CN111473966B - Rotary machine fault diagnosis method and system applied to process industry - Google Patents
Rotary machine fault diagnosis method and system applied to process industry Download PDFInfo
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Abstract
The embodiment of the invention provides a rotary machine fault diagnosis method and a rotary machine fault diagnosis system applied to process industry, wherein the method comprises the following steps: acquiring real complete data of a target rotating machine; carrying out vibration rating on the real complete data to obtain a rating result; when the rating result meets a preset standard, fault diagnosis is carried out on the real complete data by utilizing a fault rule packet to obtain a fault type result; calculating the reliability value of the fault type result according to the reliability weight corresponding to the fault type; and outputting the equipment type, the fault type result and the reliability value of the target rotating machine, selecting corresponding suggestion information from a database for displaying, analyzing the running state of the equipment in real time by using the vibration and process quantity data of the equipment, and giving a conclusion suggestion in time when the equipment fails. The problem of scarcity of fault diagnosis personnel in the process industry is solved, the manual 24-hour attendance is replaced, and the alarm and conclusion suggestion can be given when the typical fault occurs.
Description
Technical Field
The embodiment of the invention relates to the technical field of industrial equipment, in particular to a fault diagnosis method and system for a rotary machine applied to process industry.
Background
At present, fault diagnosis of the process industry mainly depends on fault diagnosis personnel for manual analysis, but professional fault diagnosis personnel have scarce resources, technical personnel have different levels, and conclusion accuracy and timeliness are difficult to guarantee. The process industrial equipment is not stopped for 24 hours, a plurality of faults occur at night, and the manual work is difficult to monitor for 24 hours.
Therefore, how to provide a fault diagnosis scheme for a rotary machine applied to the process industry, which can analyze the operation state of equipment in real time, and when the equipment fails, a conclusion suggestion can be given in time, is a technical problem to be solved urgently by those skilled in the art.
Disclosure of Invention
Therefore, the embodiment of the invention provides a rotary machine fault diagnosis method and system applied to the process industry, which can analyze the running state of equipment in real time and can give a conclusion suggestion in time when the equipment fails.
In order to achieve the above object, the embodiments of the present invention provide the following technical solutions:
in a first aspect, an embodiment of the present invention provides a method for diagnosing a fault of a rotating machine applied to a process industry, including:
acquiring real complete data of a target rotating machine;
carrying out vibration rating on the real complete data to obtain a rating result;
when the rating result meets a preset standard, fault diagnosis is carried out on the real complete data by utilizing a fault rule packet to obtain a fault type result;
calculating the reliability value of the fault type result according to the reliability weight corresponding to the fault type;
and outputting the equipment type, the fault type result and the reliability value of the target rotating machine, and selecting corresponding suggestion information from a database for displaying.
Preferably, the acquiring true complete data of the target rotating machine includes:
selecting a target rotating machine and a data time period T;
judging whether a rotation speed value, a Gap value, a vibration value, a phase value, Nc1 and a H, HH value exist in the target rotating machine in the data time period T;
if all the data time period values exist, continuously judging whether the data time period values are in a preset range or not, and the number of the data points is larger than a first preset number; if not, prompting to reselect a data time period T, wherein the number of data points is larger than a first preset number;
if so, judging whether the rotating speed value of the target rotating machine is greater than a preset rotating speed, and if the rotating speed value is less than preset data, prompting to select data with the rotating speed value above the preset rotating speed;
if the rotating speed value is larger than the preset data, judging whether all the channels Gap are in the preset range, if not, prompting that the sensor system is abnormal, and ending; if yes, taking the rotating speed value, the Gap value, the vibration value, the phase value, the Nc1 value and the H, HH value in the data time period T as real complete data; where NC1 is the first order critical speed of the rotor; h is the unit high report; HH is the unit interlock value; the Gap value is the sensor Gap voltage.
Preferably, the performing vibration rating on the real complete data to obtain a rating result includes:
the real complete data is firstly evaluated in three aspects of maximum pass frequency amplitude, frequency distribution and fluctuation dimensionality, and 3 conditions of normal, mild and severe evaluation results are obtained;
specifically, when the pass frequency is not greater than a, the output is normal; when the pass frequency is between A and 2.5A, the output is light; when the pass frequency is more than 2.5A, the output is serious;
when the 1X is more than or equal to 0.5 times of the pass frequency, the output is normal, and when the 1X is less than 0.5 times of the pass frequency, the output is light;
starting fluctuation dimension judgment when the rotation speed change is less than 500rpm, and specifically, if the pass frequency value, 1X, 2X, 0.5X and the fluctuation range vibration of the residual amount are 7 μm and the phase is below 10 degrees, outputting normally; if the pass frequency value, 1X, 2X, 0.5X and the fluctuation range vibration of the residual amount are more than 7 μm and less than 20 μm, and the phase is less than 10 degrees, the output is light; if the pass frequency value, 1X, 2X, 0.5X, the fluctuation range vibration of the residual quantity is more than 20 μm, and the phase change is more than 10 degrees, the output is serious; wherein, 1X, 0.5X, 2X refers to 1 frequency doubling, 0.5 frequency doubling, 2 frequency doubling of vibration.
Preferably, when the rating result meets a preset standard, performing fault diagnosis on the real complete data by using a fault rule package to obtain a fault type result, including:
running the key factors of each fault rule packet to detect the real complete data;
and if the real complete data does not meet the key factors of any fault rule packet, the corresponding fault type is judged, and if the real complete data does not meet the key factors of any fault rule packet, equipment information is sent by a background, a fault time interval is manually diagnosed for a diagnosis engineer, and a diagnosis result is manually output.
