CN111175041B - Valve monitoring method and system - Google Patents
Valve monitoring method and system Download PDFInfo
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- CN111175041B CN111175041B CN202010013001.5A CN202010013001A CN111175041B CN 111175041 B CN111175041 B CN 111175041B CN 202010013001 A CN202010013001 A CN 202010013001A CN 111175041 B CN111175041 B CN 111175041B
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- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M13/00—Testing of machine parts
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- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
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Abstract
The invention discloses a valve monitoring method and a valve monitoring system. The method comprises the following steps: acquiring the current actual load of the running equipment to be monitored; acquiring configuration information of all valves in a distributed control system; the configuration information is the current actual opening degree of the valve; determining associated data according to the configuration information and the association relation; the associated data are pressure, flow and post-valve temperature corresponding to the configuration information; and determining the current operation state of the valve according to the current actual load, the configuration information and the associated data. The invention can find the valve leakage in time and realize the real-time online monitoring of the valve state.
Description
Technical Field
The invention relates to the technical field of valve monitoring, in particular to a valve monitoring method and system.
Background
The running condition of the valve is particularly important when the unit runs, when the valve is jammed and leaks, the safe running of the unit is influenced, the waste of pressure loss fluid of the system can be caused, and particularly, the leakage of corrosive, flammable and explosive toxic fluid can cause great economic loss and environmental pollution. Therefore, how to timely and accurately find the jamming and leakage of the valve is very important for the safe operation of the unit.
At present, the methods for valve leakage inspection at home and abroad mainly comprise a manual inspection method, an ultrasonic detection technology, a vibration analysis detection method and the like. The detection methods have the advantages of high positioning accuracy and low false alarm rate, but the detection methods have the defects that leakage cannot be found in time and online monitoring cannot be realized.
Disclosure of Invention
Therefore, there is a need for a valve monitoring method and system, which can detect leakage in time and realize real-time online monitoring of the valve status.
In order to achieve the purpose, the invention provides the following scheme:
a valve monitoring method comprising:
acquiring the current actual load of the running equipment to be monitored;
acquiring configuration information of all valves in a distributed control system; the configuration information is the current actual opening degree of the valve;
determining associated data according to the configuration information and the association relation; the associated data are pressure, flow and post-valve temperature corresponding to the configuration information;
and determining the current operation state of the valve according to the current actual load, the configuration information and the associated data.
Optionally, the determining the current operating state of the valve according to the current actual load, the configuration information, and the associated data specifically includes:
determining the current theoretical load of the running equipment to be monitored according to the configuration information and the associated data;
calculating an error value for the valve from the current actual load and the current theoretical load,
wherein e is an error value, L1For the current actual load, L2The current theoretical load;
when the error value changes within a set time and the change value is greater than a set threshold value, determining that the current operation state of the valve is a jump state;
when the error value is not changed within the set time and the error value is within the set interval, determining that the running state of the valve is a normal state;
and when the error value is not changed within the set time and is not within the set interval, determining that the running state of the valve is a deviation state.
Optionally, before determining the current theoretical load of the operating device to be monitored according to the configuration information and the associated data, the method further includes:
and when the associated data is suddenly changed to zero, determining that the current operation state of the valve is a dead pixel state.
Optionally, after determining the current operating state of the valve according to the current actual load, the configuration information, and the associated data, the method further includes:
and pushing a pre-stored background processing scheme according to the current running state.
Optionally, after pushing the pre-stored background processing scheme according to the current operating state, the method further includes:
and monitoring the running state of the valve processed by the pushed pre-stored background processing scheme.
Optionally, the correlation is determined by valve logic experiments.
Optionally, after the obtaining of the current actual load of the operating device to be monitored, the method further includes:
judging whether the current actual load is greater than a set load or not;
if yes, executing the step of obtaining the configuration information of all valves in the distributed control system.
Optionally, after the obtaining configuration information of all valves in the distributed control system, the method further includes:
judging whether the current actual opening degree of the valve is smaller than a protection threshold value or not;
if yes, determining associated data according to the configuration information and the association relation;
if not, pushing a pre-stored background processing scheme according to the configuration information.
