警功能。(5) The main alarm switch button is used to open and close all the online monitoring and alarm functions of temperature, pressure, flow and leakage. When the device is turned on, all monitoring and alarm functions are turned on by default. After pressing the main alarm switch button, the temperature alarm indicator, pressure alarm indicator, flow alarm indicator, leakage alarm indicator and the alarm in Figure 2 cannot be used for abnormality. Call the police. After all online monitoring and alarming functions are closed, pressing the main alarm switch button again will open all online monitoring and alarming functions of temperature, pressure, flow and leakage.
在本发明的另一方面，提出了一种根据前面所述的换热器运行状况在线监测报警装置的在线监测报警方法，主要包括以下步骤。In another aspect of the present invention, an on-line monitoring and alarming method based on the above-mentioned on-line monitoring and alarming device for operating conditions of a heat exchanger is proposed, which mainly includes the following steps.
（1）传感器检测所述换热器的进出口处的流体物理参数数据，主要包括：温度、压力和流量；(1) The sensor detects the physical parameter data of the fluid at the inlet and outlet of the heat exchanger, mainly including: temperature, pressure and flow;
（2） 数据采集模块经通讯模块将采集的流体物理参数数据发送至控制系统；(2) The data acquisition module sends the collected fluid physical parameter data to the control system through the communication module;
（3）控制系统将所述采集的流体物理参数数据与设定的流体物理参数数据的阈值范围进行比较，判断数据是否异常：当所述采集的流体物理参数数据在所述阈值范围内则正常，否则异常；(3) The control system compares the collected fluid physical parameter data with the set threshold range of fluid physical parameter data to determine whether the data is abnormal: when the collected fluid physical parameter data is within the threshold range, it is normal , otherwise an exception;
（4）异常时，控制系统发送触发信号至电路通断控制器控制报警器进行报警。(4) When abnormal, the control system sends a trigger signal to the circuit on-off controller to control the alarm to give an alarm.
根据本发明的一个实施例，本发明将具体对温度参数检测报警的过程进行如下详细描述，图4为本发明一个实施例的温度监测报警运行流程图，参照图4所示，开始温度监测后，PLC读取四个温度传感器采集的热流体入口温度T1、热流体出口温度T2、冷流体入口温度T3和冷流体出口温度T4。随后将T1与设定的热流体入口处温度上限阈值TH1和温度下限阈值TL1进行比较，若当前T1大于TH1或T1小于TL1，则认为热流体入口温度T1异常，PLC控制开启温度报警指示灯，若T1在TH1和TL1两者范围内则继续对热流体出口温度T2进行判断。根据上述方法依次对T2、T3和T4温度是否异常进行判断，若T1、T2、T3和T4都运行正常则PLC控制温度报警指示灯处于关闭状态，若至少有一个温度异常则PLC控制温度报警指示灯处于开启状态，提醒使用者换热器处于温度异常状态。PLC随后判断温度监测报警功能是否处于开启状态，若开启则继续对下一周期的T1、T2、T3和T4进行温度监测，否则关闭温度报警指示灯，结束温度监测过程。可以理解的是，本发明图4仅为一个顺序的实施例，上述过程中对T1、T2、T3和T4的异常判断无先后顺序。温度上限阈值TH1、TH2、TH3、TH4和温度下限阈值TL1、TL2、TL3、TL4可由用户通过图1和图2所述触摸显示屏进行编辑后存入PLC中。According to an embodiment of the present invention, the present invention will specifically describe the temperature parameter detection and alarm process in detail as follows. FIG. 4 is a flow chart of the temperature monitoring and alarm operation of an embodiment of the present invention. Referring to FIG. , the PLC reads the temperature T1 of the inlet of the hot fluid, the temperature of the outlet of the hot fluid T2, the inlet temperature of the cold fluid T3 and the temperature of the outlet of the cold fluid T4 collected by the four temperature sensors. Then compare T1 with the temperature upper threshold TH1 and the lower temperature threshold TL1 at the set thermal fluid inlet. If the current T1 is greater than TH1 or T1 is less than TL1, it is considered that the thermal fluid inlet temperature T1 is abnormal, and the PLC controls to turn on the temperature alarm indicator. If T1 is within the range of both TH1 and TL1, continue to judge the hot fluid outlet temperature T2. According to the above method, judge whether the temperature of T2, T3 and T4 is abnormal in turn. If T1, T2, T3 and T4 are all running normally, the PLC controls the temperature alarm indicator to be off. If at least one temperature is abnormal, the PLC controls the temperature alarm indicator. The light is on to remind the user that the heat exchanger is in an abnormal temperature state. The PLC then judges whether the temperature monitoring and alarm function is on. If it is on, it will continue to monitor the temperature of T1, T2, T3 and T4 in the next cycle. Otherwise, the temperature alarm indicator will be turned off to end the temperature monitoring process. It can be understood that FIG. 4 of the present invention is only an example of a sequence, and there is no sequence in the abnormal judgment of T1 , T2 , T3 and T4 in the above process. The upper temperature thresholds TH1, TH2, TH3, TH4 and the lower temperature thresholds TL1, TL2, TL3, TL4 can be edited by the user through the touch screen shown in Figure 1 and Figure 2 and stored in the PLC.