Preferably, the fault rule package is an unbalanced fault rule package; specifically, the method comprises the following steps: key factors, cofactors;
the key factors are as follows:
1. the rotation speed range of nc1 which is 0.5-1 time within the selected time period; the selected time period is a data time period which a user wants to analyze;
2. in the selected time period, the power frequency of at least 2 channels on one side is in direct proportion to the square of the rotating speed within the range of nc1 which is 0.5-1 time of the rotating speed, nc1 is the first-order critical rotating speed of the rotor of the equipment, and a manual input way is provided;
3. at least 2 channels on one side have a high reporting value A of more than 0.8 times of power frequency vibration within the range of +/-20% of the critical rotating speed of the rotor; wherein A is a standard value given by human;
the above 3 key factors must all be satisfied, and 60% of basic weight is obtained;
cofactor:
1. in the selected time interval, the rotating speed is higher than nc1, the vibration frequency power frequency of at least 2 channels on one side is larger than C, and the vibration frequency power frequency is kept for 30min or more, wherein C is
n is the working rotating speed of the rotor or the manual setting; 10% of a compound of formula;
2. within a selected time period, the rotating speed is more than nc 130 min or more, when the rotating speed fluctuation is less than 100rpm, the power frequency phase changes within 10 DEG, and the proportion is 7%
3. In the selected time period, every 1 vibration channel is added to the fault equipment to meet the requirement of a key factor of 5 percent;
4. 2 channels of the equipment vibrate to trigger a high altitude alarm at the startup and shutdown stage, and the high altitude alarm is 10 percent
5. An axis locus ellipse at the maximum vibration moment in the selected time interval is 3 percent;
6. the whirling direction of the rotor does not change in a selected time interval, and is 1 percent;
and each time the auxiliary factor satisfies 1 strip, increasing the corresponding weight.
Preferably, the fault rule packet is a broken blade fault rule packet; specifically, the method comprises the following steps: key factors, cofactors;
the key factors are as follows:
1. the change of at least 2 channels of the selected equipment in a selected time period within 4s exceeds 10 mu m, and the change time interval of the 2 channels is less than 4 s;
2. the change of at least 2 channels of the selected equipment in the selected time period power frequency phase within 4s exceeds 10 degrees, and the change time interval of the 2 channels is less than 4 s;
3. the interval between the occurrence time of 1 and 2 is less than 4 s;
4. within 5min before 1 and 2, the change of the rotating speed is less than 100 rpm;
the above 4 key factors must all be satisfied, and 60% of basic weight is obtained;
cofactor:
1. in the selected time period, every 1 vibration channel is added to the fault equipment to meet the requirement of a key factor of-10%;
2. the fluctuation within 30min after the power frequency change is less than 7 mu m < - > - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10 percent;
3. the phase fluctuation within 30min after the power frequency phase change is less than 10 DEG-10%;
4. the whirling direction of the rotor does not change in a selected time interval, and the value of the whirling direction is 5 percent;
and each time the auxiliary factor satisfies 1 strip, increasing the corresponding weight.
In a second aspect, an embodiment of the present invention provides a rotary machine fault diagnosis system applied to process industry, including:
the data acquisition module is used for acquiring real complete data of the target rotating machine;
the vibration rating module is used for carrying out vibration rating on the real complete data to obtain a rating result;
the fault type diagnosis module is used for carrying out fault diagnosis on the real complete data by utilizing a fault rule packet when the rating result meets a preset standard so as to obtain a fault type result;
the credibility calculation module is used for calculating the credibility value of the fault type result according to the credibility weight corresponding to the fault type;
and the result output module is used for outputting the equipment type, the fault type result and the reliability value of the target rotating machine and selecting corresponding suggestion information from a database for displaying.
Preferably, the data acquisition module includes:
a time period selection unit for selecting a target rotating machine and a data time period T;
a complete determination unit, configured to determine whether a rotation speed value, a Gap value, a vibration value, a phase value, and Nc1, H, HH values exist in the data time period T of the target rotary machine;
the quantity judging unit is used for continuously judging whether the data time period value is in a preset range or not if all the data time period value exists, and the quantity of the data points is greater than a first preset quantity; if not, prompting to reselect a data time period T, wherein the number of data points is larger than a first preset number;
the rotating speed judging unit is used for judging whether the rotating speed value of the target rotating machinery is greater than a preset rotating speed or not if the rotating speed value is greater than the preset rotating speed, and prompting to select data with the rotating speed value greater than the preset rotating speed if the rotating speed value is less than preset data;
the sensing judgment unit is used for judging whether all the channels Gap are in a preset range or not if the rotating speed value is larger than preset data, and prompting that a sensor system is abnormal and ending if not; if yes, taking the rotating speed value, the Gap value, the vibration value, the phase value, the Nc1 value and the H, HH value in the data time period T as real complete data; where NC1 is the first order critical speed of the rotor; h is the unit high report; HH is the unit interlock value; the Gap value is the sensor Gap voltage.
In a third aspect, an embodiment of the present invention provides a rotary machine fault diagnosis device applied to a process industry, including:
a memory for storing a computer program;
a processor for implementing the steps of the method for diagnosing faults of a rotating machine applied to the process industry as described in any one of the above first aspects when the computer program is executed.