The invention also provides a valve monitoring system, comprising:
the load acquisition module is used for acquiring the current actual load of the running equipment to be monitored;
the configuration information acquisition module is used for acquiring the configuration information of all valves in the distributed control system; the configuration information is the current actual opening degree of the valve;
the associated data determining module is used for determining associated data according to the configuration information and the association relation; the associated data are pressure, flow and post-valve temperature corresponding to the configuration information;
and the current operation state determining module is used for determining the current operation state of the valve according to the current actual load, the configuration information and the associated data.
Optionally, the current operation state determining module specifically includes:
the theoretical load determining unit is used for determining the current theoretical load of the running equipment to be monitored according to the configuration information and the associated data;
an error value calculation unit for calculating an error value of the valve from the current actual load and the current theoretical load,
wherein e is an error value, L1For the current actual load, L2The current theoretical load;
the operation state determining unit is used for determining that the current operation state of the valve is a jumping state when the error value changes within the set time and the change value is greater than a set threshold value; when the error value is not changed within the set time and the error value is within the set interval, determining that the running state of the valve is a normal state; and when the error value is not changed within the set time and the error value is not within the set interval, determining that the running state of the valve is a deviation state.
Compared with the prior art, the invention has the beneficial effects that:
the invention provides a valve monitoring method and a valve monitoring system. The method comprises the following steps: acquiring the current actual load of the running equipment to be monitored; acquiring configuration information of all valves in a distributed control system; the configuration information is the current actual opening degree of the valve; determining associated data according to the configuration information and the association relation; the associated data are pressure, flow and post-valve temperature corresponding to the configuration information; and determining the current operation state of the valve according to the current actual load, the configuration information and the associated data. The invention can find the valve leakage in time and realize the real-time online monitoring of the valve state.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed to be used in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without inventive exercise.
Fig. 1 is a flow chart of a valve monitoring method according to embodiment 1 of the present invention;
fig. 2 is a schematic structural diagram of a valve monitoring system according to embodiment 3 of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.
Example 1
Fig. 1 is a flowchart of a valve monitoring method according to embodiment 1 of the present invention. Referring to fig. 1, the valve monitoring method of the present embodiment includes:
step S1: and acquiring the current actual load of the running equipment to be monitored.
Step S2: acquiring configuration information of all valves in a distributed control system; the configuration information is the current actual opening degree of the valve.
Step S3: determining associated data according to the configuration information and the association relation; the associated data is pressure, flow and post-valve temperature corresponding to the configuration information.
In this embodiment, the association relationship is a corresponding relationship between the configuration information and the pressure, the flow rate, and the post-valve temperature, respectively. The correlation is determined by valve logic experiments.
Step S4: and determining the current operation state of the valve according to the current actual load, the configuration information and the associated data.
The step S4 specifically includes:
41) and determining the current theoretical load of the running equipment to be monitored according to the configuration information and the associated data.
42) Calculating an error value for the valve from the current actual load and the current theoretical load,
wherein e is an error value, L1For the current actual load, L2Is the current theoretical load.
43) And when the error value changes within the set time and the change value is greater than the set threshold value, determining that the current operation state of the valve is a jump state.
And when the error value is not changed within the set time and the error value is within the set interval, determining that the running state of the valve is a normal state.
And when the error value is not changed within the set time and is not within the set interval, determining that the running state of the valve is a deviation state.
And when the associated data is suddenly changed to zero, determining that the current operation state of the valve is a dead pixel state.
Step S5: and pushing a pre-stored background processing scheme according to the current running state.
Step S6: and monitoring the running state of the valve processed by the pushed pre-stored background processing scheme.
As an optional implementation manner, after step S1, the method further includes:
judging whether the current actual load is greater than a set load or not; if so, go to step S2, otherwise, do not perform valve detection.
As an optional implementation manner, after step S2, the method further includes: judging whether the current actual opening degree of the valve is smaller than a protection threshold value or not; if yes, go to step S3; if not, pushing a pre-stored background processing scheme according to the configuration information.