可以理解的是，本发明压力监测报警和流量监测报警也采用上述温度监测报警同样的方法，此处不再赘述。It can be understood that, the pressure monitoring alarm and the flow monitoring alarm of the present invention also adopt the same method as the above temperature monitoring alarm, which will not be repeated here.
根据本发明的一个实施例，本发明将具体对泄漏检测报警的过程进行如下详细描述，图5为本发明一个实施例的泄漏监测报警运行流程图，参照图5所示，开始泄漏检测后，PLC读取四个流量计采集的热流体入口流量V1、热流体出口流量V2、冷流体入口流量V3和冷流体出口流量V4，随后计算V1和V2的差值V1-V2，若该差值大于设定的热流体泄漏的流量差阈值VL1，则认为热流程存在泄漏，PLC控制开启泄漏报警指示灯。计算V3和V4的差值V3-V4，若该差值大于设定的冷流体泄漏的流量差阈值VL2，则认为冷流程存在泄漏，PLC控制开启泄漏报警指示灯。若热流程和冷流程泄漏监测都正常则关闭泄漏报警指示灯。随后判断泄漏监测报警功能是否处于开启状态，若开启则继续对下一周期的热流程和冷流程进行泄漏监测，否则关闭泄漏报警指示灯，结束泄漏监测过程。可以理解的是，本发明图5仅为一个顺序的实施例，上述过程中对热流程和冷流程泄漏的异常判断无先后顺序。热流程和冷流程泄漏的流量差阈值VL1和VL2可由用户通过图1和图2所述触摸显示屏进行编辑后存入PLC中。According to an embodiment of the present invention, the present invention will specifically describe the leak detection and alarm process in detail as follows. FIG. 5 is a flow chart of the leak monitoring and alarm operation of an embodiment of the present invention. Referring to FIG. The PLC reads the hot fluid inlet flow V1, hot fluid outlet flow V2, cold fluid inlet flow V3 and cold fluid outlet flow V4 collected by the four flow meters, and then calculates the difference V1-V2 between V1 and V2, if the difference is greater than If the set flow difference threshold VL1 of thermal fluid leakage, it is considered that there is leakage in the thermal process, and the PLC controls to turn on the leakage alarm indicator. Calculate the difference V3-V4 between V3 and V4. If the difference is greater than the set flow difference threshold VL2 for cold fluid leakage, it is considered that there is leakage in the cold process, and the PLC controls to turn on the leakage alarm indicator. If both the hot process and the cold process leak monitoring are normal, turn off the leak alarm indicator. Then it is judged whether the leakage monitoring and alarm function is on, and if it is on, the leakage monitoring of the hot process and the cold process of the next cycle is continued, otherwise, the leakage alarm indicator is turned off, and the leakage monitoring process is ended. It can be understood that FIG. 5 of the present invention is only an example of a sequence, and there is no sequence in the abnormal judgment of the leakage of the hot process and the cold process in the above process. The flow difference thresholds VL1 and VL2 of the leakage of the hot process and the cold process can be edited by the user through the touch screen shown in Figure 1 and Figure 2 and stored in the PLC.
