CN106909698B - Dust collector operation and maintenance diagnosis and filter bag real-time service life management method - Google Patents
Dust collector operation and maintenance diagnosis and filter bag real-time service life management method Download PDFInfo
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Abstract
The invention discloses a method for diagnosing operation and maintenance of a dust remover and managing the real-time service life of a filter bag, which is characterized in that a data transmission data service center is carried out by adopting a wireless network after flue gas parameters and equipment operation parameters are collected, so that various parameters in the dust remover can be obtained in real time, the efficiency is high, the speed is high, and the operation condition of the dust remover can be obtained in the shortest time; the abnormal events are detected and reported through the parameter monitoring module, the state analysis result of the dust remover and the service life estimation analysis result of the filter bag are compared with the operation and maintenance experience database for analysis and expert analysis, and the monitoring, alarming and comprehensive diagnosis and analysis of the parameters by the dust remover are realized; according to the invention, after the state analysis result of the dust remover and the service life prediction analysis result of the filter bag are compared and analyzed with the operation and maintenance experience database, and after the analysis of expert personnel, an analysis report and a solution are given, so that the risk prediction is really realized, the occurrence of faults is prevented, and a basis is provided for scientific and reasonable use of the dust remover.
Description
Technical Field
The invention relates to the technical field of dust remover monitoring management, in particular to a dust remover operation and maintenance diagnosis and filter bag real-time service life management method.
Background
In recent years, haze phenomenon is more serious, industrial dust emission is one of important reasons, the bag type dust collector is taken as main equipment for controlling dust emission, the bag type dust collector is greatly popularized, operation and maintenance of the bag type dust collector and a filter bag of the bag type dust collector are weak links in the using process for a long time, and enterprises are troubled by various problems that the resistance of the bag type dust collector is high, the service life of the filter bag is short, the dust emission does not reach the standard, and the like.
At present, regular scheduled maintenance is still a maintenance strategy commonly applied to bag dust collector equipment in China, and the maintenance method mainly depends on inspection personnel to regularly go to the site for inspection, regular shutdown maintenance or fault shutdown maintenance, so that a large amount of manpower and material resources are wasted, and the integral fault rate of the equipment is increased.
The filter bag as the core component of the bag type dust collector is positioned in the dust collector, the surface is difficult to observe, and the service life information of the filter bag can be obtained only by testing through a detection mechanism of a special extraction sample bag feeding machine when the machine is stopped. The method is long in time consumption, the service condition of the filter bag cannot be known in time, the operation of the dust collector cannot be guided, the service life of the filter bag is far shorter than the design life, the equipment maintenance cost is increased, in addition, the shortage of environmental protection talents of enterprises is difficult to obtain technical support in time when facing the problems of high resistance of the dust collector, short service life of the filter bag, substandard dust emission and the like, small faults are gradually worsened, finally, the manpower and the fund consumed by maintenance are greatly increased, and huge pressure is brought to the enterprises.
Although industrial control software for monitoring and alarming the bag-type dust collector is available at present, comprehensive diagnosis and analysis cannot be performed, common technicians cannot find problems and provide measures for solving the problems in advance from the data, the reasons of the problems can be searched only after the faults occur, and the monitoring and alarming system is in a passive state for a long time in operation and maintenance work.
Disclosure of Invention
The invention aims to solve the problems and provides a method for diagnosing the operation and maintenance of a dust collector and managing the service life of a filter bag in real time, which realizes the automatic detection of the bag type dust collector, obtains the operation condition of the dust collector and the residual service life of the filter bag through model analysis, estimates the fault and risk in time, improves the operation efficiency of equipment and reduces the maintenance cost.
