CN111314463A - Pump station unit health assessment based method - Google Patents

Abstract

The invention relates to a method based on health assessment of pumping station units. First, according to the requirements of the health assessment of pumping station units, an overall architecture of a network system with a data acquisition front end combined with a monitoring network and remote diagnosis is established, including a perception layer, a network layer and an application layer, Then, the corresponding data of the pumping station unit is collected according to the data collection device of the perception layer, and the collected data is sent to the server of the application layer through the network layer. According to the comparison between the collected data and the preset alarm threshold value, it is judged whether to carry out the data. Analysis and fault diagnosis, and finally publish the diagnosis results. The invention further analyzes the monitoring results of the pumping station unit by comprehensively collecting data parameters such as vibration, swing, ambient temperature, etc., and objectively evaluates the health status of the pumping station unit, so as to ensure the normal operation of the pumping station unit and prolong its use to the maximum extent. life, thereby reducing costs.

Description

A Method Based on Health Assessment of Pumping Station Units

technical field

The invention relates to the technical field of intelligent operation and maintenance, in particular to a method based on health assessment of pump station units.

Background technique

Traditional pump station maintenance personnel use four methods of "look, smell, touch and listen" to carry out daily inspections of unit equipment. It can be seen that the traditional daily inspections have great limitations. If the equipment failures usually found have arrived In the end, it is irreparable. At this time, only experienced maintenance personnel can do it, and the traditional maintenance method is also regularly inspected, replaced and repaired. In view of the problems existing in the management of traditional pumping station units, the pumping station unit Full life cycle management and health assessment are defined as follows:

Full life cycle management: The whole process of the unit equipment from the start of use, to the aging and wear of the equipment, or even being unable to continue to be put into use, the equipment can be managed during the whole process, and every link of the equipment life cycle (such as the initial stage of the equipment) can be managed. Management of design defects, management of information and materials such as bumps during transportation, data management of installation process, data management of operation process, and management of equipment maintenance and replacement), maximize equipment life and reduce costs.

Health assessment: Through real-time monitoring of the operating status of the equipment of the pumping station, the health status of the equipment can be grasped in real time, so that when there is an abnormality in the equipment, major events can be avoided due to equipment failure, thereby reducing production costs.

SUMMARY OF THE INVENTION

The technical problem to be solved by the present invention is to provide a method based on the health assessment of the pumping station unit in view of the above-mentioned prior art, so as to ensure the normal operation of the pumping station unit, maximize its service life and reduce the cost.

The technical scheme adopted by the present invention to solve the above problems is as follows: a method for health assessment based on the whole life cycle management of pumping station units. First, according to the requirements of the whole life cycle management and health assessment of pumping station units, a data acquisition front-end combined monitoring network is established. And the overall architecture of the network system for remote diagnosis, including the perception layer, the network layer and the application layer, and then collect the corresponding data of the pumping station unit according to the data acquisition device of the perception layer, and send the collected data to the server of the application layer through the network layer. The received data is compared with the preset alarm threshold value to determine whether to perform data analysis and fault diagnosis, and finally publish the diagnosis results.

Preferably, the server at the application layer stores, analyzes, and manages the real-time data, historical data and various characteristic value data transmitted from each data acquisition device, and analyzes and diagnoses the data, that is, performs health assessment. Evaluate factors, divide the weights of each factor, establish a scoring system according to the weighting of each factor, and score according to the evaluation calculation rules. The higher the score, the better the health of the equipment. It will automatically update its health evaluation results.

Preferably, the evaluation calculation rules include:

1) No sensor value exceeds the alarm threshold

Scoring formula: F=PE-KP-[(A _runner /A0)×10%+(Apj/A0)×10%+(Bpj/B0)×25%+(C _stator /C0)×10%+ (Cpj/C0)×20%+(Dpj/D0)×15%+(Epj/E0)×10%]×20-M/10-N-10×ST/1000

2) When the sensor value exceeds the alarm value, but does not reach the accident shutdown value:

Scoring formula: F=PE1-KP-[(A _runner /A0)×10%+(Apj/A1)×10%+(Bpj/B1)×25%+(C _stator /C0)×10%+ (Cpj/C1)×20%+(Dpj/D1)×15%+(Epj/E1)×10%]×20-M/10-N-10×ST/1000

In this case, the score is lower than M1;

3) When the sensor value exceeds the value of accident shutdown:

Scoring formula: F=PE2-KP-[(A _runner /A0)×10%+(Apj/A1)×10%+(Bpj/B1)×25%+(C _stator /C0)×10%+ (Cpj/C1)×20%+(Dpj/D1)×15%+(Epj/E1)×10%]×20-M/10-N-10×ST/1000