In a fourth aspect, an embodiment of the present invention provides a computer-readable storage medium, on which a computer program is stored, where the computer program, when executed by a processor, implements the steps of the method for diagnosing a fault of a rotating machine applied to the process industry as described in any one of the first aspect.
The embodiment of the invention provides a fault diagnosis method of a rotating machine applied to process industry, which comprises the following steps: acquiring real complete data of a target rotating machine; carrying out vibration rating on the real complete data to obtain a rating result; when the rating result meets a preset standard, fault diagnosis is carried out on the real complete data by utilizing a fault rule packet to obtain a fault type result; calculating the reliability value of the fault type result according to the reliability weight corresponding to the fault type; and outputting the equipment type, the fault type result and the reliability value of the target rotating machine, selecting corresponding suggestion information from a database for displaying, analyzing the running state of the equipment in real time by using the vibration and process quantity data of the equipment, and giving a conclusion suggestion in time when the equipment fails. The problem of scarcity of fault diagnosis personnel in the process industry is solved, the manual 24-hour attendance is replaced, and the alarm and conclusion suggestion can be given when the typical fault occurs.
The rotating machine fault diagnosis system applied to the process industry provided by the embodiment of the invention also has the beneficial effects, and details are not repeated herein.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below. It should be apparent that the drawings in the following description are merely exemplary, and that other embodiments can be derived from the drawings provided by those of ordinary skill in the art without inventive effort.
The structures, ratios, sizes, and the like shown in the present specification are only used for matching with the contents disclosed in the specification, so as to be understood and read by those skilled in the art, and are not used to limit the conditions that the present invention can be implemented, so that the present invention has no technical significance, and any structural modifications, changes in the ratio relationship, or adjustments of the sizes, without affecting the effects and the achievable by the present invention, should still fall within the range that the technical contents disclosed in the present invention can cover.
FIG. 1 is a flow chart of a method for fault diagnosis of a rotating machine for use in the process industry according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of a fault diagnosis system for a rotary machine applied in the process industry according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a fault diagnosis system for a rotary machine applied in the process industry according to an embodiment of the present invention;
fig. 4 is a schematic structural diagram of a fault diagnosis apparatus for a rotary machine applied to the process industry according to an embodiment of the present invention.
Detailed Description
The present invention is described in terms of particular embodiments, other advantages and features of the invention will become apparent to those skilled in the art from the following disclosure, and it is to be understood that the described embodiments are merely exemplary of the invention and that it is not intended to limit the invention to the particular embodiments disclosed. 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.
Referring to fig. 1, fig. 1 is a flowchart illustrating a fault diagnosis method for a rotating machine applied to a process industry according to an embodiment of the present invention.
In a first aspect, an embodiment of the present invention provides a method for diagnosing a fault of a rotating machine applied to a process industry, including:
step S11: acquiring real complete data of a target rotating machine;
step S12: carrying out vibration rating on the real complete data to obtain a rating result;
step S13: when the rating result meets a preset standard, fault diagnosis is carried out on the real complete data by utilizing a fault rule packet to obtain a fault type result;
step S14: calculating the reliability value of the fault type result according to the reliability weight corresponding to the fault type;
step S15: and outputting the equipment type, the fault type result and the reliability value of the target rotating machine, and selecting corresponding suggestion information from a database for displaying.
In the prior art, manual diagnosis is adopted, so that the manual diagnosis efficiency is low, the stability is poor, and the 24-hour attendance is difficult to realize. The invention creatively combines the vibration characteristic and the past diagnosis experience, extracts the vibration and process quantity characteristic of the fault as a 'key factor' of a fault model from a fault mechanism; the field diagnosis experience of many years is structured and extracted into 'auxiliary factors'. The diagnosis accuracy and the misdiagnosis rate can achieve better practical effect.
Firstly, the actual complete data of the target rotating machine needs to be acquired, that is, the integrity and authenticity of the data are ensured, so as to facilitate the subsequent test, specifically, in order to acquire the actual complete data of the target rotating machine, the following steps may be performed:
selecting a target rotating machine and a data time period T;
judging whether a rotation speed value, a Gap value, a vibration value, a phase value, Nc1 and a H, HH value exist in the target rotating machine in the data time period T;
if all the data time period values exist, continuously judging whether the data time period values are in a preset range or not, and the number of the data points is larger than a first preset number; if not, prompting to reselect a data time period T, wherein the number of data points is larger than a first preset number;
if so, judging whether the rotating speed value of the target rotating machine is greater than a preset rotating speed, and if the rotating speed value is less than preset data, prompting to select data with the rotating speed value above the preset rotating speed;
if the rotating speed value is larger than the preset data, judging whether all the channels Gap are in the preset range, if not, prompting that the sensor system is abnormal, and ending; if yes, taking the rotating speed value, the Gap value, the vibration value, the phase value, the Nc1 value and the H, HH value in the data time period T as real complete data; where NC1 is the first order critical speed of the rotor; h is the unit high report; HH is the unit interlock value; the Gap value is the sensor Gap voltage.
