A kind of intelligent diagnosis system and method for output pump unit on-line monitoring failure
Technical field
The present invention relates to output pump unit on-line monitoring field, and in particular to a kind of output pump unit monitors failure intelligence on-line
Can diagnostic system and method.
Background technology
The crucial overwhelming majority of the outer defeated main pump unit of Changqing oilfields involves great expense, unit from esbablished corporation all over the world
Long-term 24 hours continuous, high rotary speed workings, plant maintenance is extremely important, arduousness.Once damaging or hang-up, not only directly damage
Lose huge and cause the indirect loss that whole line stops production more to be unable to estimate.Output pump unit is not monitored, and indivedual pump groups are based on
The collection of single data and position limitation protection, without special on-line monitoring Fault Intelligent Diagnosis System;Most of Long-term Vibration surpasses
Mark, while wasting substantial amounts of electric energy, because the degree of association of each parameter is not high, also can stop because wrong report or maloperation cause sometimes,
Further force completely stopping transportation outside the plan.Once Key generating unit is shut down will also cause great economic loss, sometimes can also be with messenger
Member's injures and deaths and serious environmental pollution, conventional planned maintenance means cannot meet the production model of equipment high efficiency operation.Pass through
Document Investigation, as a result shows that the country not yet carries out further investigation in this field, outside no comprehensively grasp oil field domestic at present
Defeated pump assembly operation information, uses for reference the on-line monitoring system of the identification, judgement and solve problem experience of the failure for having occurred.It is external
Main flow monitoring technology is increasingly becoming for the continuous on-line monitoring system that becomes more meticulous based on vibration frequency specturm analysis, is tieed up with intelligence precognition
The Typical Representative that the main equipment safety monitoring series instrument system to dominate is such product is protected, and the present invention is output pump group
On-line monitoring intelligent fault diagnosis Maintenance Expert System.
In sum, need a kind of new output pump unit on-line monitoring intelligent fault diagnosis technology badly to meet oil field development
Requirement.
The content of the invention
The purpose of the present invention be overcome defeated main pump unit outside oil field do not have single-minded on-line monitoring Fault Intelligent Diagnosis System,
Long-term Vibration is exceeded, it is dangerous to there are problems that and wastes electric energy, easily cause stopping transportation, there is provided a kind of output pump machine
The intelligent diagnosis system and method for group on-line monitoring failure.
The intelligent diagnosis system for monitoring failure on-line there is provided a kind of output pump unit is the technical scheme is that, including
Output pump unit, harvester, on the spot many mouthfuls of transponders, monitoring unit and remote monitoring unit.The output pump unit includes phase
The motor and output pump of connection, output pump is provided with detection vibration compound sensor, and the detection is vibrated compound sensor and adopted
Storage is electrically connected, and the harvester, on the spot monitoring unit and remote monitoring unit are both electrically connected with many mouthfuls of transponders.
The monitoring unit on the spot includes Central Control Room computer and engineer station's host computer, the Central Control Room computer and work
Cheng Shi stations host computer is all used for data storage and monitoring, and Central Control Room computer can also on the spot be diagnosed to be output pump unit failure, and
Data are uploaded in digitalized network.
The remote monitoring unit includes Web server and remote diagnostic center, and the Web server is used for long-range monitoring
Output pump unit operation situation and data storage, carry out Web issues, and the remote diagnostic center is used for remote data storage and prison
Survey, and diagnose output pump unit fail result in time.
The Central Control Room computer and remote diagnostic center are both provided with Database Unit, data acquisition unit, state prison
Survey unit, dynamic balance calculation unit and analyzing and diagnosing unit.
The output pump unit can be single group or multigroup.
Detection vibration compound sensor, the inspection are equipped with the horizontal direction of the output pump front and back end and disposal direction
The dynamic compound sensor of vibration measuring includes vibration acceleration sensor, temperature sensor, speed probe and pressure transducer, is a kind of
Amplitude, acceleration, temperature, rotating speed and pressure integrated special type compound sensor can be detected simultaneously, through ATEX certification of explosion protection.
Explosion-proof tank is provided with the harvester.
A kind of output pump unit monitors the intelligent diagnosing method of failure on-line, it is characterised in that:Comprise the following steps:
Step 1)Detection vibration compound sensor is loaded onto on the output pump of defeated pump assembly outside, by detection vibration compound sensor electricity
Harvester is connected to, and harvester, on the spot monitoring unit and remote monitoring unit are both electrically connected with many mouthfuls of transponders;
Step 2)Harvester collects the signal of detection vibration compound sensor and is translated into data, and transmission at most mouth turns
Send out device;
Step 3)Many mouthfuls of transponders send data to monitoring unit on the spot, and Central Control Room computer and engineer station's host computer can
To carry out data storage and monitoring simultaneously, engineer station's host computer can also on the spot be diagnosed to be the various failures of output pump unit, and
Data are uploaded in digitalized network, while local operation personnel are according to the fail result being diagnosed to be and carry out guiding dimension
Repair;
Step 4)Data are also uploaded to remote monitoring unit, Web server by many mouthfuls of transponders by oil field private network optical fiber simultaneously
Simultaneously data storage and monitoring are carried out with remote diagnostic center, Web server can also carry out Web issues, remote diagnosis to data
Center can realize the monitoring of output pump set state, data analysiss and Remote Fault Diagnosis result.