In this case, the score is lower than M2;

in:

A _runner : the reading of the vibration sensor in the runner chamber; take the average value of the maximum values of each measuring point during this operation;

A _Others : other parts of the vibration sensor readings;

B: Swing sensor reading;

C _stator : the reading of the three-phase temperature sensor of the motor stator; take the maximum value during this operation;

C _other : other temperature sensor readings;

D: pressure pulsation sensor reading;

E: Noise sensor reading;

An: the reading of the vibration sensor numbered n;

max[An]: The maximum valid value collected by the vibration sensor numbered n# during the just-ended operation;

Apj: arithmetic mean of max[An] of all vibration sensors;

A0: Vibration alarm threshold value;

A1: Vibration accident shutdown threshold;

K: The range of stable operation under different working conditions, that is, whether the average vibration amplitude A of the runner chamber is close _to each other under different working conditions; K=max{A _{runner low head} /A _{runner middle head} , A runner _{Wheel low lift} /A _{runner maximum lift} , A _{wheel middle lift} /A _{wheel maximum lift} , A _{wheel middle lift} /A _{wheel low lift} , A _{wheel maximum lift} /A _{wheel minimum lift} , A _{wheel maximum} lift _Head /A _{runner intermediate head} }; the maximum, minimum and intermediate head refer to the head during this operation;

P: Under the design condition, that is, when the measured head = the design head, the ratio of the measured flow to the design flow, P=100-100*Q _measured /Q _design , if Q _measured /Q _design is less than 1, then P is positive value; if Q _measured /Q _design is greater than 1, then P is a negative value; if this operation does not reach the design head, then Q _design will take the maximum flow rate among all units that are powered on this time;

M: The number of months since the last major overhaul;

N: The number of faults that have occurred since the last major overhaul;

S: the number of unresolved failures;

T: The running time since the previous overhaul;

F: health assessment score;

PE, PE1, PE2: The upper limit of each stage's score.

Preferably, the server collects the numerical value of the corresponding measuring point by receiving the data acquisition device, and expresses the current alarm state of the measuring point in combination with the change between 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, that is, normal;

When the value of the vibration data exceeds the alarm threshold, the background color will change to yellow, that is, a high alarm;

When the value of the vibration data exceeds the danger threshold, the background color will change to red, that is, high alarm.

Compared with the prior art, the advantages of the present invention are:

The invention realizes the monitoring of the online running status of the pumping station unit by relying on the computer monitoring system. The management of the pumping station unit equipment should start from the planning and purchasing of the equipment, and manage the equipment comprehensively and reasonably in the whole process until the equipment is scrapped and loses its use value. On the other hand, by comprehensively collecting data parameters such as vibration, swing, ambient temperature and other data parameters to further analyze the monitoring results of the pumping station unit, objectively evaluate the health status of the pumping station unit, so as to ensure the normal operation of the pumping station unit and maximize the extension of time. its service life, thereby reducing costs.

Description of drawings

FIG. 1 is an overall architecture diagram of a network system based on health assessment of pumping station units in an embodiment of the present invention.

Detailed ways

The present invention will be further described in detail below with reference to the embodiments of the accompanying drawings.

A method based on the health assessment of the pumping station unit in this embodiment mainly includes the following contents:

1. Building a network structure

In view of the needs of the whole life cycle management and health assessment of pumping station units, combined with "Internet +" technology, the overall network system architecture of data acquisition front-end combined with monitoring network and remote diagnosis is proposed. The whole system consists of perception layer, network layer and application layer. Among them, the perception layer realizes the intelligent perception, 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 the network layer can rely on the public telecommunication network and the Internet. The application layer includes application infrastructure, middleware and corresponding applications. The overall structure of the pumping station is divided into three parts: data acquisition front end and remote diagnosis center. The network structure of the whole life cycle monitoring management and health assessment of the host group is shown in Figure 1.

1) The data acquisition device of each unit in the pump station is responsible for collecting the vibration, swing and pressure signals of the pump station unit.

2) The WEB server is used to store, analyze and manage the real-time data, historical data and various characteristic value data transmitted from each data acquisition device, analyze and diagnose the data, and publish the data.

The WEB server collects the value of the corresponding measuring point by receiving the data acquisition device, and in the background of the system, you can set the measuring point for the desired alarm prompt. Generally, it depends on whether the data of this object will have any impact after reaching a certain level. If it feels affected, the alarm will be turned on, and the corresponding alarm limit value will be set. For example, if the noise reaches a certain value, there may be a problem with a certain hardware. At this time, you can set the alarm threshold value, and when it exceeds, it will alarm. It acts as a reminder to the staff, and at the same time combines the changes between different colors to express the current alarm state of the measuring point:

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, that is, normal;

When the value of the vibration data exceeds the alarm threshold, the background color will change to yellow, that is, a high alarm;

When the value of the vibration data exceeds the danger threshold, the background color will change to red, that is, high alarm.