Further, in order to perform vibration rating on the real complete data, the following steps may be performed to obtain a rating result:
the real complete data is firstly evaluated in three aspects of maximum pass frequency amplitude, frequency distribution and fluctuation dimensionality, and 3 conditions of normal, mild and severe evaluation results are obtained;
specifically, when the pass frequency is not greater than a, the output is normal; when the pass frequency is between A and 2.5A, the output is light; when the pass frequency is more than 2.5A, the output is serious;
when the 1X is more than or equal to 0.5 times of the pass frequency, the output is normal, and when the 1X is less than 0.5 times of the pass frequency, the output is light;
starting fluctuation dimension judgment when the rotation speed change is less than 500rpm, and specifically, if the pass frequency value, 1X, 2X, 0.5X and the fluctuation range vibration of the residual amount are 7 μm and the phase is below 10 degrees, outputting normally; if the pass frequency value, 1X, 2X, 0.5X and the fluctuation range vibration of the residual amount are more than 7 μm and less than 20 μm, and the phase is less than 10 degrees, the output is light; if the pass frequency value, 1X, 2X, 0.5X, the fluctuation range vibration of the residual quantity is more than 20 μm, and the phase change is more than 10 degrees, the output is serious; wherein, 1X, 0.5X, 2X refers to 1 frequency doubling, 0.5 frequency doubling, 2 frequency doubling of vibration. In the practice of the method, the first and second,
of course, other artificial setting values are also possible.
Specifically, in the rating, the rating standard may be set in each failure rule package, and the rating standard in each failure rule package may be different, and of course, the same rating standard may be set, and a separate database is provided for storing these rating standards, and the setting of the relevant data of the rating standard may be performed according to the actual situation.
Further, when the rating result meets a preset standard, a fault rule package is used to perform fault diagnosis on the real complete data to obtain a fault type result, which specifically includes:
running the key factors of each fault rule packet to detect the real complete data;
and if the real complete data does not meet the key factors of any fault rule packet, the corresponding fault type is judged, and if the real complete data does not meet the key factors of any fault rule packet, equipment information is sent by a background, a fault time interval is manually diagnosed for a diagnosis engineer, and a diagnosis result is manually output.
It is worth to be noted that the fault rule packet is an unbalanced fault rule packet; specifically, the method comprises the following steps: key factors, cofactors; the key factors are as follows:
1. the rotation speed range of nc1 which is 0.5-1 time within the selected time period; the selected time period is a data time period which a user wants to analyze;
2. in the selected time period, the power frequency of at least 2 channels on one side is in direct proportion to the square of the rotating speed within the range of nc1 which is 0.5-1 time of the rotating speed, nc1 is the first-order critical rotating speed of the rotor of the equipment, and a manual input way is provided;
3. at least 2 channels on one side have a high reporting value A of more than 0.8 times of power frequency vibration within the range of +/-20% of the critical rotating speed of the rotor; wherein A is a standard value given by human;
the above 3 key factors must all be satisfied, and 60% of basic weight is obtained;
cofactor:
1. in the selected time interval, the rotating speed is higher than nc1, the vibration frequency power frequency of at least 2 channels on one side is larger than C, and the vibration frequency power frequency is kept for 30min or more, wherein C is
n is the working speed of the rotor orManually setting; 10% of a compound of formula;
2. within a selected time period, the rotating speed is more than nc 130 min or more, when the rotating speed fluctuation is less than 100rpm, the power frequency phase changes within 10 DEG, and the proportion is 7%
3. In the selected time period, every 1 vibration channel is added to the fault equipment to meet the requirement of a key factor of 5 percent;
4. 2 channels of the equipment vibrate to trigger a high altitude alarm at the startup and shutdown stage, and the high altitude alarm is 10 percent
5. An axis locus ellipse at the maximum vibration moment in the selected time interval is 3 percent;
6. the whirling direction of the rotor does not change in a selected time interval, and is 1 percent;
and each time the auxiliary factor satisfies 1 strip, increasing the corresponding weight.
In another embodiment of the present invention, another failure rule packet is provided, that is, the failure rule packet is a broken blade failure rule packet; specifically, the method comprises the following steps: key factors, cofactors;
the key factors are as follows:
1. the change of at least 2 channels of the selected equipment in a selected time period within 4s exceeds 10 mu m, and the change time interval of the 2 channels is less than 4 s;
2. the change of at least 2 channels of the selected equipment in the selected time period power frequency phase within 4s exceeds 10 degrees, and the change time interval of the 2 channels is less than 4 s;
3. the interval between the occurrence time of 1 and 2 is less than 4 s;
4. within 5min before 1 and 2, the change of the rotating speed is less than 100 rpm;
the above 4 key factors must all be satisfied, and 60% of basic weight is obtained;
cofactor:
1. in the selected time period, every 1 vibration channel is added to the fault equipment to meet the requirement of a key factor of-10%;
2. the fluctuation within 30min after the power frequency change is less than 7 mu m < - > - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10 percent;
3. the phase fluctuation within 30min after the power frequency phase change is less than 10 DEG-10%;
4. the whirling direction of the rotor does not change in a selected time interval, and the value of the whirling direction is 5 percent;
and each time the auxiliary factor satisfies 1 strip, increasing the corresponding weight.
Of course, in practice, the model of the fault rule package may also be specifically constructed according to other fault types to facilitate fault analysis.
Referring to fig. 2, fig. 2 is a flowchart illustrating a fault diagnosis of a rotating machine applied to the process industry according to another embodiment of the present invention.
In practice, the first step is to extract the system spectrum features, identify the spectrum features of the unit within a period of time and refine the extracted spectrum features into conditions, wherein the conditions specifically include numerical values and fluctuations such as "pass frequency value", "0.5X", "1X", "2X", "residual amount", "phase", and "process amount". Specific forms for distinguishing time domain waveforms and axis tracks are as follows: "clipping" in the waveform map, and "banana-type", "8-type", and the like in the axis locus are refined as "conditions".