The step 2)In data including output pump front-end and back-end real-time operating conditions, specifically include vibration amplitude
Data, acceleration information, rotary speed data, pressure data and temperature data.
Beneficial effects of the present invention:
(1) intelligent diagnosis system and method for this output pump unit on-line monitoring failure that the present invention is provided can be realized outer defeated
The timely discovery and the analysis of causes and the guidance of precognition equipment maintenance of monitoring, the equipment fault of the running status of pump assembly,
Thoroughly solve the existing failure problems of output pump unit.
(2) it is remote that the intelligent diagnosis system and method for this output pump unit on-line monitoring failure that the present invention is provided is adopted
Journey diagnostic center stores relevant data automatically for the different running status of unit, forms various data bases.Equipment can be realized
The timely discovery and the analysis of causes and the guidance of precognition equipment maintenance of monitoring, the equipment fault of running status.
(3) intelligent diagnosis system and method for this output pump unit on-line monitoring failure that the present invention is provided can be simultaneously
Monitoring single group or multigroup output pump unit, by output pump front and back end horizontally and vertically on be equipped with detection and shake
Dynamic compound sensor, can in time find and diagnose mass unbalance, initial bending, thermal flexure, the leaf of the presence of output pump unit
The failure condition such as piece comes off, misaligns, oil whip, steam flow excitation, electromagnetic exciting, friction, bearing shell loosen and resonate and in time
The handling suggestion of directiveness is reported to the police and proposes, so as to avoid non-programmed halt, improve production efficiency.
(4) intelligent diagnosis system and method for this output pump unit on-line monitoring failure that the present invention is provided is by adopting
Explosion-proof tank is provided with storage, the security reliability of system is improve, harvester of the present invention is distributed vibration number
According to intelligent collector, its vibrating data collection system is a operating mode for being adapted to Oil Field, powerful data acquisition
Device, make use of the experience for for many years manufacturing Diagnosing System for Oil Pump vibration protecting device, from too many levels such as design, buying, productions
The reliability and stability of product quality are ensured.
The present invention is described in further details below with reference to accompanying drawing.
Description of the drawings
Fig. 1 is the structural representation of the intelligent diagnosis system of output pump unit on-line monitoring failure of the present invention;
Description of reference numerals:1st, Web server;2nd, remote diagnostic center;3rd, Central Control Room computer;4th, many mouthfuls of transponders;5th, work
Cheng Shi stations host computer;6th, harvester;7th, motor;8th, output pump;9th, detection vibration compound sensor.
Specific embodiment
Embodiment 1:
In order to overcome defeated main pump unit outside oil field do not have single-minded on-line monitoring Fault Intelligent Diagnosis System, Long-term Vibration it is exceeded,
There are problems that dangerous and waste electric energy, easily cause stopping transportation, present embodiments provide a kind of as shown in Figure 1
Output pump unit monitors the intelligent diagnosis system of failure on-line, including output pump unit, harvester 6, many mouthfuls of transponders 4, on the spot
Monitoring unit and remote monitoring unit.The output pump unit includes motor 7 and the output pump 8 being connected, and output pump 8 is provided with
Detection vibration compound sensor 9, the detection vibration compound sensor 9 is electrically connected with harvester 6, the harvester 6, is supervised on the spot
Control unit and remote monitoring unit are both electrically connected with many mouthfuls of transponders 4.
This output pump unit of the present invention monitors the intelligent diagnosing method of failure on-line, comprises the following steps:
Step 1)Detection vibration compound sensor 9 is loaded onto on the output pump 8 of defeated pump assembly outside, by detection vibration compound sensor
9 are electrically connected to harvester 6, and harvester 6, on the spot monitoring unit and remote monitoring unit are both electrically connected with many mouthfuls of transponders 4;
Step 2)Harvester 6 collects the signal of detection vibration compound sensor 9 and is translated into data, transmission at most mouth
Transponder 4, the data that harvester 6 is collected include the data of the real-time running state of the front-end and back-end of output pump 8, including vibration
Amplitude data, acceleration information, rotary speed data, pressure data and temperature data;
Step 3)Many mouthfuls of transponders 4 send data to monitoring unit on the spot, and on the spot monitoring unit includes the He of Central Control Room computer 3
Engineer station's host computer 5, the Central Control Room computer 3 and engineer station's host computer 5 are all used for data storage and monitoring, Central Control Room
Computer 3 can also on the spot be diagnosed to be the various failures of output pump unit, and data are uploaded in digitalized network, while on the spot
Operator are according to the fail result being diagnosed to be and carry out guiding maintenance;
Step 4)Data are also uploaded to remote monitoring unit by many mouthfuls of transponders 4 by oil field private network optical fiber simultaneously, described long-range
Monitoring unit includes Web server 1 and remote diagnostic center 2, and the Web server 1 is used for long-range monitoring output pump unit fortune
Market condition and data storage, carry out Web issues, and remote diagnostic center 2 is used for remote data storage and monitoring, realizes output pump machine
Group status monitoring, data analysiss and Remote Fault Diagnosis result.