2. Health assessment

A. Health assessment needs to involve the weight of each factor and score each factor. Because the factors for health assessment do not have to be the same, the factors can be selected according to the actual situation. The general rules are as follows:

1) The weight division of each factor (percentage, 100% in total): 10% weight of runner chamber vibration index, 10% weight of other vibration index, 25% weight of swing index, 10% weight of stator temperature index, 20% weight of other temperature index , the weight of the pressure pulsation index is 15%, and the weight of the noise index is 10%.

2) Scored on a 100-point scale, with a full score of 100. The higher the score, the better the device health.

3) After each operation of the unit, the system will automatically update its health evaluation results according to the operation conditions.

B. Because there are many symbols involved in the health assessment algorithm, the symbols are explained as follows:

1) A _runner : the reading of the vibration sensor in the runner chamber; take the average value of the maximum values of each measuring point during this operation;

2) A _other : other parts of the vibration sensor readings;

3) B: Swing sensor reading;

4) C _stator : the reading of the three-phase temperature sensor of the motor stator; take the maximum value during this operation;

5) C _other : other temperature sensor readings;

6) D: pressure pulsation sensor reading;

7) E: noise sensor reading;

8) An: the reading of the vibration sensor numbered n;

9) max[An]: the maximum valid value collected by the vibration sensor numbered n# during the operation process just ended;

10) Apj: the arithmetic mean of max[An] of all vibration sensors;

11) A0: Vibration alarm threshold;

12) A1: Vibration accident shutdown threshold;

13) K: The range of stable operation under different working conditions. That is to compare whether the average vibration amplitude A of the runner chamber is close to each other under different working conditions. K=max{A _{runner low lift} /A _{runner middle lift} , A _{runner low lift} /A _{runner maximum lift} , A _{runner middle lift} /A _{runner maximum lift} , A _{runner middle lift} /A _{runner low Head} , _{maximum lift} of _{runner A/minimum lift} of _{runner A, maximum lift} of runner A/ _{intermediate lift} of runner A}; the maximum, minimum and middle lifts refer to the lift during this operation;

14) P: The ratio of the measured flow to the design flow under the design condition (when the measured head = the design head). P=100-100*Q _{actual measurement} /Q _design , if Q _{actual measurement} /Q _design is less than 1, then P is a positive value. If Q _measured /Q _design is greater than 1, then P is a negative value; if this operation does not reach the design head, then Q _design will take the largest flow rate among all units that are powered on this time;

15) M: The number of months since the last major overhaul

16) N: The number of failures that have occurred since the last major overhaul

17) S: Number of unresolved failures

18) T: The running time since the previous overhaul (directly divided by 1000 when calculating);

19) F: Health Assessment Score

C: Evaluation calculation

1) No sensor value exceeds the alarm threshold:

Scoring formula: F=100-KP-[(A _runner /A0)×10%+(Apj/A0)×10%+(Bpj/B0)×25%+(C _stator /C0)×10%+ (Cpj/C0)×20%+(Dpj/D0)×15%+(Epj/E0)×10%]×20-M/10-N-10×ST/1000

in:

A _runner refers to the maximum value of each vibration measuring point on the runner during this operation;

C _stator , swing Bpj and noise Epj also take the maximum value;

Other Apj, Cpj, Dpj take the average of the maximum values.

2) When the sensor value exceeds the alarm value, but does not reach the accident shutdown value:

Scoring formula: F=80-KP-[(A _runner /A0)×10%+(Apj/A1)×10%+(Bpj/B1)×25%+(C _stator /C0)×10%+ (Cpj/C1)×20%+(Dpj/D1)×15%+(Epj/E1)×10%]×20-M/10-N-10×ST/1000

In this case, the score is less than 80 points.

3) When the sensor value exceeds the value of accident shutdown:

Scoring formula: F=60-KP-[(A _runner /A0)×10%+(Apj/A1)×10%+(Bpj/B1)×25%+(C _stator /C0)×10%+ (Cpj/C1)×20%+(Dpj/D1)×15%+(Epj/E1)×10%]×20-M/10-N-10×ST/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 points: good

70-85 points: Available

60-70 points: abnormal

Below 60 minutes: stop

According to the above final score range, the health assessment results of pumping station units are divided into: good (green), available (orange), abnormal (yellow), and need to be shut down (red).

In addition to the above-mentioned embodiments, the present invention also includes other embodiments, and all technical solutions formed by equivalent transformation or equivalent replacement shall fall within the protection scope of the claims of the present invention.