And the second step of carrying out regulation judgment and comparing the extracted data with the key factors and the auxiliary factors. Calculating a key factor of the unbalanced fault, if the key factor condition is met, obtaining 60% of basic weight, then continuing to calculate the auxiliary factor of the unbalanced fault, and outputting a result; if not.
Thirdly, calculating key factors of the fault in the misalignment, if the key factor conditions are met, obtaining 60% of basic weight, then continuing to calculate the auxiliary factors of the fault of the broken blade, and waiting for outputting the result; if not.
Fourthly, outputting the results of the second step and the third step, and selecting a conclusion from a database according to the probability, the equipment type and the fault severity degree for suggestion and output;
a probability module A-;
probability module "cofactor";
the auxiliary factors are fault characteristics based on experience or characteristics weakly related to faults and used for assisting judgment, fault type judgment is not influenced, the fault probability A is only influenced to a certain extent, and each auxiliary factor is individually weighted;
the fault conclusion output by the key factors is met, and the basic probability rating is obtained at the same time by 60%;
the accessory factors are added on the basis of the addition;
the vibration level evaluation module B takes data and evaluates the vibration level firstly, and the evaluation result is normal, mild and serious 3 conditions (later can be graded to be more exquisite)
The rating module includes several dimensions;
1. passing the maximum amplitude of the frequency;
2. a frequency distribution;
3. a fluctuation dimension;
the ratings were normal, mild, severe;
normal;
simultaneously satisfies the following conditions;
1. the pass frequency amplitude is less than API 617;
2. the power frequency accounts for more than 50% of the pass frequency;
3. the passing frequency value, 1X, 2X, 0.5X, the fluctuation range of the residual quantity vibrate by 7 mu m, and the phase position is below 10 degrees;
4, all process quantities are in a set range;
the output is normal, the fault is generated, and the probability module does not work;
mild;
the module is started when the normal condition is not met and the alarm value is not reached, and the module outputs light degree, fault, probability and conclusion;
severe;
the existence of an alarm value or serious output of a specific fault (such as blade breakage);
when the rating result is normal, the operation is terminated, and the result is output;
"XX user-synthesis plant-synthesis gas compressor can continue to operate without obvious abnormality;
when the rating output result is mild or severe, starting a fault conclusion module;
a fault conclusion module C-;
fault determination module "key factor";
the key factor is a fault characteristic which is derived according to a fault diagnosis theoretical basis and is necessary for each fault, is strongly related to the fault, is used as a necessary condition for fault judgment, and is removed when the key factor is not satisfied;
a suggestion module D-;
fault type fault severity fault device;
and screening the keywords according to each type of machine and fault type from a database by adopting a retrieval mode.
Judging the unbalance fault:
the key factors are as follows:
1. the vibration frequency power frequency of 2 channels on the same side is more than 25.4 or API617 (application program interface) relative vibration standard (time period);
2. the power frequency of 2 channels on the same side is in direct proportion to the square of the rotating speed;
3. the power frequency vibration of 2 channels on the same side exceeds an alarm value within the range of +/-10% of the critical rotating speed of the rotor;
the above 3 key factors must all be satisfied;
cofactor:
1. the phase change of the power frequency phase is within 10 DEG when the rotating speed is constant, and the phase is within-10%;
2. an axis locus ellipse-5%;
3. the vortex direction of the rotor is synchronous positive precession-7%;
4. the increase of 1 vibration channel of the fault equipment meets a key factor of-5%;
each time the auxiliary factor satisfies 1, increasing the corresponding weight;
considering the possibility that a unit objectively has multiple faults, each fault adopts an independent key factor and an independent auxiliary factor, the key factor is met, namely a conclusion is output, the probability calculation module works, the key factor condition is not met, the conclusion is not output, and the probability calculation module does not work.
An example of a slight imbalance fault determination for a device is as follows:
firstly, evaluating and grading vibration values;
1. judging whether the selected time period contains data with the rotating speed of more than 200rpm (judging the shutdown state), if so, entering the next step 2, and if not, returning and prompting that the operation data is selected;
2. judging the maximum value X (any channel) of the vibration pass frequency in the selected time period and a vibration standard A, wherein A is a function related to the rotating speed;
a. passing through a frequency vibration value dimension;
x is less than A, the operation is terminated, the output is normal,
x is more than A and less than 2.5A, entering the next step, and outputting 'mild';
2.5A is less than X, entering the next step, and outputting serious;
b. a frequency distribution dimension;
the amplitude of the frequency outside the sigma power frequency is less than 0.5A, the output is normal,
the amplitude of frequency beyond the sigma power frequency is more than 0.5A, light is output,
c. fluctuation dimension (enabled within 500rpm of speed change);
the frequency passing value, 1X, 2X, 0.5X, residual fluctuation are all less than 7 mu m, the phase change is less than 10 degrees, and the output is normal;
7 μm is less than the pass frequency value, 1X, 2X, 0.5X, the residual fluctuation is all less than 20 μm, or the phase change is more than 10 degrees, and 'mild' is output;
3. the final output result has priority of 'severe' > 'mild' > 'normal';
when the grading result is abnormal, starting a diagnosis module;
secondly, judging the fault type;
1. judging whether the rotating speed in the selected time period reaches 30% of the rated rotating speed or above 2000rpm, and if so, entering 2; if not, outputting 'the rotating speed of the data section selected by you is too low, and the diagnostic man does not want to' and returns to reselect the data section;
2. judging whether the change of the rotating speed of the data in the selected time period is more than 1000rpm, and if so, entering 3; if not, prompting the time period for suggesting the selection of the rotation speed change, greatly improving the diagnosis accuracy rate, providing the selection, reselecting the data segment, and entering the next step 3;
3. judging whether all unbalanced key factors are met, if so, entering an output conclusion of unbalance, assigning a basic probability of 60 percent, entering the next step 4, and if not, entering a second fault type judgment;
3 key factors for an imbalance fault;
(1) in a 30min section of the highest rotating speed interval in a selected time period, the vibration frequency power frequency of any 2 channels is larger than A;
(2) the power frequency of any 2 channels is in direct proportion to the square of the rotating speed;
4 auxiliary factors of the unbalance fault of the alarm value caused by the power frequency vibration of any 2 channels within the range of the critical rotating speed +/-10% of the rotor;
(1) the rotating speed is stable within 30min, and the phase change of the time power frequency phase is within 10 degrees to minus 10 percent;
(2) an axis locus ellipse-5%;
(3) the vortex direction of the rotor is synchronous positive precession-7%;
(4) every time 1 vibration channel is added to the fault equipment, the requirement of a key factor is met, and the requirement is 5 percent;
4. calculating the reliability probability according to the auxiliary factors and outputting a result;
thirdly, outputting a conclusion and giving a fault suggestion;
retrieving standard processing opinions of a synthesis gas compressor and a serious unbalance from a suggestion library and outputting the standard processing opinions;
referring to fig. 3, fig. 3 is a schematic structural diagram of a fault diagnosis system of a rotating machine applied to a process industry according to an embodiment of the present invention.