A more specific embodiment is provided below.
Example 2
The first step is as follows: valve data extraction
All valve data in a Distributed Control System (DCS) operation screen are based on a configuration (logical relationship in an operation System background), and the configuration meaning of each valve data in the operation screen is decomposed (each logical meaning is described by characters). And monitoring and early warning corresponding to data aiming at configuration association (text meaning of background logic).
For example, the condensate tank water supply regulating valve is an adjusting valve in a DCS operation picture, only real-time flow data and opening information of the condensate tank water supply regulating valve can be seen on the operation picture, but the meaning of the valve in the configuration is that the opening of the valve is related to the water supply flow, the related condensate pump is shut down after the valve is in fault, but the correlation of the valve in the operation picture cannot be displayed, and only the correlation of the data is seen in the DCS configuration. The configuration association in the DCS can not be seen by operators, and only relevant professionals can see the association in an engineer station. Therefore, all valve thresholds and configurations are first extracted from the DCS.
The second step is that: valve reset data
After the extraction of the valve data in the DCS configuration is completed, the diagnosis and warning are performed again on the corresponding associated or protected data thresholds (e.g., one a valve has its threshold 50, and its threshold is reset to 45 at this step to achieve early warning). The threshold is a critical value, which is a value where the effect can be the lowest and highest. The protection threshold is the lowest and highest limit of the protection data in the system, and exceeding the protection threshold causes great danger to the system.
For example, a water supply regulating valve in the operation picture is in a normal state, and the correlation is as follows: the valve opening is 50%, the corresponding pressure is 4Mpa, the corresponding flow is 30th, the corresponding post-valve temperature is 300 ℃, but in the abnormal state of the valve, the valve opening is 50%, the pressure value after the valve is 2Mpa, the flow value is 15th, the post-valve temperature is 200 ℃, the diagnosis result is obtained by integrating the associated equipment information, the valve opening is wrong, the corresponding background processing scheme is pushed, and the background processing scheme is operated, so that the valve is overhauled.
The third step: valve debugging data
After the valve threshold value is reset, firstly, the numerical value of the load is artificially implanted into the data by more than 25%, and each power plant operation system can artificially implant the data. Therefore, the virtual operation system can be used for debugging the valve early warning, valves of different systems are controlled aiming at valves at different positions, different comparison conditions are carried out, for example, a valve needing pressure control is compared by using the pressure values before and after the valve with a load value and an opening degree, and for example, the temperature values before and after the valve are compared with the load value and the valve opening degree by using the valve needing temperature adjustment. And testing in the DCS before starting the machine, and forcing the required valve association condition so as to judge whether the processing scheme pushed by the redefined valve logic and the valve monitoring system is correct or not. The practical experience of the maintenance for years and the knowledge base of old experts are combined to be used as the basic reference of big data, the treatment opinions can be continuously perfected in practice, and the treatment opinions can be added and modified by the background of the system.
For example, before starting the machine, an experiment is performed on the valve correlation threshold, in an operation picture, a pressure point and a corresponding flow point temperature are regularly changed to a large extent at the same time, and the valve opening is unchanged, at this time, the valve monitoring system pushes out a valve fault early warning and simultaneously pushes out a corresponding solution, so that whether the processing scheme pushed by the valve monitoring system is correct is monitored, and a valve logic experiment is performed on each correlation valve.
The fourth step: automatic monitoring
The load is used as a target for monitoring, when the load is more than 25%, the operating system is intelligently monitored, and when the load is less than 25%, the intelligence is released according to the logic relation in the DCS configuration and the chain starting condition. The valve early warning method is the most important condition of valve early warning, when the load of a unit is lower than 25%, all data such as valve pressure, temperature, flow and the like and a valve early warning system are invalid, and the actual protection of the unit is also invalid, so that the valve early warning system and the unit protection system are in accordance with the precedent condition, and the unit load can take effect only when the load of the unit is higher than 25%.