In order to achieve the purpose, the invention adopts the technical scheme that:
a dust collector operation and maintenance diagnosis and filter bag real-time life management method adopts a dust collector operation and maintenance diagnosis and filter bag real-time life management system which comprises an industrial database, a relational database, data receiving software integrated with a parameter monitoring module, an application layer integrated with a dust collector state analysis module, a filter bag life management module, an operation and maintenance diagnosis module and an operation and maintenance experience database and a client, wherein the application layer is respectively connected with the client and a data service center, and the method is implemented by the following steps:
s1, collecting flue gas parameters and equipment operation parameters in a dust remover, and transmitting the flue gas parameters and the equipment operation parameters to a data service center through a wireless network;
s2, receiving the smoke parameters and the equipment operation parameters by data receiving software of the data service center, monitoring and judging whether the parameters are abnormal or not by a parameter monitoring module, automatically initiating an abnormal event to report to an application layer if the parameters are abnormal, and caching all data received by the data receiving software in a relational database;
s3, after receiving the report of the abnormal event, the application layer performs dust collector state analysis and filter bag service life estimation analysis through a dust collector state analysis module and a filter bag service life management module, and both the dust collector state analysis result and the filter bag service life estimation analysis result are stored in an industrial database;
s4, comparing and analyzing the state analysis result of the dust collector and the service life estimation analysis result of the filter bag in the application layer calling with data stored in an operation and maintenance experience database, judging whether a coping strategy exists in the operation and maintenance experience database through an operation and maintenance diagnosis module, and if so, generating an abnormal event analysis report and a solution by the operation and maintenance diagnosis module; when the abnormal event is not detected, the application layer feeds the abnormal event back to the operation and maintenance personnel and executes the step S5;
s5, extracting abnormal smoke parameters and equipment operation parameters by an operation and maintenance person through a client integrating a human-computer interaction interface, analyzing the parameters by the operation and maintenance person, generating an abnormal analysis report and initiating expert consultation, informing experts in related fields by the client, establishing contact between the experts and the operation and maintenance person through the client, reporting the abnormal smoke parameters, the equipment operation parameters and the abnormal parameter analysis report to the related experts through the client, providing a coping strategy after the expert analyzes, generating an abnormal event analysis report and a solution, and feeding the abnormal event analysis report and the solution back to the operation and maintenance person.
In the step S1, acquiring the flue gas parameters and the device operation parameters by using the parameter detection device, uploading the parameters to the data service center by using the RTU device, reading the signals of the parameter detection device by using the RTU device, and transmitting the signals to the IP address designated by the data service center by using the TCP/IP or modbus data transmission protocol through the built-in remote communication system and through the GPRS, 3G or 4G wireless network;
the collected flue gas parameters comprise sulfur dioxide concentration, nitrogen oxide concentration, inlet dust concentration, outlet dust concentration, flue gas flow velocity, inlet oxygen content and outlet oxygen content, inlet flue gas temperature and outlet flue gas temperature, and the collected equipment operation parameters comprise inlet pressure and outlet pressure.
And the data receiving software of the data service center is KingSCADA, a smoke parameter threshold value and an equipment operation parameter threshold value are set in the KingSCADA, and if the smoke parameter and the equipment operation parameter received by the KingSCADA exceed the threshold values, an event is automatically initiated to be reported to the application layer.
The client is one or more of a computer client, a mobile phone APP and a browser, and the client communicates with the application layer through the Internet.
The filter bag service life estimation analysis and the dust collector state analysis in the step S3 are both analyzed by adopting mathematical models, wherein the mathematical models of the filter bag service life estimation analysis are established according to corresponding filter bag models, the filter bag service time data are recorded in the filter bag service life estimation analysis module, and the abnormal parameters and the filter bag service time data are substituted into the mathematical models to calculate and obtain the residual service life of the filter bag.
Further, the mathematical model of the filter bag life estimation analysis is as follows:
y≥35000－t－f(SO2)－f(O2)；
f(SO2)＝251+755.78(SO2×0.01)－108.9(SO2×0.01)2+6.16(SO2×
0.01)3；
f(O2)＝24.5－60.587×O2+29.406×O2 2－1.018×O2 3；
in the formula: y is the residual service life of the filter bag, h;
t-elapsed time, h;
SO2inlet sulfur dioxide concentration, mg/m 3;
O2inlet oxygen content,%.
Further: the mathematical model of the dust collector state analysis is as follows:
in the formula: IRSiThe operation state of the control factor i is divided into indexes, and L is more than or equal to L and less than or equal to H;
Ci-a monitored value of the control factor i;
BH-and CiHigh values of similar control factor limits;
BL-and CiThe low value of the similar control factor limit value;
IRSH-and BHDividing indexes into corresponding running states;
IRSL-and BLDividing indexes into corresponding running states;
RS＝max(IRSTOT,IRSP,IRSy)；
in the formula: RS-operating state index;
IRSTOT-outlet dust fraction index;
IRSP-dividing the dust collector operating resistance into indices;
IRSy-residual life indexing of the filter bag.
The client is one or more of a computer client, a mobile phone APP and a browser, and the client communicates with the application layer through the Internet.