The embodiment of the present invention provides a rotating machinery fault diagnosis system 300 applied to process industry, including:
a data acquisition module 310, configured to acquire real complete data of the target rotating machine;
the vibration rating module 320 is used for performing vibration rating on the real complete data to obtain a rating result;
the fault type diagnosis module 330 is configured to perform fault diagnosis on the real complete data by using a fault rule packet when the rating result meets a preset standard, so as to obtain a fault type result;
the credibility calculation module 340 is configured to calculate a credibility value of the fault type result according to the credibility weight corresponding to the fault type;
and a result output module 350, configured to output the equipment type, the fault type result, and the reliability value of the target rotary machine, and select corresponding suggestion information from a database to display.
Preferably, the data acquisition module includes:
a time period selection unit for selecting a target rotating machine and a data time period T;
a complete determination unit, configured to determine whether a rotation speed value, a Gap value, a vibration value, a phase value, and Nc1, H, HH values exist in the data time period T of the target rotary machine;
the quantity judging unit is used for continuously judging whether the data time period value is in a preset range or not if all the data time period value exists, and the quantity of the data points is greater than a first preset quantity; if not, prompting to reselect a data time period T, wherein the number of data points is larger than a first preset number;
the rotating speed judging unit is used for judging whether the rotating speed value of the target rotating machinery is greater than a preset rotating speed or not if the rotating speed value is greater than the preset rotating speed, and prompting to select data with the rotating speed value greater than the preset rotating speed if the rotating speed value is less than preset data;
the sensing judgment unit is used for judging whether all the channels Gap are in a preset range or not if the rotating speed value is larger than preset data, and prompting that a sensor system is abnormal and ending if not; if yes, taking the rotating speed value, the Gap value, the vibration value, the phase value, the Nc1 value and the H, HH value in the data time period T as real complete data; where NC1 is the first order critical speed of the rotor; h is the unit high report; HH is the unit interlock value; the Gap value is the sensor Gap voltage.
Referring to fig. 4, fig. 4 is a schematic structural diagram of a fault diagnosis apparatus for a rotary machine applied to a process industry according to an embodiment of the present invention.
An embodiment of the present invention provides a rotating machine fault diagnosis apparatus 400 applied to a process industry, including:
a memory 410 for storing a computer program;
a processor 420 for implementing the steps of the method for diagnosing faults of a rotating machine applied to the process industry according to any one of the embodiments described above when executing the computer program.
The embodiment of the present invention provides a computer-readable storage medium, on which a computer program is stored, and the computer program, when executed by a processor, implements the steps of the method for diagnosing a fault of a rotating machine applied to a process industry, as described in any one of the embodiments above.
As will be appreciated by one skilled in the art, embodiments of the present application may be provided as a method, system, or computer program product. Accordingly, the present application may take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment combining software and hardware aspects. Furthermore, the present application may take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, and the like) having computer-usable program code embodied therein.
The present application is described with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the application. It will be understood that each flow and/or block of the flow diagrams and/or block diagrams, and combinations of flows and/or blocks in the flow diagrams and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
In a typical configuration, a computing device includes one or more processors (CPUs), input/output interfaces, network interfaces, and memory. The memory may include forms of volatile memory in a computer readable medium, Random Access Memory (RAM) and/or non-volatile memory, such as Read Only Memory (ROM) or flash memory (flash RAM). The memory is an example of a computer-readable medium.
Computer-readable media, including both non-transitory and non-transitory, removable and non-removable media, may implement information storage by any method or technology. The information may be computer readable instructions, data structures, modules of a program, or other data. Examples of computer storage media include, but are not limited to, phase change memory (PRAM), Static Random Access Memory (SRAM), Dynamic Random Access Memory (DRAM), other types of Random Access Memory (RAM), Read Only Memory (ROM), Electrically Erasable Programmable Read Only Memory (EEPROM), flash memory or other memory technology, compact disc read only memory (CD-ROM), Digital Versatile Discs (DVD) or other optical storage, magnetic cassettes, magnetic tape magnetic disk storage or other magnetic storage devices, or any other non-transmission medium that can be used to store information that can be accessed by a computing device. As defined herein, a computer readable medium does not include a transitory computer readable medium such as a modulated data signal and a carrier wave.