The intelligent diagnosis system of this output pump unit on-line monitoring failure of the present invention can realize output pump unit
The timely discovery and the analysis of causes and the guidance of precognition equipment maintenance of monitoring, the equipment fault of running status, thoroughly solves
Output pump unit existing failure problems.Following zero failure rate of output pump unit is realized simultaneously, realizes that output pump unit shakes
Dynamic value drops to international vibration severity standard(ISO2372)Below.The state change and development for preferably grasping feeding oil pump becomes
Gesture, accident prevention eliminates accident in rudiment in possible trouble, so as to avoid the generation of major accident, reduces the hazardness of accident.And
This intelligent diagnosing method is easy to operate, improves the efficiency of management, greatly prolongs the service life of outer defeated unit, extends maintenance week
Phase, the hang-up accident of output pump group equipment is reduced, the preparation of output pump group plant maintenance is carried out in advance, tie up equipment
The efficiency that nurse makees is greatly improved, with good promotional value.
Embodiment 2:
Present embodiments provide the intelligent diagnosis system that a kind of output pump unit monitors failure on-line, further, the middle control
Room computer 3 and remote diagnostic center 2 are both provided with Database Unit, data acquisition unit, Condition Monitoring Unit, dynamic balancing meter
Unit and analyzing and diagnosing unit are calculated, and these units are special cell, belong to prior art.
Wherein, Database Unit is used for the storage of data, and it is by lifting speed data base, historical data base and event database
Deng composition, it is stored to relevant data in different data bases according to the different conditions of unit, in order to subsequent analysis.Data are adopted
Collection unit also includes setting unit, and data acquisition unit is used for data acquisition, the running status of its energy automatic identification unit, such as opens
Shutdown, lifting speed and normal or abnormality, and data acquisition is carried out by data acquisition device according to the state of unit.Stable
Under running status, data acquisition device is acquired with timing mode, and the change then according to rotating speed under lifting speed state is carried out
Collection;For the equipment such as gear-box, rolling bearing are gathered using high-speed encryption.The data for collecting through Condition Monitoring Unit and
Dynamic balance calculation unit obtains data, is classified according to the data base of Database Unit, and ultimate analysis diagnosis unit is carried out point
Analysis diagnosis.Condition Monitoring Unit has many picture monitoring functions, using tree-shaped equipment navigational structure, can enter according to technological process
The editor of row monitoring picture and setting.There is system the forms such as the main watch circle of emulation, rod figure, data and list of thing, curve to show
Show the state of measuring point, the icon of the abnormal corresponding warning of appearance carries out color exception and shows automatically.Analyzing and diagnosing unit contains powerful
Bearing database analysises system and expert's Analysis on Fault Diagnosis system database, full and accurate foundation can be provided for analyzing and diagnosing,
Analyzing and diagnosing unit mainly carries out online or off-line analysiss to various data, to judge the running status of unit and can be given automatically
Unit failure cause and handling suggestion.
Remote diagnostic center 2 has various data storage methods:Constant duration samples storage, etc. rotating speed interval sampling deposit
Storage, etc. load spacer samples storage, report to the police storage and manual type data storage.
Constant duration sampling refers to unit in steady-state operation(Rotating speed is between the rotating speed upper limit and lower rotation speed limit of setting),
Often through a period of time, one group of data is stored in historical data base;
Refer to unit when transient state startup-shutdown runs Deng rotating speed interval sampling(Rotating speed setting the rotating speed upper limit on or lower rotation speed limit
Under), rotating speed often changes △ RPM, one group of data stored in startup-shutdown data base;
Warning storage is the storing data automatically when reporting to the police occurs in equipment, and forms black box data storehouse;
Artificial storage is data storage as needed, can be deposited unit first time log-on data as the original data that compare
Storage.Variable quantity and alarming value, the rotating speed upper limit, lower rotation speed limit, the △ RPM of time, rotating speed and load can be by user in system
In be configured.
Remote diagnostic center 2 stores relevant data automatically for the different running status of unit, forms various data bases.
