CN111314463A - Pump station unit health assessment based method - Google Patents
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Abstract
The invention relates to a method based on pump station unit health assessment, which comprises the steps of firstly establishing a network system integral framework of a data acquisition front end combination monitoring network and remote diagnosis according to the requirement of the pump station unit health assessment, wherein the network system integral framework comprises a sensing layer, a network layer and an application layer, then acquiring corresponding data of a pump station unit according to a data acquisition device of the sensing layer, sending the acquired data to a server of the application layer through the network layer, judging whether data analysis and fault diagnosis are required or not after comparing the acquired data with a preset alarm threshold value, and finally issuing a diagnosis result. The invention further analyzes the monitoring result of the pump station unit by comprehensively collecting data parameters such as vibration, swing, environment temperature and the like, objectively evaluates the health condition of the pump station unit, ensures the normal operation of the pump station unit, prolongs the service life of the pump station unit to the maximum extent, and reduces the cost.
Description
Technical Field
The invention relates to the technical field of intelligent operation and maintenance, in particular to a method based on pump station unit health assessment.
Background
Traditional pump station maintainer comes to carry out daily point inspection to unit equipment through "look, hear, touch, listen" 4 kinds of methods, it is very big to see out traditional daily point inspection limitation from this, if the equipment trouble of discovering usually has arrived the last irretrievable ground step, probably only experienced maintainer can accomplish this time, and traditional maintenance mode also can regularly just inspect change and maintenance, to the problem that traditional pump station unit management exists, the full life cycle management and the health assessment definition of pump station unit are as follows:
managing the whole life cycle: the whole process from the beginning of use to the aging and wear of the equipment, even the equipment can not be continuously put into use, the equipment can be managed in the whole process, each link of the life cycle of the equipment (such as the management of the initial design defect of the equipment, the management of information data such as collision in the transportation process and the like, the data management in the installation process, the data management in the operation process and the maintenance, replacement and management of the equipment) is made, the service life of the equipment is prolonged to the maximum extent, and the cost is reduced.
Health assessment: through the running state of real-time supervision pump station unit equipment, grasp the health status of equipment in real time to when equipment exists unusually, can avoid causing the major affairs to take place because of equipment trouble, thereby reduction in production cost.
Disclosure of Invention
The technical problem to be solved by the invention is to provide a method based on the health assessment of the pump station unit aiming at the prior art, so as to ensure the normal operation of the pump station unit, prolong the service life of the pump station unit to the maximum extent and reduce the cost.
The technical scheme adopted by the invention for solving the problems is as follows: a health assessment method based on pump station unit full life cycle management comprises the steps of firstly, establishing a network system overall architecture of a data acquisition front end combination monitoring network and remote diagnosis according to requirements of the pump station unit full life cycle management and the health assessment, wherein the network system overall architecture comprises a sensing layer, a network layer and an application layer, then acquiring corresponding data of a pump station unit according to a data acquisition device of the sensing layer, sending the acquired data to a server of the application layer through the network layer, judging whether data analysis and fault diagnosis are needed or not after comparing the acquired data with a preset alarm threshold value, and finally issuing a diagnosis result.
Preferably, the server of the application layer stores, analyzes and manages the real-time data, the historical data and various characteristic value data transmitted from each data acquisition device, analyzes and diagnoses the data, namely, performs health assessment, firstly, the assessment factors are taken according to actual conditions, the factors are subjected to weight division, a scoring system is established according to the weight division of the factors, scoring is performed according to assessment calculation rules, the health condition of the equipment is better when the score is higher, and after the unit finishes operating every time, the system automatically performs health assessment on the health assessment result according to the operating condition.
