摘要
为了追求更高的经济效益,化工企业大量采用了结构复杂的现代化工装备。在高温、高压的操作条件下,装备更容易发生故障。化工过程系统是一个由人、工艺过程、装备、仪表控制系统和环境等因素组成的复杂系统。任何偏离设计意图的偏差都有可能使系统进入非正常工况。一旦导致紧急停车不仅会造成经济损失,由此偏离引发重大事故甚至会造成严重的社会灾难。当前的DCS等控制系统依然存在着报警点过多、报警逻辑简单以及无法及时判断报警重要性大小等诸多问题。
工程实践表明,事故的发生是有一个渐进过程的,都有一个由正常工况向非正常工况变化的趋势。如果事先认识并能及时遏止这种变化趋势,事故是可以避免的。本文研究的化工过程非正常工况自愈调控系统,以系统中变量间的相互影响关系模型及能够正确描述系统的机理模型等为依据,实时监测系统中重要变量的变化,将危险与可操作性(HAZOP)分析报表等资料与实际化工生产结合在一起。在实际装置中,应用化工过程非正常工况自愈调控系统,可减少非计划停车次数,保障企业本质安全,由此提高经济效益。
论文的主要研究内容和具有技术创新性的研究成果如下:
1、阐述了化工过程复杂系统自愈调控理论。化工过程系统是一个耗散结构,也是一个由许多相互联系且实时变化的因素构成的开放的复杂系统。化工过程非正常工况自愈调控的目的就是在化工生产系统运行过程中实时监测分析可能引发事故的条件及事故发生前的征兆,采用诊断预测、智能决策和主动控制等方法使化工生产系统在事故早期阶段就发现最初的原因并彻底根除它。
2、针对化工过程中大多数事故是由于人工误操作而导致的这一问题,本论文总结了常见的误操作形式和导致误操作的原因,开发了人工误操作危险与可操作性(MO-HAZOP)分析软件,并提出了系统的误操作分析方法,从而弥补了危险与可操作性分析方法对分析操作步骤颠倒和遗漏操作步骤等分析不全的缺陷。计算误操作发生概率值大小,并对所有的情况进行排序,可以找出较容易发生的或后果较严重的误操作。确定风险等级后,采取防范措施避免由误操作导致的事故发生,或采取有效措施将事故发生造成的不利后果的影响控制在最小程度;
3、针对计算机辅助HAZOP分析结果过多,主次性差等问题,本论文以层次分析法与基于符号定向图的HAZOP(SDG-HAZOP)分析方法结合为例,介绍了基于层次分析法的计算机辅助HAZOP分析方法。建立过程中节点变量间的层次结构,将危险路径按照相对重要度进行排序,减少了人为因素对分析结果的影响。这些优势在一定程度上可弥补SDG-HAZOP分析报表结论多且主次性差等缺点,为定量和定性方法的结合提供技术依据。这种方法可以使专家忽略小概率事件而关注紧急或严重的问题,有针对性地对化工生产过程中存在的重要危险隐患提出防范建议或措施。
4、针对化工过程中爆炸事故重复发生的问题,本论文归纳和总结了化工过程中爆炸事故案例原因五类46种,以及导致事故发生的65个影响因素。以此为建立化工过程非正常工况自愈调控系统的知识库基础依据之一,可以更有针对性地避免重大事故的重复发生。
5、以硝基苯初馏塔分离工艺为例,阐述了防范人工误操作及爆炸事故分析技术的应用。基于前述方法的分析结果,采用程序控制、联锁或联动机构等措施可以减少和防范误操作并且保证正常生产。
6、基于多功能过程与控制实验系统(MPCE)建立丙烯聚合过程非正常工况操作指导系统,可以保障MPCE的丙烯聚合过程成功开车,实时应对生产过程中出现的各种问题。将此系统应用于丙烯聚合过程,可以及时发现过程中存在的故障、事故原因,尽可能地将故障或事故消除在萌芽阶段,减少非计划停车次数,拓宽复杂化工过程正常工况的范围,在一定程度上提高企业的经济效益。
7、本质安全应该是系统风险为0或接近于0。从设计阶段通过最小化或强化、替代、简化、稀释或缓和等手段消除或减少风险;在系统运行阶段通过技术手段来控制风险,可以在一定程度上提高石化企业本质安全水平。本论文以轻质碳酸镁的制备过程为研究对象,分析了化工过程本质安全化的相关问题,并给出了提高石化企业本质安全水平的建议。
In order to obtain more economic benefits, chemical industries always adopt complex modern chemical plants. Furthermore, the plants are often operated at extremes of pressure and temperature to achieve optimal performance, which makes equipment more vulnerable to failures. Chemical process system is a complex system which includes human, process, equipment, environment, instrument and control system and so on. The system state will become abnormal because of every deviation from design intent. It will bring catastrophic consequences to the society if an accident occurs. Although emergency shutdown can eliminate this abnormal situation, it may cause economic losses. The current DCS and other control system have some disadvantages, such as too many alarm points, too simple warning logic and too many difficulties in judging the importance of alarm instantly.