The invention has the beneficial effects that:
according to the invention, a wireless network is adopted for data (parameter) transmission, so that various parameters in the dust remover can be obtained in real time, the efficiency is high, the speed is high, and the running condition of the dust remover can be obtained in the shortest time;
secondly, setting a three-level parameter detection mechanism, sequentially detecting and reporting abnormal events from a parameter monitoring module, comparing and analyzing a dust remover state analysis result and a filter bag service life estimation analysis result with an operation and maintenance experience database, and analyzing by expert personnel to realize parameter monitoring alarm and comprehensive diagnosis and analysis of the dust remover;
and thirdly, after the state analysis result of the dust remover, the service life estimation analysis result of the filter bag and the operation and maintenance experience database are compared and analyzed respectively, and after the analysis by experts, an analysis report and a solution are given, so that the risk estimation is really realized, the occurrence of faults is prevented, and a basis is provided for scientifically and reasonably using the dust remover.
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The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the invention and not to limit the invention. In the drawings:
FIG. 1 is a schematic flow diagram of the process of the present invention.
Detailed Description
In order to make the technical problems, technical solutions and advantageous effects of the present invention more clear and obvious, the present invention is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
As shown in fig. 1, a method for dust collector operation and maintenance diagnosis and real-time filter bag life management includes an application layer integrated with a dust collector state analysis module, a filter bag life management module, an operation and maintenance diagnosis module and an operation and maintenance experience database, and a client, wherein the application layer is respectively connected with the client and a data service center, and the method is implemented by the following steps:
s1, collecting flue gas parameters and equipment operation parameters in a dust remover, and transmitting the flue gas parameters and the equipment operation parameters to a data service center through a wireless network;
s2, receiving the smoke parameters and the equipment operation parameters by data receiving software of the data service center, monitoring and judging whether the parameters are abnormal or not by a parameter monitoring module, automatically initiating an abnormal event to report to an application layer if the parameters are abnormal, and caching all data received by the data receiving software in a relational database;
s3, after receiving the report of the abnormal event, the application layer performs dust collector state analysis and filter bag service life estimation analysis through a dust collector state analysis module and a filter bag service life management module, and both the dust collector state analysis result and the filter bag service life estimation analysis result are stored in an industrial database;
s4, comparing and analyzing the state analysis result of the dust collector and the service life estimation analysis result of the filter bag in the application layer calling with data stored in an operation and maintenance experience database, judging whether a coping strategy exists in the operation and maintenance experience database through an operation and maintenance diagnosis module, and if so, generating an abnormal event analysis report and a solution by the operation and maintenance diagnosis module; when the abnormal event is not detected, the application layer feeds the abnormal event back to the operation and maintenance personnel and executes the step S5;
s5, extracting abnormal smoke parameters and equipment operation parameters by an operation and maintenance person through a client integrating a human-computer interaction interface, analyzing the parameters by the operation and maintenance person, generating an abnormal analysis report and initiating expert consultation, informing experts in related fields by the client, establishing contact between the experts and the operation and maintenance person through the client, reporting the abnormal smoke parameters, the equipment operation parameters and the abnormal parameter analysis report to the related experts through the client, providing a coping strategy after the expert analyzes, generating an abnormal event analysis report and a solution, feeding the abnormal event analysis report and the solution back to the operation and maintenance person, and sending the solution to the client through the client by the operation and maintenance person.
In the step S1, acquiring the flue gas parameters and the device operation parameters by using the parameter detection device, uploading the parameters to the data service center by using the RTU device, reading the signals of the parameter detection device by using the RTU device, and transmitting the signals to the IP address designated by the data service center by using the TCP/IP or modbus data transmission protocol through the built-in remote communication system and through the GPRS, 3G or 4G wireless network;
the collected flue gas parameters comprise sulfur dioxide concentration, nitrogen oxide concentration, inlet dust concentration, outlet dust concentration, flue gas flow velocity, inlet oxygen content and outlet oxygen content, inlet flue gas temperature and outlet flue gas temperature, and the collected equipment operation parameters comprise inlet pressure and outlet pressure.
And the data receiving software of the data service center is KingSCADA, a smoke parameter threshold value and an equipment operation parameter threshold value are set in the KingSCADA, and if the smoke parameter and the equipment operation parameter received by the KingSCADA exceed the threshold values, an event is automatically initiated to be reported to the application layer.
The client is one or more of a computer client, a mobile phone APP and a browser, and the client communicates with the application layer through the Internet.