Preferably, the evaluation calculation rule includes:
1) the value of no sensor exceeds the alarm threshold value
The score calculation formula is as follows: f ═ PE-K-P- [ (A)Rotating wheel/A0)×10％+(Apj/A0)×10％+(Bpj/B0)×25％+(CStator/C0)×10％+(Cpj/C0)×20％+(Dpj/D0)×15％+(Epj/E0)×10％]×20-M/10-N-10×S-T/1000
2) When the value of the sensor exceeds the alarm value but does not reach the accident shutdown value:
the score calculation formula is as follows: f ═ PE1-K-P- [ (a)Rotating wheel/A0)×10％+(Apj/A1)×10％+(Bpj/B1)×25％+(CStator/C0)×10％+(Cpj/C1)×20％+(Dpj/D1)×15％+(Epj/E1)×10％]×20-M/10-N-10×S-T/1000
In this case, the score is lower than M1;
3) when the sensor value exceeds the value of the accident shutdown:
the score calculation formula is as follows: f ═ PE2-K-P- [ (a)Rotating wheel/A0)×10％+(Apj/A1)×10％+(Bpj/B1)×25％+(CStator/C0)×10％+(Cpj/C1)×20％+(Dpj/D1)×15％+(Epj/E1)×10％]×20-M/10-N-10×S-T/1000
In this case, the score is lower than M2;
wherein:
Arotating wheel: reading by a runner chamber vibration sensor; taking the average value of the maximum values of all measuring points in the operation process;
Aothers: reading by other vibration sensors;
b: reading by a swing sensor;
Cstator: reading of a three-phase temperature sensor of a motor stator; taking the maximum value in the operation process;
Cothers: other temperature sensor readings;
d: pressure pulsation sensor readings;
e: noise sensor readings;
an: the vibration sensor reading numbered n;
max [ An ]: the vibration sensor with the number of n # acquires the maximum effective numerical value in the running process just finished;
apj: the arithmetic mean of max [ An ] for all vibration sensors;
a0: a vibration alarm threshold value;
a1: a vibration accident shutdown threshold;
k: under different working conditions, the stable operation range is obtained, namely whether the average vibration amplitude A of the runner chamber is close to that under different working conditions is compared; k ═ max { A-Low lift of runner/AMiddle lift of runner、ALow lift of runner/AMaximum lift of runner、AMiddle lift of runner/AMaximum lift of runner、AMiddle lift of runner/ALow lift of runner、AMaximum lift of runner/AMinimum lift of runner、AMaximum lift of runner/AMiddle lift of runner}; the maximum, minimum and middle lift refer to the lift during the operation;
p: under the design condition, namely when the measured lift is the design lift, the ratio of the measured flow to the design flow is large, and P is 100-Measured in fact/QDesign ofIf Q isMeasured in fact/QDesign ofIf less than 1, P is positive value; if QMeasured in fact/QDesign ofIf greater than 1, P is negative; if the operation does not reach the design lift, QDesign ofTaking the maximum flow in all the units started at this time;
m is the number of months of the last major revision;
n is the number of faults which have occurred up to now in the latest overhaul;
s, the number of unsolved faults;
t is the running time of the previous overhaul till now;
f: a health assessment score;
PE, PE1, PE 2: upper score limit for each stage.
Preferably, the server acquires the value of the corresponding measuring point through the receiving data acquisition device, and expresses the current alarm state of the measuring point by combining the change among different colors:
when there is no data, the background color of the data display area is gray;
when the data is in the normal range, the background color will change to green, i.e. normal;
when the numerical value of the vibration data exceeds the alarm threshold, the color of the background is changed into yellow, namely, the background is reported;
when the value of the vibration data exceeds the danger threshold, the background color changes to red, i.e., a high report.
Compared with the prior art, the invention has the advantages that:
the invention realizes the monitoring of the online operation condition of the pump station unit by depending on a computer monitoring system, and the management of the pump station unit equipment is comprehensively and reasonably managed in the whole process from the planning and purchasing of the equipment until the equipment is scrapped and loses the use value. On the other hand, the health condition of the pump station unit is objectively evaluated by further analyzing the monitoring result of the pump station unit through comprehensively collecting data parameters such as vibration, swing degree and environmental temperature, so that the normal operation of the pump station unit is ensured, the service life of the pump station unit is prolonged to the maximum extent, and the cost is reduced.
Drawings
Fig. 1 is an overall architecture diagram of a pump station unit health assessment based network system in an embodiment of the present invention.
