What are the intelligent monitoring systems for chemical companies？

What are the intelligent monitoring systems for chemical companies？

The intelligent monitoring system of a chemical company mainly includes the following core application scenarios and technical solutions:

1、 Intelligent monitoring of production equipment

Real time monitoring of equipment status

Deploy vibration, temperature, and pressure sensors in key equipment such as reaction vessels and pipelines, collect real-time operating parameters (range 0-25MPa, accuracy 0.075% FS), and combine AI to predict faults.

The belt conveyor detects deviation, blockage, and foreign objects through AI vision, with a detection rate of over 90%, reducing the risk of equipment damage.

Process safety control

The explosion-proof camera (Ex d Ⅱ C T6 level) is linked with the infrared thermal imaging device, and automatically alarms when the temperature difference exceeds 5 ℃.

Multi modal monitoring of gasifier wall temperature to enhance operational safety and efficiency.

2、 Hazardous chemical storage management

Stereoscopic monitoring network

Laser gas telemetry instrument (detection distance of 300 meters, accuracy ± 2ppm) monitors gas leaks in the storage tank area.

RFID tags or weight sensors manage reagent inventory and achieve automatic warning of expiration dates.

Intelligent inbound and outbound control

UWB positioning technology (with an accuracy of 30cm) tracks the access of hazardous chemicals, and electronic fences are used to classify and control cross-border behavior.

3、 Intelligent analysis of personnel behavior

Supervision of safety regulations

AI video analysis of safety helmets and protective clothing compliance, with a recognition accuracy rate of 98.7%.

Real time detection of off-duty, sleeping on duty, and illegal activities (such as smoking and mobile phone use).

Regional permission control

Explosion proof facial recognition gate (recognition speed<0.5 seconds) combined with electronic work signs, restricts unauthorized personnel from entering high-risk areas.

4、 Monitoring of major hazard sources

Multi parameter linkage warning

Monitor pressure, liquid level (radar level gauge error ± 1mm), and concentration of flammable/toxic gases (accuracy 0.1% LEL).

The three-level warning mechanism (blue/yellow/red) automatically pushes the disposal plan, and the red warning needs to be responded to within 5 minutes.

5、 Environmental and gas safety monitoring

What are the intelligent monitoring systems for chemical companies?

Global gas detection

Distributed deployment of combustible/toxic gas detectors (such as H ₂ S, NH ∝, etc.) reduces the false alarm rate of leaks to 0.3 times per month.

Real time monitoring of oxygen content and toxic gases in confined space operations to prevent suffocation and poisoning.

6、 Emergency Command and Decision Support

3D digital twin platform

1: 1. Restore the factory area, integrate 5000+IoT nodes, support emergency resource scheduling and simulation exercises.

Intelligent linkage control

The leakage alarm automatically closes the valve and starts spraying within 3 seconds, reducing the accident response time by 82%.

Key points of implementation

Explosion proof compliance: The equipment must comply with the Ex d Ⅱ C T4/T5 level, and the wiring must meet the GB50058 specification.

System integration: Connect SCADA/ERP through OPC UA protocol to achieve data interoperability.

Information security: Deploy a situational awareness platform and use GPT models to intelligently analyze logs, reducing manual intervention by 90%.

Note: Typical cases include Guangxi Huayi New Materials’ full process AI factory (with a 100% CNC rate for key equipment) and Hubei Yihua Group’s AI inspection system (replacing three shift manpower).