For example, in the linkage relationship of the steam turbine, the load refers to the normal power of the steam turbine during operation. When the load is lower than 25% of the load of the generator set before the current value, the water supply pump motor valve and the condensate pump motor front inlet valve cannot reach the opening condition, and the load state directly influences the opening of each valve of the steam turbine auxiliary engine.
The fifth step: flash defect identification
The defect is defined as: the defect, deviation and jump are logically defined in software, and defect characteristics are obtained through background logic conversion.
The main defects include: 1. data points in the system plot show purple color (a phenomenon of dead spots), and such defects generally affect the malfunction of many valves. 2. The data displayed by the data points in the system diagram is larger or smaller, and in general system diagrams, two or three data points are used as the basis for judging the running state of the equipment, but when the data points are different in size, the data deviation occurs, so that the problem of the data is further judged below.
The background logic is: corresponding to the load as a standard, each data point corresponding to the load is regular in each process of the load change, for example: when the load runs to 70%, the corresponding data points are 70%, and the data points are larger or smaller than the corresponding data points and are deviation defects, and the defects can cause abnormal shutdown of the unit.
The logic algorithm is respectively as follows: fnu (device name vs. quantitative) — current state load% vs. current state, the meaning of the logic algorithm is: for example, when the load of the unit is 50%, the valve B should be in a closed state, the load state is compared with the valve, and if the valve is opened, the valve is indicated to be in a fault state. The method specifically comprises the following steps: comparing the load state with the theoretical load state corresponding to the current valve state to determine the defect type, if the current actual load and the current theoretical load calculate the error value of the valve,
wherein e is an error value, L1For the current actual load, L2The current theoretical load; when the error value is setIf the change value is greater than the set threshold value, the current operation state of the valve is determined to be a jumping state; when the error value is not changed within the set time and the error value is within the set interval, determining that the running state of the valve is a normal state; when the error value is not changed within the set time and the error value is not within the set interval, determining that the running state of the valve is a deviation state; and when the correlation data are suddenly changed into zero, determining that the current operation state of the valve is a dead pixel state.
For example, the set interval is set to be [ 0-10%]The current actual load is 50%, the current valve is open, and the corresponding current theoretical load is greater than 60%, whereby it can be determined that the current operating condition of the valve is defective. Then the current load state 50% exceeds the critical value of 10%, and the calculation formula is
The type of defect is determined to be a deviation, i.e. the operating state of the valve is a deviation state.
And a sixth step: defect push
And (4) remanufacturing a system picture, identifying defective data fault points by a data flashing method, and pushing a background processing scheme. The determination mode of the background processing scheme is as follows: the valve data are monitored in real time, a method for comparing the data of a valve database in real time by using a function command is used, the type of the defect of the valve is recorded in advance, the information of the defect of the valve and a processing method are correspondingly recorded, and a method for correspondingly pushing the defect and the processing scheme by using the valve database is adopted in the pushing scheme. For example: the computer enters data indicating 000 for a valve with a defect in advance. The correspondence processing information is: check valve data channel-valve data hardware address is a board of a cabinet. The detection method comprises the following steps: and measuring whether the local and cabinet voltages are normal. Processing the opinions: the defect treatment of the valve is a general defect, no protection interlocking (or protection interlocking) exists between the valve and a DCS, after the interlocking relation needs to be confirmed, the suggestion that whether power supply connection on the spot and two sides of a cabinet is loosened or broken and short-circuited is firstly checked, and the like.
When the corresponding valve defect and the processing scheme pushed by the corresponding valve defect occur, the corresponding fault point on the operation picture flickers, and a dialog box is popped up by clicking the flicking point, wherein the dialog box is the basic information of the processing scheme and the fault of operation and maintenance.
The seventh step: identifying defect data
When the defect occurs and the processing is completed, the data point is monitored in real time, and the data is intelligently incorporated into data recovery after being effectively compared with the range data in a data acquisition period.
The step is realized based on the last step, the last step is the identification of the defects, after the defects are identified, the system monitors when the data are recovered, namely the data are compared in real time, once the compared data are reasonable data, the system automatically identifies the data as recovered, so the system considers that the important basis of the defect recovery is the normal of the data, and then the real-time monitoring is automatically carried out again.