当所有监测报警功能为开启状态时，只要换热器的温度、压力、流量和泄漏四类监测参数中至少一个存在异常，则报警器处于打开声光报警状态，若换热器的温度、压力、流量和泄漏四类监测参数全部正常运行，则报警器处于关闭声光报警状态。When all monitoring and alarm functions are turned on, as long as at least one of the four monitoring parameters of the heat exchanger, including temperature, pressure, flow rate and leakage, is abnormal, the alarm is in the sound and light alarm state. If all four monitoring parameters of flow and leakage are in normal operation, the alarm is in the state of turning off the sound and light alarm.
综上所述，本发明采用多个电子式传感器，可同时对换热器进出口处温度、压力和流量的多个物理参数进行在线监测并直观屏幕显示，无需使用者在换热器现场观看仪表读数，减小了劳动强度；本发明可通过人为设置参数报警的上下限阈值范围，换热器运行异常时能够自动声光报警，及时发现隐患，与传统的人工不间断检测方式相比，该装置有利于维持生产过程中温度、压力等工艺参数的稳定，并有利于提高应急状况的处理效率；本发明除具备温度、压力和流量的多参数检测外，还具有泄漏监测和泄漏报警功能，可通过流程进出口端的流量差值判断是否发生泄漏。In summary, the present invention adopts multiple electronic sensors, which can simultaneously monitor multiple physical parameters of temperature, pressure and flow at the inlet and outlet of the heat exchanger and display them on the screen intuitively, without the need for users to watch the heat exchanger on-site. Instrument reading reduces labor intensity; the present invention can manually set the upper and lower threshold ranges of parameter alarms, and can automatically sound and light alarms when the heat exchanger runs abnormally, so as to find hidden dangers in time. Compared with the traditional manual uninterrupted detection method, The device is conducive to maintaining the stability of process parameters such as temperature and pressure in the production process, and is conducive to improving the treatment efficiency of emergency situations; in addition to the multi-parameter detection of temperature, pressure and flow, the present invention also has the functions of leakage monitoring and leakage alarming , the leakage can be judged by the flow difference between the inlet and outlet of the process.
在本发明中，除非另有明确的规定和限定，术语“相连”、“连接”等术语应做广义理解，例如，可以是固定连接，也可以是可拆卸连接，或成一体；可以是机械连接，也可以是电连接；可以是直接相连，也可以通过中间媒介间接相连，可以是两个元件内部的连通或两个元件的相互作用关系。对于本领域的普通技术人员而言，可以根据具体情况理解上述术语在本发明中的具体含义。In the present invention, unless otherwise expressly specified and limited, terms such as "connected" and "connected" should be understood in a broad sense, for example, it may be a fixed connection, a detachable connection, or an integration; it may be a mechanical The connection can also be an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, and it can be the internal communication between two elements or the interaction relationship between the two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.
在本说明书的描述中，参考术语“一个实施例”、“一些实施例”、“实施例”等的描述意指结合该实施例或示例描述的具体特征、结构、材料或者特点包含于本发明的至少一个实施例或示例中。在本说明书中，对上述术语的示意性表述不必针对的是相同的实施例或示例。而且，描述的具体特征、结构、材料或者特点可以在任一个或多个实施例或示例中以合适的方式结合。此外，在不相互矛盾的情况下，本领域的技术人员可以将本说明书中描述的不同实施例或示例以及不同实施例或示例的特征进行结合和组合。In the description of this specification, reference to the description of the terms "one embodiment," "some embodiments," "an embodiment," etc. means that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in the present invention at least one embodiment or example of . In this specification, schematic representations of the above terms are not necessarily directed to the same embodiment or example. Furthermore, the particular features, structures, materials or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, those skilled in the art may combine and combine the different embodiments or examples described in this specification, as well as the features of the different embodiments or examples, without conflicting each other.
尽管上面已经示出和描述了本发明的实施例，可以理解的是，上述实施例是示例性的，不能理解为对本发明的限制，本领域的普通技术人员在本发明的范围内可以对上述实施例进行变化、修改、替换和变型，同时，对于本领域的一般技术人员，依据本申请的思想，在具体实施方式及应用范围上均会有改变之处。Although the embodiments of the present invention have been shown and described above, it should be understood that the above-mentioned embodiments are exemplary and should not be construed as limiting the present invention. Changes, modifications, substitutions and modifications are made to the embodiments, and at the same time, for those skilled in the art, according to the idea of the present application, there will be changes in the specific implementation manner and application scope.
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