It should also be noted that the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising an … …" does not exclude the presence of other identical elements in the process, method, article, or apparatus that comprises the element.
The above are merely examples of the present application and are not intended to limit the present application. Various modifications and changes may occur to those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application should be included in the scope of the claims of the present application.
Claims (9)
1. A fault diagnosis method for a rotary machine applied to process industry is characterized by comprising the following steps:
acquiring real complete data of a target rotating machine;
carrying out vibration rating on the real complete data to obtain a rating result;
when the rating result meets a preset standard, fault diagnosis is carried out on the real complete data by utilizing a fault rule packet to obtain a fault type result;
calculating the reliability value of the fault type result according to the reliability weight corresponding to the fault type;
outputting the equipment type, the fault type result and the reliability value of the target rotating machine, and selecting corresponding suggestion information from a database for displaying;
the fault rule packet is a broken blade fault rule packet; specifically, the method comprises the following steps: key factors, cofactors;
the key factors are as follows:
1. the change of at least 2 channels of the selected equipment in a selected time period within 4s exceeds 10 mu m, and the change time interval of the 2 channels is less than 4 s;
2. the change of at least 2 channels of the selected equipment in the selected time period power frequency phase within 4s exceeds 10 degrees, and the change time interval of the 2 channels is less than 4 s;
3. the interval between the occurrence time of 1 and 2 is less than 4 s;
4. within 5min before 1 and 2, the change of the rotating speed is less than 100 rpm;
the above 4 key factors must all be satisfied, and 60% of basic weight is obtained;
cofactor:
1. in the selected time period, every 1 vibration channel is added to the fault equipment to meet the requirement of a key factor of-10%;
2. the fluctuation within 30min after the power frequency changes is less than 7 mu m < - > - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10 percent;
3. the phase fluctuation within 30min after the phase change of the power frequency is less than 10 DEG-10%;
4. the whirling direction of the rotor does not change in a selected time interval, and the value of the whirling direction is 5 percent;
and each time the auxiliary factor satisfies 1 strip, increasing the corresponding weight.
2. The rotary machine fault diagnosis method according to claim 1,
the acquiring of the real complete data of the target rotating machine comprises:
selecting a target rotating machine and a data time period T;
judging whether a rotation speed value, a Gap value, a vibration value, a phase value, Nc1 and a H, HH value exist in the target rotating machine in the data time period T;
if all the data time period values exist, continuously judging whether the data time period values are in a preset range or not, and the number of the data points is larger than a first preset number; if not, prompting to reselect a data time period T, wherein the number of data points is larger than a first preset number;
if so, judging whether the rotating speed value of the target rotating machine is greater than a preset rotating speed, and if the rotating speed value is less than preset data, prompting to select data with the rotating speed value above the preset rotating speed;
if the rotating speed value is larger than the preset data, judging whether all the channels Gap are in the preset range, if not, prompting that the sensor system is abnormal, and ending; if yes, taking the rotating speed value, the Gap value, the vibration value, the phase value, the Nc1 value and the H, HH value in the data time period T as real complete data; where NC1 is the first order critical speed of the rotor; h is the unit high report; HH is the unit interlock value; the Gap value is the sensor Gap voltage.
3. The rotary machine fault diagnosis method according to claim 1,
the vibration rating of the real complete data to obtain a rating result comprises the following steps:
the real complete data is firstly evaluated in three aspects of maximum pass frequency amplitude, frequency distribution and fluctuation dimensionality, and 3 conditions of normal, mild and severe evaluation results are obtained;
specifically, when the pass frequency is not greater than a, the output is normal; when the pass frequency is between A and 2.5A, the output is light; when the pass frequency is more than 2.5A, the output is serious; wherein A is a standard value given by human;
when the 1X is more than or equal to 0.5 times of the pass frequency, the output is normal, and when the 1X is less than 0.5 times of the pass frequency, the output is light;
starting fluctuation dimension judgment when the rotation speed change is less than 500rpm, and specifically, if the pass frequency value, 1X, 2X, 0.5X and the fluctuation range vibration of the residual amount are 7 μm and the phase is below 10 degrees, outputting normally; if the pass frequency value, 1X, 2X, 0.5X and the fluctuation range vibration of the residual amount are more than 7 μm and less than 20 μm, and the phase is less than 10 degrees, the output is light; if the pass frequency value, 1X, 2X, 0.5X, the fluctuation range vibration of the residual quantity is more than 20 μm, and the phase change is more than 10 degrees, the output is serious; wherein, 1X, 0.5X, 2X refers to 1 frequency doubling, 0.5 frequency doubling, 2 frequency doubling of vibration.
4. The rotary machine fault diagnosis method according to claim 1,
when the rating result meets a preset standard, performing fault diagnosis on the real complete data by using a fault rule packet to obtain a fault type result, wherein the fault type result comprises the following steps:
running the key factors of each fault rule packet to detect the real complete data;
and if the real complete data does not meet the key factors of any fault rule packet, the corresponding fault type is judged, and if the real complete data does not meet the key factors of any fault rule packet, equipment information is sent by a background, a fault time interval is manually diagnosed for a diagnosis engineer, and a diagnosis result is manually output.