Eighth step: defect integration
Each defect data generation records detailed basic information, occurrence time, processing time, and recovery time in the background.
The embodiment also applies the method to a DCS control system to actually monitor the running state of the valve equipment. For example, the method is applied to the SIS system of Yuhua thermal power plant in Zhejiang, and through field practical application, the valve monitoring method carries out accurate and timely diagnosis, early warning and shape and shadow processing schemes when equipment fails.
The valve monitoring method of the embodiment has the following advantages:
1) a diagnostic model is developed on the basis of original valve equipment in a plant and is connected to a DCS or an SIS system for application, and investment of a large amount of funds caused by upgrading of the DCS can be reduced. The butt joint construction period is short, the normally operated unit is not influenced, and the implementation and operation synchronization is realized.
2) The management of the test data of being more convenient for, conveniently realize trend tracking, historical data contrast, make data analysis more convenient, it is more convenient to equipment failure diagnosis and equipment state aassessment, propelling movement processing scheme in advance when the valve trouble appears, effectual arrangement maintenance preparation work of overhauing avoids emergency to take place, can drop to the minimum with the influence of system outage, and the non-accident that causes drops to minimumly.
3) The valve data are collected in real time, the state of the valve equipment is automatically monitored, the state of the valve equipment is rapidly judged, the valve equipment with serious defects or major hidden dangers is rapidly screened out from a large amount of test data, the working strength of operation operators and users is greatly reduced, the working efficiency is improved, the effectiveness of a diagnosis result is improved, the valve equipment state monitoring method has great significance, and the development trend of intelligent monitoring of the power plant valve is met. The embodiment also realizes automatic classification and arrangement of test data by a valve logic judgment method, and avoids the troubles of manual identification and classification.
4) Based on the operation data, the failure reason of the valve is automatically acquired and analyzed in the first time, the process of firstly judging and then maintaining of the maintenance personnel of the power plant is further simplified, the working strength of a user or the analysis personnel is reduced, the accuracy of the maintenance personnel is improved, and the reliability of the stable operation of the valve equipment in a unit is improved.
Fig. 2 is a schematic structural diagram of a valve monitoring system according to embodiment 3 of the present invention.
Referring to fig. 2, the valve monitoring system of the present embodiment includes:
the load obtaining module 201 is configured to obtain a current actual load of the operating device to be monitored.
A configuration information obtaining module 202, configured to obtain configuration information of all valves in the distributed control system; the configuration information is the current actual opening degree of the valve.
The associated data determining module 203 is configured to determine associated data according to the configuration information and the association relationship; the associated data is pressure, flow and post-valve temperature corresponding to the configuration information.
A current operation state determining module 204, configured to determine a current operation state of the valve according to the current actual load, the configuration information, and the associated data.
As an optional implementation manner, the current operation state determining module 204 specifically includes:
and the theoretical load determining unit is used for determining the current theoretical load of the running equipment to be monitored according to the configuration information and the associated data.
An error value calculation unit for calculating an error value of the valve from the current actual load and the current theoretical load,
wherein e is an error value, L1For the current actual load, L2Is the current theoretical load.
The operation state determining unit is used for determining that the current operation state of the valve is a jumping state when the error value changes within the set time and the change value is greater than a set threshold value; when the error value is not changed within the set time and the error value is within the set interval, determining that the running state of the valve is a normal state; and when the error value is not changed within the set time and the error value is not within the set interval, determining that the running state of the valve is a deviation state.
The valve monitoring system of this embodiment can discover in time that the valve leaks, realizes the real-time on-line monitoring to the valve state.
The embodiments in the present description are described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments are referred to each other. For the system disclosed by the embodiment, the description is relatively simple because the system corresponds to the method disclosed by the embodiment, and the relevant points can be referred to the method part for description.
The principles and embodiments of the present invention have been described herein using specific examples, which are provided only to help understand the method and the core concept of the present invention; meanwhile, for a person skilled in the art, according to the idea of the present invention, the specific embodiments and the application range may be changed. In view of the above, the present disclosure should not be construed as limiting the invention.