Timely discovery and the finger of the analysis of causes and precognition equipment maintenance of monitoring, the equipment fault of equipment running status can be realized
Lead.
Embodiment 3:
Present embodiments provide the intelligent diagnosis system that a kind of output pump unit monitors failure on-line, the output pump unit can be with
For single group or multigroup.The intelligent diagnosis system of this output pump unit on-line monitoring failure of the present invention can simultaneously monitor list
Group or multigroup output pump unit.
Further, the front and back end of the output pump 8 horizontally and vertically on be equipped with that detection vibration is compound to be passed
Sensor 9, the detection vibration compound sensor 9 includes vibration acceleration sensor, temperature sensor, speed probe and pressure
Sensor integration special type compound sensor, through ATEX certification of explosion protection.
Sensor used in the present invention, is that a kind of piezoelectricity of the advanced electromechanical integration of built-in IEPE circuits, structure shakes
Dynamic measurement sensor, temperature sensing sensor, Hall element and press sensor.Sensitivity principle system is utilizing passive piezoquartz just
Piezoelectric effect, sensitive structure adopts advanced shear constitution, is converted to the output charge of piezoquartz and vibration by IEPE
The low-resistance voltage signal that amount is directly proportional.Instrument can directly be matched and show that reading, record, data acquisition unit are acquired analysis, Jing
The suitable parameter such as instrument or software expandable measuring speed, displacement.Because the sensing element in sensor is made pottery using P5 piezoelectricity
Porcelain crystal, the crystal is function ceramics crystal, belongs to brittle non-metallic material, is become without significantly machinery yield limit and plasticity
Shape, in the range of stress for allowing to use, belongs to without tired material, and its base metal material --- rustless steel also has higher
Mechanical strength, piezoelectric structure itself no-movable part in addition, therefore service life is extremely long.Single sensitive measurement centered on the sensor
Acceleration transducer, the vibration of measurable vertical direction can also be horizontally mounted the vibration in detection level direction, if need to detect
The vibration of angle, then by frock should be measurable along direction of vibration impression by sensor.Because the small product size is little, rigidity
Greatly, frequency response width, voltage sensibility height, life-span length, Low ESR(100 Ω of <=signal transmission, good airproof performance, installation reliability, wiring
It is easy to use, the sensitive series of advantages such as passive.Temperature detection is completed using temperature sensing sensor, and pressure detecting adopts silicon crystal
Piezoresistive effect pressure transducer completing, Rotating speed measring is completed using Hall switch sensor.Scene is using in the world
First piece supports being digitally transmitted for " one-wire bus " interface, substantially increases the anti-interference of system.Cable is using screen
4 core twisted-pair feeders, one pair of which line earth lead and holding wire are covered, another that VCC and ground wire are connect to line, screen layer connects in source single-point
Ground.
By being equipped with detection vibration compound sensor 9 in the horizontal direction of the front and back end of output pump 8 and disposal direction, can
With find and diagnose in time mass unbalance, initial bending, thermal flexure, leaf abscission that output pump unit is present, misalign, oil
The failure conditions such as film vibration, steam flow excitation, electromagnetic exciting, friction, bearing shell loosening and resonance and and alarm and proposition directiveness
Handling suggestion, so as to avoid non-programmed halt, improve production efficiency.
Embodiment 4:
The intelligent diagnosis system that a kind of output pump unit monitors failure on-line is present embodiments provided, in order to improve the peace of the system
Full reliability, on the harvester 6 explosion-proof tank is provided with.
Harvester of the present invention is distributed vibration data intelligent collector, and its vibrating data collection system is one
Money is adapted to the operating mode of Oil Field, powerful data acquisition unit.Make use of and for many years manufacture Diagnosing System for Oil Pump to shake
The experience of dynamic protection device, from too many levels such as design, buying, productions the reliability and stability of product quality have been ensured.
Vibration data intelligent collector has the advantage that:
1st, high hardware reliability:Data acquisition equipment is produced with the technique of manufacture Large-scale machine set protection system, is possessed
The stability and reliability of superelevation.
2nd, strict EMC designs:Design source has just taken into full account EMC indexs, and has passed through recognizing for national authority department
Card.
3rd, " seamless " data acquisition technology:Intelligent collector has seamless data acquisition technology, you can with to all passages
Continual data acquisition is carried out with transmission.The maximum data length of endless.
4th, full technical grade chip, ultra-wide temperature adaptation scope has ensured the stability of system.
5th, ultra-high-speed data acquisition speed:The up to data acquisition rate of 400K, can safeguards system have superelevation point
Analysis frequency capabilities.
Exemplified as above is only the illustration to the present invention, does not constitute the restriction to protection scope of the present invention, all
It is that design same or analogous with the present invention is belonged within protection scope of the present invention.