5. The rotary machine fault diagnosis method according to any one of claims 1 to 4,
the fault rule packet can be replaced by an unbalanced fault rule packet; specifically, the method comprises the following steps: key factors, cofactors;
the key factors are as follows:
1. the rotation speed range of nc1 which is 0.5-1 time within the selected time period; the selected time period is a data time period which a user wants to analyze;
2. in the selected time period, the power frequency of at least 2 channels on one side is in direct proportion to the square of the rotating speed within the range of nc1 which is 0.5-1 time of the rotating speed, nc1 is the first-order critical rotating speed of the rotor of the equipment, and a manual input way is provided;
3. at least 2 channels on one side have a high reporting value A of more than 0.8 times of power frequency vibration within the range of +/-20% of the critical rotating speed of the rotor; wherein A is a standard value given by human;
the above 3 key factors must all be satisfied, and 60% of basic weight is obtained;
cofactor:
1. in the selected time interval, the rotating speed is higher than nc1, the vibration frequency power frequency of at least 2 channels on one side is larger than C, and the vibration frequency power frequency is kept for 30min or more, wherein C is
n is the working rotating speed of the rotor or the manual setting; 10% of- -C- -O- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -;
2. within a selected time period, the rotating speed is more than nc 130 min or more, when the rotating speed fluctuation is less than 100rpm, the power frequency phase changes within 10 DEG, and the temperature is lower than the set temperature
3. In the selected time period, every 1 vibration channel is added to the fault equipment to meet the requirement of a key factor of 5 percent;
4. 2 channels of the equipment vibrate to trigger a high altitude alarm at the startup and shutdown stage, and the high altitude alarm is 10 percent
5. An axis locus ellipse at the maximum vibration time within a selected time interval is 3%;
6. the whirling direction of the rotor does not change in a selected time interval, and the value of the whirling direction is 1 percent;
and each time the auxiliary factor satisfies 1 strip, increasing the corresponding weight.
6. A rotary machine fault diagnostic system for use in the process industry, comprising:
the data acquisition module is used for acquiring real complete data of the target rotating machine;
the vibration rating module is used for carrying out vibration rating on the real complete data to obtain a rating result; the fault type diagnosis module is used for carrying out fault diagnosis on the real complete data by utilizing a fault rule packet when the rating result meets a preset standard so as to obtain a fault type result; the fault rule packet is a broken blade fault rule packet; specifically, the method comprises the following steps: key factors, cofactors;
the key factors are as follows:
1. the change of at least 2 channels of the selected equipment in a selected time period within 4s exceeds 10 mu m, and the change time interval of the 2 channels is less than 4 s;
2. the change of at least 2 channels of the selected equipment in the selected time period power frequency phase within 4s exceeds 10 degrees, and the change time interval of the 2 channels is less than 4 s;
3. the interval between the occurrence time of 1 and 2 is less than 4 s;
4. within 5min before 1 and 2, the change of the rotating speed is less than 100 rpm;
the above 4 key factors must all be satisfied, and 60% of basic weight is obtained;
cofactor:
1. in the selected time period, every 1 vibration channel is added to the fault equipment to meet the requirement of a key factor of-10%;
2. the fluctuation within 30min after the power frequency changes is less than 7 mu m < - > - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10 percent;
3. the phase fluctuation within 30min after the phase change of the power frequency is less than 10 DEG-10%;
4. the whirling direction of the rotor does not change in a selected time interval, and the value of the whirling direction is 5 percent;
each time the auxiliary factor satisfies 1, increasing the corresponding weight;
the credibility calculation module is used for calculating the credibility value of the fault type result according to the credibility weight corresponding to the fault type;
and the result output module is used for outputting the equipment type, the fault type result and the reliability value of the target rotating machine and selecting corresponding suggestion information from a database for displaying.
7. Rotary machine fault diagnosis system according to claim 6,
the data acquisition module comprises:
a time period selection unit for selecting a target rotating machine and a data time period T;
a complete determination unit, configured to determine whether a rotation speed value, a Gap value, a vibration value, a phase value, and Nc1, H, HH values exist in the data time period T of the target rotary machine;
the quantity judging unit is used for continuously judging whether the data time period value is in a preset range or not if all the data time period value exists, and the quantity of the data points is greater than a first preset quantity; if not, prompting to reselect the data time period T, wherein the number point of the data is larger than a first preset number;
the rotating speed judging unit is used for judging whether the rotating speed value of the target rotating machinery is greater than a preset rotating speed or not if the rotating speed value is greater than the preset rotating speed, and prompting to select data with the rotating speed value greater than the preset rotating speed if the rotating speed value is less than preset data;
the sensing judgment unit is used for judging whether all the channels Gap are in the preset range or not if the rotating speed value is larger than the preset data, and prompting the abnormality of the sensor system and ending if not; if yes, taking the rotating speed value, the Gap value, the vibration value, the phase value, the Nc1 value and the H, HH value in the data time period T as real complete data; where NC1 is the first order critical speed of the rotor; h is the unit high report; HH is the unit interlock value; the Gap value is the sensor Gap voltage.
8. A rotary machine fault diagnosis apparatus applied to a process industry, comprising:
a memory for storing a computer program;
a processor for implementing the steps of the method for diagnosing faults of rotating machinery applied to the process industry according to any one of claims 1 to 5 when the computer program is executed.
9. A computer-readable storage medium, characterized in that the computer-readable storage medium has stored thereon a computer program which, when being executed by a processor, carries out the steps of the method for diagnosing faults of rotating machinery applied to the process industry according to any one of claims 1 to 5.
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