The word "intelligence" sung in the process of automation transformation of the company not only condenses the power of production management, but also pushes the technical force to a new height. Beiyuan Group Chemical Branch is stepping out of the road of intelligent construction with Beiyuan characteristics step by step.

01 "one key" polymerizer automatic discharge

"Xiao Chen, the No. 5 polymerizer is about to start discharging. You hurry to the scene and open the discharge valve and inverted shut valve."

"I understand, Lao Song. I have arrived at the scene and am opening the valve. You pay close attention to the pressure change of the polymerizer. "

Before the transformation, such operations need to be carried out an average of 8 times per class. Each operation is a heavy task for the field staff, because they need to manually turn on and off the main discharge slurry valve, a single polymerizer discharge valve and the bottom inverted shut-off valve. At the same time, DCS operators must constantly monitor the pressure drop in the polymerizer.

After the transformation, the DCS operator only needs to click on the discharge program with one button, and automatically open the discharge valve and the kettle bottom inverted closing valve according to the predetermined procedure. When the kettle pressure drop rate or kettle pressure difference reaches the preset value, the system automatically closes the discharge valve and the kettle bottom reverse closing valve. This transformation not only makes the whole discharge process without human intervention, but also increases the intelligent protection function. If there is a valve failure during the discharge process, the DCS interface will immediately pop up the alarm message, and the program will automatically enter the safe mode to ensure the smooth progress of the production process.

02 "one key" polymerizer automatic drainage

"now, the drainage operation of the polymerization kettle has also become easy, with only one button, all automatic completion." Niu Dong, the day shift leader of the PVC plant, said proudly, "as long as we start the 'drainage procedure', the system will automatically implement the drainage process, which gives us more time and energy to carry out equipment inspection and hidden trouble detection."

In the past, the drainage process of polymerizer depended entirely on manual operation. Each time drainage, the site staff need to manually open and close the bottom of the kettle valve, coating kettle steam valve twice, but also manually operate the bottom drain valve once. This kind of operation process is not only labor-intensive, but also requires high concentration and accuracy of the operators.

However, after the recent intelligent transformation, the DCS operator only needs to click on the "drainage procedure", and the system will automatically follow the preset steps. What is more intelligent is that the program can independently judge whether the drainage is over according to the pressure difference of the polymerizer, so as to realize the full automation of the drainage process.

03 "one key" feeding trough automatic feeding

"in the past, when there was no automatic dumping system, we had to go to the scene every hour to manually dump the material, which was a really time-consuming and laborious task." Lin Feng, a staff member on the spot, recalled with a wry smile.

Since the automatic refueling system was put into use, the work of DCS personnel has become much easier. Now they simply click on the "one-click" reverse program, and the system will follow the default procedure in turn. First of all, the system will automatically open the reverse valve of the receiving tank and start the reverse pump. When the liquid level of the receiving tank reaches the preset value, the system will automatically close the inverted shut-off valve and open the flushing water cut-off valve at the bottom of the tank for flushing. After flushing for a certain period of time, the system will automatically close the flushing water valve and stop the backfilling pump.

04 "one-button" monomer automatic conveying

The "one-button" monomer automatic conveying system shows the ultimate charm of intelligent control. The program realizes the automatic queuing function of fresh single storage tank ABC, and can automatically select the priority feeding tank according to the preset logic. Moreover, the system can automatically start and stop the monomer feeding pump, automatically switch the discharge valve of the metering tank and the fresh monomer storage tank, and automatically control the amount of monomer. This series of complex operations can now be completed with only one button, and the whole process does not require human monitoring and manual operation.

More importantly, when the system executes the automatic program, if a valve or pump fails on the spot, the DCS screen will immediately pop up an alarm message to remind the operator to pay attention. At the same time, the program will automatically jump to the safety steps to ensure the safety and stability of the production process.

05 "one key" caustic soda washing tower closed for alkali exchange

Before the transformation, the alkali exchange operation of the alkali washing tower completely depends on the manual execution of the on-site personnel. This includes manual start and stop of waste alkali pump, manual switch of waste alkali discharge valve, water feeding valve and alkali receiving valve, etc. Each alkali exchange operation takes up to 2 hours, which is not only labor-intensive, but also due to the vinyl chloride dissolved in the alkali bath, the gas alarm device gives frequent alarms, which brings a lot of pressure and safety risks to the operators.

However, after the transformation, the alkali exchange operation becomes simple and efficient. Now, only one button is needed to start the alkali exchange procedure. After the program starts, the operation of discharging waste alkali and adding water for 3 times will be carried out automatically, and then the flow rate of adding water and adding alkali will be automatically controlled to achieve a fixed ratio to replenish alkali. Source: Beiyuan Group