CN113487189A - Petrochemical equipment fault probability risk assessment system and assessment method - Google Patents
Petrochemical equipment fault probability risk assessment system and assessment method Download PDFInfo
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- CN113487189A CN113487189A CN202110774507.2A CN202110774507A CN113487189A CN 113487189 A CN113487189 A CN 113487189A CN 202110774507 A CN202110774507 A CN 202110774507A CN 113487189 A CN113487189 A CN 113487189A
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- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q10/00—Administration; Management
- G06Q10/06—Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
- G06Q10/063—Operations research, analysis or management
- G06Q10/0635—Risk analysis of enterprise or organisation activities
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F18/00—Pattern recognition
- G06F18/20—Analysing
- G06F18/25—Fusion techniques
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06N—COMPUTING ARRANGEMENTS BASED ON SPECIFIC COMPUTATIONAL MODELS
- G06N5/00—Computing arrangements using knowledge-based models
- G06N5/02—Knowledge representation; Symbolic representation
- G06N5/022—Knowledge engineering; Knowledge acquisition
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q10/00—Administration; Management
- G06Q10/06—Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
- G06Q10/063—Operations research, analysis or management
- G06Q10/0639—Performance analysis of employees; Performance analysis of enterprise or organisation operations
- G06Q10/06393—Score-carding, benchmarking or key performance indicator [KPI] analysis
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F18/00—Pattern recognition
- G06F18/20—Analysing
- G06F18/25—Fusion techniques
- G06F18/257—Belief theory, e.g. Dempster-Shafer
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F2218/00—Aspects of pattern recognition specially adapted for signal processing
- G06F2218/02—Preprocessing
- G06F2218/04—Denoising
Abstract
The invention discloses a petrochemical equipment fault probability risk assessment system and a petrochemical equipment fault probability risk assessment method. The invention can find the fault in the running process of the petrochemical equipment in time and carry out fault probability risk level evaluation, thereby obviously reducing the loss caused by the halt of the petrochemical equipment.
Description
Technical Field
The invention relates to the field of petrochemical equipment fault diagnosis, in particular to a petrochemical equipment fault probability risk assessment system and method.
Background
Petrochemical equipment is an important base stone for production of petrochemical enterprises and is a key link related to production quality and efficiency of the petrochemical equipment. Petrochemical equipment is often complicated in structure, and degree of automation is high, and operating environment has high temperature, high pressure, and the production medium is easily flammable, explosive, perishable to production intensity is big, the continuity is strong, in case equipment breaks down, can influence the safety of relevant equipment even whole enterprise complete set equipment, orderly production, and the more serious safety that can threaten the enterprise.
At the present stage, monitoring of the faults of the petrochemical equipment mainly comprises the steps of collecting images or sounds in the running process of the petrochemical equipment or directly observing the running condition of the equipment by a worker in a production field, and judging whether the petrochemical equipment has the faults or not and the severity of the faults by the worker or an expert according to self experience, wherein the judgment has high subjectivity, and correct judgment cannot be made when the equipment faults exceed the experience range. And the severity of the fault cannot be accurately graded. And the fine faults can not be judged in time, and the hidden danger of equipment faults can not be diagnosed and classified accurately at the first time.
Therefore, a system and a method for evaluating risk of failure probability of petrochemical equipment are needed to timely find and evaluate failure levels of petrochemical equipment during operation, so as to provide accurate basis for maintenance of maintenance personnel.
Disclosure of Invention
The invention aims to provide a real-time fault detection device for petrochemical equipment, which is used for solving the problems in the prior art, timely finding faults in the running process of the petrochemical equipment and carrying out fault probability risk level evaluation, and remarkably reducing the loss caused by shutdown of the petrochemical equipment.
In order to achieve the purpose, the invention provides the following scheme: the invention provides a petrochemical equipment fault probability risk assessment system, which comprises a working state information acquisition module, an information storage module, an information preprocessing module, a fault risk assessment module, a fault knowledge base module, a man-machine interaction device and a communication module,
the working state information acquisition module is used for acquiring working data of petrochemical equipment;
the information storage module is used for storing the working data of the petrochemical equipment;
the information preprocessing module is used for preprocessing the working data of the petrochemical equipment;
the fault risk assessment module is used for diagnosing and assessing fault risks possibly existing in petrochemical equipment and grading the fault risks;
the fault knowledge base module is used for storing the fault type of the petrochemical equipment, the fault risk level and the judgment standard of the fault risk level;
the human-computer interaction device is used for displaying the fault risk, the fault risk level and input information;
the communication module is used for the petrochemical equipment fault probability risk assessment system to perform information interaction with the Internet;
the working state information acquisition module, the information storage module, the information preprocessing module, the fault risk assessment module and the human-computer interaction device are sequentially connected, the fault risk assessment module is connected with the fault knowledge base module, the human-computer interaction device is connected with the fault knowledge base module, and the human-computer interaction device is connected with the internet through the communication module.
Preferably, the working state information acquisition module comprises a vibration data acquisition unit, a pressure data acquisition unit, a temperature data acquisition unit, a voltage data acquisition unit and a current data acquisition unit, and the vibration data acquisition unit, the pressure data acquisition unit, the temperature data acquisition unit, the voltage data acquisition unit and the current data acquisition unit are all connected with the information storage module.