Claims (4)

1. a method based on pumping station unit health assessment, is characterized in that: at first according to the demand of pumping station unit health assessment, establish the overall architecture of the network system of data acquisition front end in conjunction with monitoring network and remote diagnosis, including perception layer, network layer and The application layer, and then collect the corresponding data of the pumping station unit according to the data acquisition device of the perception layer, send the collected data to the server of the application layer through the network layer, and judge whether the collected data is compared with the preset alarm threshold value. To carry out data analysis and fault diagnosis, and finally publish the diagnosis results. 2. a kind of method based on pumping station unit health assessment according to claim 1, is characterized in that: the server of application layer stores, analyzes, manages real-time data, historical data and various features that are transmitted from each data acquisition device Value data, analyze the data and diagnose faults, that is, conduct health assessment. First, take the assessment factors according to the actual situation, and divide the weights of each factor. According to the weight division of each factor, a scoring system is established, and the scores are scored according to the evaluation calculation rules. The higher the value, the better the health of the equipment. After each unit ends its operation, the system will automatically update its health evaluation results according to the operating conditions. 3. a kind of method based on pumping station unit health assessment according to claim 2, is characterized in that: described assessment calculation rule comprises: 1) No sensor value exceeds the alarm threshold Scoring formula: F=PE-KP-[(A _runner /A0)×10%+(Apj/A0)×10%+(Bpj/B0)×25%+(C _stator /C0)×10%+ (Cpj/C0)×20%+(Dpj/D0)×15%+(Epj/E0)×10%]×20-M/10-N-10×ST/1000 2) When the sensor value exceeds the alarm value, but does not reach the accident shutdown value: Scoring formula: F=PE1-KP-[(A _runner /A0)×10%+(Apj/A1)×10%+(Bpj/B1)×25%+(C _stator /C0)×10%+ (Cpj/C1)×20%+(Dpj/D1)×15%+(Epj/E1)×10%]×20-M/10-N-10×ST/1000 In this case, the score is lower than M1; 3) When the sensor value exceeds the value of accident shutdown: Scoring formula: F=PE2-KP-[(A _runner /A0)×10%+(Apj/A1)×10%+(Bpj/B1)×25%+(C _stator /C0)×10%+ (Cpj/C1)×20%+(Dpj/D1)×15%+(Epj/E1)×10%]×20-M/10-N-10×ST/1000 In this case, the score is lower than M2; in: A _runner : the reading of the vibration sensor in the runner chamber; take the average value of the maximum values of each measuring point during this operation; A _Others : other parts of the vibration sensor readings; B: Swing sensor reading; C _stator : the reading of the three-phase temperature sensor of the motor stator; take the maximum value during this operation; C _other : other temperature sensor readings; D: pressure pulsation sensor reading; E: Noise sensor reading; An: the reading of the vibration sensor numbered n; max[An]: The largest valid value collected by the vibration sensor numbered n# during the just-ended operation; Apj, Cpj, Dpj, Epj: arithmetic mean of max[An] of all vibration sensors; A0: Vibration alarm threshold value; A1: Vibration accident shutdown threshold; K: The range of stable operation under different working conditions, that is, whether the average vibration amplitude A of the runner chamber is close _to each other under different working conditions; K=max{A _{runner low head} /A _{runner middle head} , A runner _{Wheel low lift} /A _{runner maximum lift} , A _{wheel middle lift} /A _{wheel maximum lift} , A _{wheel middle lift} /A _{wheel low lift} , A _{wheel maximum lift} /A _{wheel minimum lift} , A _{wheel maximum} lift _Head /A _{runner intermediate head} }; the maximum, minimum and intermediate head refer to the head during this operation; P: Under the design condition, that is, when the measured head = the design head, the ratio of the measured flow to the design flow, P=100-100*Q _measured /Q _design , if Q _measured /Q _design is less than 1, then P is positive value; if Q _measured /Q _design is greater than 1, then P is a negative value; if this operation does not reach the design head, then Q _design will take the maximum flow rate among all units that are powered on this time; M: The number of months since the last major overhaul; N: The number of faults that have occurred since the last major overhaul; S: the number of unresolved failures; T: The running time since the previous overhaul; F: health assessment score; PE, PE1, PE2: The upper limit of each stage's score. 4. a kind of method based on pumping station unit health assessment according to claim 3, is characterized in that: the server collects the numerical value of corresponding measuring point by receiving data acquisition device, and expresses this measuring point current in conjunction with the change between different colors The alarm status of: 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, that is, normal; When the value of the vibration data exceeds the alarm threshold, the background color will change to yellow, that is, a high alarm; When the value of the vibration data exceeds the danger threshold, the background color will change to red, that is, high alarm.

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