Detailed Description
The invention is described in further detail below with reference to the accompanying examples.
The method for evaluating the health of the unit based on the pump station in the embodiment mainly comprises the following steps:
one, build network structure
Aiming at the requirements of the pump station unit full life cycle management and health assessment, the 'internet plus' technology is combined, the whole architecture of a network system with a monitoring network and remote diagnosis combined at the data acquisition front end is provided, and the whole system is composed of a sensing layer, a network layer and an application layer. The sensing layer realizes intelligent sensing, information processing and automatic control of the physical world, and connects the physical entity to the network layer and the application layer through the communication module. The network layer mainly realizes the transmission, routing and control of information, and can depend on public telecommunication networks and the Internet. The application layer includes an application infrastructure, middleware, and corresponding applications. The overall structure of the pump station is divided into a data acquisition front end and a remote diagnosis center. Fig. 1 shows a network structure of monitoring management and health assessment for the whole life cycle of a host group.
1) And the data acquisition device of each unit of the pump station is responsible for acquiring signals of the pump station unit, such as vibration, swing degree, pressure and the like.
2) The WEB server is used for storing, analyzing and managing real-time data, historical data and various characteristic value data transmitted from each data acquisition device, analyzing and diagnosing faults of the data and issuing the data.
The WEB server collects the numerical values of corresponding measuring points through the receiving data acquisition device, the measuring points for warning of the wanted prompt can be set in the background of the system, generally, the data of the object can not be influenced after reaching a certain degree, the warning can be started if the data are influenced by the feeling, and corresponding warning limit numerical values are set, for example, when the noise reaches a certain numerical value, a certain hardware can have problems, a warning threshold value can be set at the time, the warning can be given when the noise exceeds the threshold value, the warning is given to the working personnel, and the current warning state of the measuring points can be expressed by combining the change among different colors:
when there is no data, the background color of the data display area is gray;
when the data is in the normal range, the background color will change to green, i.e. normal;
when the numerical value of the vibration data exceeds the alarm threshold, the color of the background is changed into yellow, namely, the background is reported;
when the value of the vibration data exceeds the danger threshold, the background color changes to red, i.e., a high report.
Second, health assessment
A. The health assessment needs to relate to the weight of each factor and score each factor, because the factors for the health assessment are not necessarily the same, the factors can be taken according to the actual situation, and the general rule is as follows:
1) each factor is divided by weight (percentage, total 100%): the weight of a vibration index of the runner chamber is 10%, the weight of other vibration indexes is 10%, the weight of a swing index is 25%, the weight of a stator temperature index is 10%, the weight of other temperature indexes is 20%, the weight of a pressure pulsation index is 15%, and the weight of a noise index is 10%.
2) The score is 100 points, and the full score is 100 points. The higher the score, the better the equipment health.
3) After the unit finishes running each time, the system automatically updates the health evaluation result according to the running condition.