Engineering practice shows that accident which has a gradual process from normal situation to abnormal situation can be avoided if the development trend of the accident can be understood beforehand and prevented instantly. The abnormal situation self-recovering system studied in this thesis, taking interactional relationship models of variables and other mechanism models which can correctly simulate the system as a basic and monitoring the fluctuation of the key variables which were determined beforehand in this system, can integrate the hazard and operability (HAZOP) analysis report and other information into the practical chemical industry producing process. Applying this system into real plant can decrease the times of non-plan shutdown to ensure the inherently safe of the industry and obtain more economic benefits.
The main contributions of this dissertation are summarized as follows:
(1) Abnormal situation self-recovery regulation for chemical process is presented in this thesis. Chemical process system is not only a dissipative structure, but also a complex system made up of a lot of factors which are interrelated and real-time changing. The objective of the system is preventing accidents before emergency shutdown system (ESD) or shutdown by adopting diagnosis and prediction, intelligent decision and active control method used to automatically find the initial cause, and eliminate the accidents at their very early stage after the real-time monitoring of conditions which will cause accident and analyzing symptoms of accident.
(2) According to most of accidents caused by misoperations, this thesis summarizes presentation forms of common misoperations and the reasons which will cause misoperations, and then it introduces the misoperation hazard and operability (MO-HAZOP) software and an analysis method developed for misoperation, which makes up for the deficiency that HAZOP analysis can not systematically analyze the operation step neglect and inversion. The misoperations are arranged in terms of the probability, with high probability misoperations assigned as the critical situations. Adopting preventive measure , may prevent misoperation or control the influence of the accident consequence to the least extent after the risk rank.
(3) According to the problem, the report of the computer aided HAZOP analysis has a huge number of HAZOP results and the important issues can not be separated from the general ones, this thesis presents a SDG (signed directed graph)- HAZOP analysis method based analytic hierarchy process (AHP), taken as an example to introduce the computer aided HAZOP analysis method. Establishing hierarchical structure of nodes and variables in the process, dangerous paths are arranged in terms of the relative importance degree, with high relative importance degree paths assigned as the critical situations which will decrease the effect of human factor to the analysis result. These advantages will make up for the deficiencies that computer aided HAZOP analysis has a huge number of HAZOP results and the important issues can not be separated from the general ones, and this method will provide technological basis for the combination of qualitative and quantitative method. This method not only can help experts ignore small probability events, but also can help experts focus on the urgent and serious problems and provide correspondingly preventive measures for potential hazards which are important in the chemical process.
(4) According to the explosion repeated emergence problem in chemical process, 5 categories and 46 kinds of explosion accidents and 65 kinds of influence factors are summarized in this thesis. Taking them as one of the basics to establish the knowledge database of abnormal situation self-recovery system for chemical process will correspondingly prevent the repeated emergence of major explosions.
(5) The separation process of nitrobenzene primary tower was taken as an example to explain real application of misoperations prevention and the explosion accidents analysis technology in chemical process. Based on the results got from the above analysis, the measures in terms of full automatic mechanism, programmed control system and interlock mechanism, can be adopted to reduce and prevent misoperations and to maintain the normal production.
(6) Abnormal situation operation guide system for propylene polymerization process based multifunction process and control experiment system (MPCE) can ensure the starting of process successfully, and it may resolve problems occurring in the production process instantly. Before ESD or shutdown, the system utilized in the propylene polymerization process, on the one hand, may automatically find the initial cause and then eliminate the accidents at their very early stage as much as possible. On the other hand, it may extend the range of normal situation of chemical process and gain more benefits for the industry to a certain extent.
(7) Inherently safe system means that the risk of a system is 0 or close to 0. At the design stage, some measures, such as intensification, minimization, substitution, attenuation or moderation, can be utilized to eliminate or , decrease risk. At the operation stage of the system, some control measures can be used to control risk. All of those technological methods can enhance the level of inherently safe of chemical industry. Taking the production process of light magnesium carbonate as a research objective, this thesis studies the inherently safe process of chemical process and provides some suggestions for improving of the inherent safe level for chemical industry.
引文
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