Foreword

In the process of starting the sulfur acid making plant, due to the process parameters are not up to standard, improper valve setting or inadequate inspection, accidents in production, safety and environmental protection often occur. These accidents include “ Sublimation sulfur, water hammer steam explosion pipe, smoke, dilute acid corrosion ” Such serious problems have brought huge economic losses and negative social impacts to enterprises. With the improvement of automation level and long-term stable operation of sulfuric acid plant, the operation skills and emergency response ability of production operators have weakened, and the mastery of operation data and information thresholds of the plant has also decreased significantly. This has led to a weakening of safety controls on sulphuric acid devices during driving. According to 2024 statistics, a number of highly automated sulfur acid making devices have suffered safety accidents during driving due to substandard process parameters and improper valve Settings. Under the background of the popularization of automation of sulfur acid making equipment and the reduction of operators, the development of a set of automatic control system for driving safety has become the key to prevent driving accidents. Lilly Technology has been focusing on the digital research and development of sulfuric acid plants, and is committed to solving industry problems. In order to meet the needs of the industry, we developed the DSC-100 sulfuric acid plant driving safety automatic control system. The system is designed according to the characteristics of each section of the sulfuric acid plant and the conditions required for driving, and has the following functions: the sequential operation in the preparation stage of starting, the automatic confirmation of key process parameters before starting, the automatic confirmation of the safety position of each valve position before starting, the confirmation of the satisfaction of the required conditions before starting, and the safety control during driving.

One, control logic

Starting a sulfur acid plant is a complex and time-consuming process, which includes the pre-start-up preparation sequence, fine adjustment of process parameters, correct setting of control valves, and careful confirmation of all start-up conditions.

Only after these links have been properly handled can the fan be turned on and the sulfur can be sprayed. In the start-up process, the process flow of the device changes from a static state to a dynamic state, and the process parameters may fluctuate sharply. If the device is not prepared enough, it is very easy to cause accidents. Therefore, strict safety control over the start-up process is essential. Based on the possible changes in the startup process, it is particularly important to design a set of sound and reasonable control logic. See Figure 1 for details on the automatic control logic for driving safety.

Automatic control system for Driving safety (Figure 1)

Two, driving safety automatic control system

The device is often the busiest in the process of driving, after maintenance or emergency treatment, the operator needs to carry out a number of manual confirmation of the current state of the device, due to the tight time and high-intensity operation will make the operator in the process of driving physically and mentally tired, difficult to concentrate, the accident in the process of driving usually occurs in this case. American ASM (Abnormal State Management Association) research, chemical equipment caused by abnormal state of 36% is caused by equipment failure, 22% is caused by process, 42% is caused by operator error. Therefore, a set of human-friendly driving safety automatic control system is particularly important, can guide the operator to automatically complete the automatic inspection of driving safety, failure can assist the operator to complete the troubleshooting, make the key conditions of the device 100% meet the requirements before driving, effectively prevent the occurrence of driving accidents caused by personnel errors. Figure 2 and Figure 3 show the control screen of the DSC-100 sulfuric acid plant driving safety automatic control system on the 800,000 tons sulfur acid making plant.

Condition of not being able to drive (Figure 2)

Complete state of automatic control for driving safety (Figure 3)