B. Since many symbols are involved in the health assessment algorithm, the symbols are interpreted as follows:
1)Arotating wheel: reading by a runner chamber vibration sensor; taking the average value of the maximum values of all measuring points in the operation process;
2)Aothers: reading by other vibration sensors;
3) b: reading by a swing sensor;
4)Cstator: reading of a three-phase temperature sensor of a motor stator; taking the maximum value in the operation process;
5)Cothers: other temperature sensor readings;
6) d: pressure pulsation sensor readings;
7) e: noise sensor readings;
8) an: the vibration sensor reading numbered n;
9) max [ An ]: the vibration sensor with the number of n # acquires the maximum effective numerical value in the running process just finished;
10) apj: the arithmetic mean of max [ An ] for all vibration sensors;
11) a0: a vibration alarm threshold value;
12) a1: a vibration accident shutdown threshold;
13) k: and under different working conditions, the range of stable operation is achieved. Namely, the average vibration amplitude A of the runner chamber is close to the average vibration amplitude A under different working conditions. K ═ max { A-Low lift of runner/AMiddle lift of runner、ALow lift of runner/AMaximum lift of runner、AMiddle lift of runner/AMaximum lift of runner、AMiddle lift of runner/ALow lift of runner、AMaximum lift of rotating wheelProgram for programming/AMinimum lift of runner、AMaximum lift of runner/AMiddle lift of runner}; the maximum, minimum and middle lift refer to the lift during the operation;
14) p: under the design operating mode (when measuring the lift be the design lift), the specific value size of actual measurement flow and design flow. 100-Measured in fact/QDesign ofIf Q isMeasured in fact/QDesign ofLess than 1, P is positive. If QMeasured in fact/QDesign ofIf greater than 1, P is negative; if the operation does not reach the design lift, QDesign ofTaking the maximum flow in all the units started at this time;
15) m month number of most recent major repair
16) N number of failures occurred in the latest overhaul
17) S number of unresolved faults
18) T is the running time of the previous overhaul to the present (directly dividing by 1000 in calculation);
19) f: health assessment score
C: evaluation calculation
1) The value without any sensor exceeds the alarm threshold value:
the score calculation formula is as follows: F-100-K-P- [ (A)Rotating wheel/A0)×10％+(Apj/A0)×10％+(Bpj/B0)×25％+(CStator/C0)×10％+(Cpj/C0)×20％+(Dpj/D0)×15％+(Epj/E0)×10％]×20-M/10-N-10×S-T/1000
Wherein:
Arotating wheelThe numerical value of the maximum value of each vibration measuring point on the rotating wheel in the running process is indicated;
CstatorThe swing Bpj and the noise Epj also take the maximum value;
the other values Apj, Cpj, and Dpj are averaged to obtain the maximum value.
2) When the value of the sensor exceeds the alarm value but does not reach the accident shutdown value:
the score calculation formula is as follows: f ═ 80-K-P- [ (A)Rotating wheel/A0)×10％+(Apj/A1)×10％+(Bpj/B1)×25％+(CStator/C0)×10％+(Cpj/C1)×20％+(Dpj/D1)×15％+(Epj/E1)×10％]×20-M/10-N-10×S-T/1000
In this case, the score is lower than 80 points.
3) When the sensor value exceeds the value of the accident shutdown:
the score calculation formula is as follows: 60-K-P- [ (A)Rotating wheel/A0)×10％+(Apj/A1)×10％+(Bpj/B1)×25％+(CStator/C0)×10％+(Cpj/C1)×20％+(Dpj/D1)×15％+(Epj/E1)×10％]×20-M/10-N-10×S-T/1000
In this case, the score is less than 60 points.
The meaning of calculating the final score range is defined as follows:
85-100 parts: good effect
70-85 min: can be used
60-70 parts: abnormality (S)
60 points are as follows: need to be stopped
According to the final score range, the health assessment result of the pump station unit is divided into: good (green), available (orange), abnormal (yellow), shut down required (red).
In addition to the above embodiments, the present invention also includes other embodiments, and any technical solutions formed by equivalent transformation or equivalent replacement should fall within the scope of the claims of the present invention.
Claims (4)
1. A method based on pump station unit health assessment is characterized in that: the method comprises the steps of firstly, establishing a network system overall architecture of a data acquisition front end combination monitoring network and remote diagnosis according to the health assessment requirement of the pump station unit, wherein the network system overall architecture comprises a sensing layer, a network layer and an application layer, then acquiring corresponding data of the pump station unit according to a data acquisition device of the sensing layer, sending the acquired data to a server of the application layer through the network layer, judging whether data analysis and fault diagnosis are needed or not after comparing the acquired data with a preset alarm threshold value, and finally issuing a diagnosis result.
2. The pump station unit health assessment based method according to claim 1, wherein: the server of the application layer stores, analyzes and manages real-time data, historical data and various characteristic value data transmitted from each data acquisition device, analyzes and diagnoses the data and faults, namely, health assessment is carried out, firstly, assessment factors are taken according to actual conditions, weight division is carried out on the factors, a scoring system is established according to the weight division of the factors, scoring is carried out according to assessment calculation rules, the higher the score is, the better the health condition of equipment is, and after the unit finishes running each time, the system automatically carries out better health assessment results according to running conditions.