The filter bag service life estimation analysis and the dust collector state analysis in the step S3 are both analyzed by adopting mathematical models, wherein the mathematical models of the filter bag service life estimation analysis are established according to corresponding filter bag models, the filter bag service time data are recorded in the filter bag service life estimation analysis module, and the abnormal parameters and the filter bag service time data are substituted into the mathematical models to calculate and obtain the residual service life of the filter bag.
The mathematical model for estimating and analyzing the service life of the filter bag adopted in the embodiment is as follows:
y≥35000－t－f(SO2)－f(O2)；
f(SO2)＝251+755.78(SO2×0.01)－108.9(SO2×0.01)2+6.16(SO2×
0.01)3；
f(O2)＝24.5－60.587×O2+29.406×O2 2－1.018×O2 3；
in the formula: y is the residual service life of the filter bag, h;
t-elapsed time, h;
SO2inlet sulfur dioxide concentration, mg/m 3;
O2inlet oxygen content,%.
The mathematical model for the state analysis of the dust remover adopted in the embodiment is as follows:
in the formula: IRSiThe operation state of the control factor i is divided into indexes, and L is more than or equal to L and less than or equal to H; ci-a monitored value of the control factor i;
BH-and CiHigh values of similar control factor limits;
BL-and CiThe low value of the similar control factor limit value;
IRSH-and BHDividing indexes into corresponding running states;
IRSL-and BLDividing indexes into corresponding running states;
RS＝max(IRSTOT,IRSP,IRSy)；
in the formula: RS-operating state index;
IRSTOT-outlet dust fraction index;
IRSP-dividing the dust collector operating resistance into indices;
IRSy-residual life indexing of the filter bag.
Table 1: operation state sub-index and corresponding control factor limit
Table 2: operating state index and related information
| Index of operating conditions | Categories | Representing color |
| 0～100 | Superior food | Green colour |
| 101～200 | Good wine | Yellow colour |
| 201～300 | Difference (D) | Red colour |
From the table 1-2, it can be seen that the operating state index IRS is increased, the outlet dust concentration is reduced, the operating resistance of the dust collector is increased, the service life of the filter bag is reduced, the obtained operating state index is increased, the finally obtained operating state of the dust collector is from good to good and poor, the operating state of the dust collector and the service life of the filter bag can be effectively diagnosed, an analysis basis is provided for operation and maintenance personnel and experts, and the obtained operating state index is used as an important reference for an abnormal analysis report and a solution.
Taking the bag filter used in a certain power plant as an example, the bag filter is 550g/m2Pure PPS filter material, the parameters collected include 124 ℃ of the inlet temperature of the dust remover, 7.95% of the inlet oxygen content and 1459mg/m of the inlet sulfur dioxide concentration3Concentration of nitrogen oxide at inlet 411mg/m3And substituting the used time of the filter bag for 8640 hours into a mathematical model for estimating and analyzing the service life of the filter bag to obtain:
f(SO2)＝7228h；f(O2)＝890h，y＝18242h。
substituting into a mathematical model for analyzing the running state of the dust remover to obtain:
while the above description shows and describes the preferred embodiments of the present invention, it is to be understood that the invention is not limited to the forms disclosed herein, but is not to be construed as excluding other embodiments and is capable of use in various other combinations, modifications, and environments and is capable of changes within the scope of the inventive concept as expressed herein, commensurate with the above teachings, or the skill or knowledge of the relevant art. And that modifications and variations may be effected by those skilled in the art without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (7)
1. A method for diagnosing the operation and maintenance of a dust collector and managing the real-time service life of a filter bag is characterized by comprising the following steps: the system comprises an application layer and a client, wherein the application layer is formed by integrating an industrial database, a relational database, data receiving software integrated with a parameter monitoring module, a dust remover state analysis module, a filter bag service life management module, an operation and maintenance diagnosis module and an operation and maintenance experience database, the application layer is respectively connected with the client and a data service center, and the method is specifically implemented by the following steps:
s1, collecting flue gas parameters and equipment operation parameters in a dust remover, and transmitting the flue gas parameters and the equipment operation parameters to a data service center through a wireless network;
s2, receiving the smoke parameters and the equipment operation parameters by data receiving software of the data service center, monitoring and judging whether the parameters are abnormal or not by a parameter monitoring module, automatically initiating an abnormal event to report to an application layer if the parameters are abnormal, and caching all data received by the data receiving software in a relational database;
s3, after the application layer receives the report of the abnormal event, the state analysis module of the dust collector and the service life prediction analysis module of the filter bag are used for respectively carrying out the state analysis of the dust collector and the service life prediction analysis of the filter bag, and the state analysis result of the dust collector and the service life prediction analysis result of the filter bag are both stored in an industrial database;
s4, comparing and analyzing the state analysis result of the dust collector and the service life estimation analysis result of the filter bag in the application layer calling with data stored in an operation and maintenance experience database, judging whether a coping strategy exists in the operation and maintenance experience database through an operation and maintenance diagnosis module, and if so, generating an abnormal event analysis report and a solution by the operation and maintenance diagnosis module; when the abnormal event is not detected, the application layer feeds the abnormal event back to the operation and maintenance personnel and executes the step S5;
s5, extracting abnormal smoke parameters and equipment operation parameters by an operation and maintenance person through a client integrating a human-computer interaction interface, analyzing the parameters by the operation and maintenance person, generating an abnormal analysis report and initiating expert consultation, informing experts in related fields by the client, establishing contact between the experts and the operation and maintenance person through the client, reporting the abnormal smoke parameters, the equipment operation parameters and the abnormal parameter analysis report to the related experts through the client, providing a coping strategy after the expert analyzes, generating an abnormal event analysis report and a solution, and feeding the abnormal event analysis report and the solution back to the operation and maintenance person.