Claims (7)
1. A method of monitoring a valve, comprising:
acquiring the current actual load of the running equipment to be monitored;
acquiring configuration information of all valves in a distributed control system; the configuration information is the current actual opening degree of the valve;
determining associated data according to the configuration information and the association relation; the associated data are pressure, flow and post-valve temperature corresponding to the configuration information;
determining the current operation state of the valve according to the current actual load, the configuration information and the associated data;
the incidence relation is the corresponding relation between the configuration information and the pressure, the flow and the post-valve temperature respectively; the incidence relation is determined through a valve logic experiment;
determining the current operating state of the valve according to the current actual load, the configuration information and the associated data specifically includes:
41) determining the current theoretical load of the running equipment to be monitored according to the configuration information and the associated data;
42) calculating an error value for the valve from the current actual load and the current theoretical load,
wherein e is an error value, L1For the current actual load, L2The current theoretical load;
43) when the error value changes within a set time and the change value is greater than a set threshold value, determining that the current operation state of the valve is a jump state;
when the error value is not changed within the set time and the error value is within the set interval, determining that the running state of the valve is a normal state;
when the error value is not changed within the set time and the error value is not within the set interval, determining that the running state of the valve is a deviation state;
and when the associated data is suddenly changed to zero, determining that the current operation state of the valve is a dead pixel state.
2. The method of claim 1, wherein prior to determining the current theoretical load of the operating device to be monitored based on the configuration information and the associated data, the method further comprises:
and when the associated data is suddenly changed to zero, determining that the current operation state of the valve is a dead pixel state.
3. The method of claim 1, wherein after determining the current operating state of the valve based on the current actual load, the configuration information, and the associated data, further comprising:
and pushing a pre-stored background processing scheme according to the current running state.
4. The valve monitoring method according to claim 3, further comprising, after the pushing a pre-stored background processing scheme according to the current operating state:
and monitoring the running state of the valve processed by the pushed pre-stored background processing scheme.
5. The valve monitoring method according to claim 1, further comprising, after the obtaining of the current actual load of the operating device to be monitored:
judging whether the current actual load is greater than a set load or not;
if yes, executing the step of obtaining the configuration information of all valves in the distributed control system.
6. The method of claim 1, further comprising, after obtaining configuration information for all valves in the distributed control system:
judging whether the current actual opening degree of the valve is smaller than a protection threshold value or not;
if yes, determining associated data according to the configuration information and the association relation;
if not, pushing a pre-stored background processing scheme according to the configuration information.
7. A valve monitoring system, comprising:
the load acquisition module is used for acquiring the current actual load of the running equipment to be monitored;
the configuration information acquisition module is used for acquiring the configuration information of all valves in the distributed control system; the configuration information is the current actual opening degree of the valve;
the associated data determining module is used for determining associated data according to the configuration information and the association relation; the associated data are pressure, flow and post-valve temperature corresponding to the configuration information;
a current operation state determination module, configured to determine a current operation state of the valve according to the current actual load, the configuration information, and the associated data;
the incidence relation is the corresponding relation between the configuration information and the pressure, the flow and the post-valve temperature respectively; the incidence relation is determined through a valve logic experiment;
the current operation state determination module specifically includes:
the theoretical load determining unit is used for determining the current theoretical load of the running equipment to be monitored according to the configuration information and the associated data;
an error value calculation unit for calculating an error value of the valve from the current actual load and the current theoretical load,
wherein e is an error value, L1For the current actual load, L2The current theoretical load;
the operation state determining unit is used for determining that the current operation state of the valve is a jumping state when the error value changes within the set time and the change value is greater than a set threshold value;
when the error value is not changed within the set time and the error value is within the set interval, determining that the running state of the valve is a normal state;
when the error value is not changed within the set time and the error value is not within the set interval, determining that the running state of the valve is a deviation state;
and when the associated data is suddenly changed to zero, determining that the current operation state of the valve is a dead pixel state.
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