3. The pump station unit health assessment based method according to claim 2, wherein: the evaluation calculation rule includes:
1) the value of no sensor exceeds the alarm threshold value
The score calculation formula is as follows: f ═ PE-K-P- [ (A)Rotating wheel/A0)×10％+(Apj/A0)×10％+(Bpj/B0)×25％+(CStator/C0)×10％+(Cpj/C0)×20％+(Dpj/D0)×15％+(Epj/E0)×10％]×20-M/10-N-10×S-T/1000
2) When the value of the sensor exceeds the alarm value but does not reach the accident shutdown value:
the score calculation formula is as follows: f ═ PE1-K-P- [ (a)Rotating wheel/A0)×10％+(Apj/A1)×10％+(Bpj/B1)×25％+(CStator/C0)×10％+(Cpj/C1)×20％+(Dpj/D1)×15％+(Epj/E1)×10％]×20-M/10-N-10×S-T/1000
In this case, the score is lower than M1;
3) when the sensor value exceeds the value of the accident shutdown:
the score calculation formula is as follows: f ═ PE2-K-P- [ (a)Rotating wheel/A0)×10％+(Apj/A1)×10％+(Bpj/B1)×25％+(CStator/C0)×10％+(Cpj/C1)×20％+(Dpj/D1)×15％+(Epj/E1)×10％]×20-M/10-N-10×S-T/1000
In this case, the score is lower than M2;
wherein:
Arotating wheel: reading by a runner chamber vibration sensor; taking the average value of the maximum values of all measuring points in the operation process;
Aothers: reading by other vibration sensors;
b: reading by a swing sensor;
Cstator: reading of a three-phase temperature sensor of a motor stator; taking the maximum value in the operation process;
Cothers: other temperature sensor readings;
d: pressure pulsation sensor readings;
e: noise sensor readings;
an: the vibration sensor reading numbered n;
max [ An ]: the vibration sensor with the number of n # acquires the maximum effective numerical value in the running process just finished;
apj, Cpj, Dpj, Epj: the arithmetic mean of max [ An ] for all vibration sensors;
a0: a vibration alarm threshold value;
a1: a vibration accident shutdown threshold;
k: under different working conditions, the stable operation range is obtained, namely whether the average vibration amplitude A of the runner chamber is close to that under different working conditions is compared; k ═ max { A-Low lift of runner/AMiddle lift of runner、ALow lift of runner/AMaximum lift of runner、AMiddle lift of runner/AMaximum lift of runner、AMiddle lift of runner/ALow lift of runner、AMaximum lift of runner/AMinimum lift of runner、AMaximum lift of runner/AMiddle lift of runner}; the maximum, minimum and middle lift refer to the lift during the operation;
p: under the design condition, namely when the measured lift is the design lift, the ratio of the measured flow to the design flow is large, and P is 100-Measured in fact/QDesign ofIf Q isMeasured in fact/QDesign ofIf less than 1, P is positive value; if QMeasured in fact/QDesign ofIf greater than 1, P is negative; if the operation does not reach the design lift, QDesign ofTaking the maximum flow in all the units started at this time;
m is the number of months of the last major revision;
n is the number of faults which have occurred up to now in the latest overhaul;
s, the number of unsolved faults;
t is the running time of the previous overhaul till now;
f: a health assessment score;
PE, PE1, PE 2: upper score limit for each stage.
4. The pump station unit health assessment based method according to claim 3, wherein: the server acquires the numerical value of the corresponding measuring point through the receiving data acquisition device, and expresses the current alarm state of the measuring point by combining the change among different colors:
when there is no data, the background color of the data display area is gray;
when the data is in the normal range, the background color will change to green, i.e. normal;
when the numerical value of the vibration data exceeds the alarm threshold, the color of the background is changed into yellow, namely, the background is reported;
when the value of the vibration data exceeds the danger threshold, the background color changes to red, i.e., a high report.
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| CN115204588A (en) * | 2022-06-08 | 2022-10-18 | 欣皓创展信息技术有限公司 | Water pump comprehensive health state assessment method introducing weight factors |
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