2. The method for dust collector operation and maintenance diagnosis and real-time filter bag life management as claimed in claim 1, wherein: in the step S1, acquiring the flue gas parameters and the device operation parameters by using the parameter detection device, uploading the parameters to the data service center by using the RTU device, reading the signals of the parameter detection device by using the RTU device, and transmitting the signals to the IP address designated by the data service center by using the TCP/IP or modbus data transmission protocol and through the GPRS, 3G or 4G wireless network by using the built-in remote communication system;
the collected flue gas parameters comprise sulfur dioxide concentration, nitrogen oxide concentration, inlet dust concentration, outlet dust concentration, flue gas flow velocity, inlet oxygen content and outlet oxygen content, inlet flue gas temperature and outlet flue gas temperature, and the collected equipment operation parameters comprise inlet pressure and outlet pressure.
3. The method for dust collector operation and maintenance diagnosis and real-time filter bag life management as claimed in claim 1, wherein: and the data receiving software of the data service center is KingSCADA, a smoke parameter threshold value and an equipment operation parameter threshold value are set in the KingSCADA, and if the smoke parameter and the equipment operation parameter received by the KingSCADA exceed the threshold values, an event is automatically initiated to be reported to the application layer.
4. The method for dust collector operation and maintenance diagnosis and real-time filter bag life management as claimed in claim 1, wherein: the filter bag service life estimation analysis and the dust collector state analysis in the step S3 are both analyzed by adopting mathematical models, wherein the mathematical models of the filter bag service life estimation analysis are established according to corresponding filter bag models, the filter bag service time data are recorded in the filter bag service life estimation analysis module, and the abnormal parameters and the filter bag service time data are substituted into the mathematical models to calculate and obtain the residual service life of the filter bag.
5. The method for dust collector operation and maintenance diagnosis and real-time filter bag life management as claimed in claim 4, wherein: the mathematical model of the filter bag service life estimation analysis is as follows:
y≥35000－t－f(SO2)－f(O2)；
f(SO2)＝251+755.78(SO2×0.01)－108.9(SO2×0.01)2+6.16(SO2×0.01)3；
f(O2)＝24.5－60.587×O2+29.406×O2 2－1.018×O2 3；
in the formula: y is the residual service life of the filter bag, h;
t-elapsed time, h;
SO2inlet sulfur dioxide concentration, mg/m 3;
O2inlet oxygen content,%.
6. The method for dust collector operation and maintenance diagnosis and real-time filter bag life management as claimed in claim 4, wherein: the mathematical model of the dust collector state analysis is as follows:
in the formula: IRSiThe operation state of the control factor i is divided into indexes, and L is more than or equal to L and less than or equal to H;
Ci-a monitored value of the control factor i;
BH-and CiHigh values of similar control factor limits;
BL-and CiThe low value of the similar control factor limit value;
IRSH-and BHDividing indexes into corresponding running states;
IRSL-and BLDividing indexes into corresponding running states;
RS＝max(IRSTOT,IRSP,IRSy)；
in the formula: RS-operating state index;
IRSTOT-outlet dust fraction index;
IRSP-dividing the dust collector operating resistance into indices;
IRSy-residual life indexing of the filter bag.
7. The method for dust collector operation and maintenance diagnosis and real-time filter bag life management as claimed in claim 1, wherein: and the client communicates with the application layer through the Internet.
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