Preferably, the vibration data acquisition unit with acceleration sensor on the petrochemical equipment is connected, pressure data acquisition unit with pressure sensor on the petrochemical equipment is connected, temperature data acquisition unit with temperature sensor on the petrochemical equipment is connected, voltage data acquisition unit with voltage sensor on the petrochemical equipment is connected, current data acquisition with current sensor on the petrochemical equipment is connected.
Preferably, the information preprocessing module converts the petrochemical equipment working data into an electric signal and performs filtering and noise reduction to obtain data to be detected.
Preferably, the fault risk assessment module includes a fault risk type determination unit, a fault feature extraction unit, and a fault risk level assessment unit, the fault risk type determination unit is configured to determine a component in which an operational data abnormality occurs, the fault feature extraction unit is configured to acquire feature information required for fault diagnosis, the fault risk level assessment unit is configured to assess a fault risk level, the fault risk type determination unit, the fault feature extraction unit, and the fault risk level assessment unit are sequentially connected, the fault risk level assessment unit is connected to the fault knowledge base module, and the fault risk level assessment unit is connected to the human-computer interaction device.
Preferably, the human-computer interaction device comprises a display unit and an alarm unit, wherein the display unit is used for displaying a fault occurrence position, a fault risk level and a fault reason.
Preferably, the alarm unit adopts an alarm which can give out different alarm sounds according to the fault grade.
The petrochemical equipment fault probability risk assessment method comprises the following steps:
acquiring historical fault data of petrochemical equipment, and constructing a fault knowledge base of the petrochemical equipment;
acquiring real-time operation data of the petrochemical equipment, and preprocessing the real-time operation data to obtain data to be detected;
comparing the data to be detected with the fault database, evaluating the fault probability risk of the petrochemical equipment, and obtaining a fault probability risk evaluation result;
and displaying the fault probability risk assessment result, and carrying out early warning prompt according to the fault probability risk assessment result.
Preferably, the preprocessing includes converting the real-time operation data into an electrical signal, generating a signal wave pattern based on the electrical signal, and filtering and denoising the signal wave pattern.
The invention discloses the following technical effects:
the petrochemical equipment fault probability risk assessment system and the assessment method provided by the invention have the advantages that the working state information of the petrochemical equipment is acquired in real time by adopting the working state information acquisition module, the component with the fault and the fault probability risk are rapidly diagnosed by the fault risk assessment module and the fault knowledge base module, and the fault knowledge base is continuously enriched to be a judgment basis for continuously accumulating fault probability risk assessment. The invention can deal with the fault diagnosis and processing of various petrochemical equipment, monitor the working condition of the petrochemical equipment in real time, quickly judge the probability risk of the fault and obviously reduce the loss caused by the halt of the petrochemical equipment.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed to be used in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without inventive exercise.
FIG. 1 is a schematic diagram of a petrochemical plant real-time fault detection system according to the present invention;
FIG. 2 is an external view of a real-time fault detection apparatus for petrochemical equipment according to the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.
The invention provides a petrochemical equipment fault probability risk assessment system which is used for monitoring the working state of petrochemical equipment in real time and detecting faults of the petrochemical equipment in time. Referring to fig. 1, the petrochemical equipment fault probability risk assessment system comprises a working state information acquisition module, an information storage module, an information preprocessing module, a fault risk assessment module, a fault knowledge base module, a human-computer interaction device and a communication module. The working state information acquisition module, the information storage module, the information preprocessing module, the fault risk assessment module, the fault knowledge base module and the human-computer interaction device are sequentially connected, the human-computer interaction device is connected with the fault knowledge base module, and the human-computer interaction device is connected with the internet through the communication module.
The working state information acquisition module is used for acquiring working data of petrochemical equipment and comprises a vibration data acquisition unit, a pressure data acquisition unit, a temperature data acquisition unit, a voltage data acquisition unit and a current data acquisition unit, wherein the vibration data acquisition unit is connected with an acceleration sensor on the petrochemical equipment to acquire vibration data of components of the petrochemical equipment, the pressure data acquisition unit is connected with a pressure sensor on the petrochemical equipment to acquire pressure data of the petrochemical equipment, the temperature data acquisition unit is connected with a temperature sensor on the petrochemical equipment to acquire real-time temperature of the components in the working process of the petrochemical equipment, the voltage data acquisition unit is connected with a voltage sensor on the petrochemical equipment to acquire real-time working voltage of the petrochemical equipment, the current data acquisition unit is connected with a current sensor on the petrochemical equipment to acquire real-time working current of the petrochemical equipment, the vibration data acquisition unit, the temperature data acquisition unit, the pressure data acquisition unit, the temperature data acquisition unit, the current sensor acquisition unit, the pressure data acquisition unit and the current sensor acquisition unit are connected with the pressure data acquisition unit, The pressure data acquisition unit, the temperature data acquisition unit, the voltage data acquisition unit and the current data acquisition unit are all connected with the information storage module, and store the acquired vibration, pressure, temperature, voltage and current data in the fault detection device, so as to provide a data basis for fault diagnosis work.
And the working state data of the petrochemical equipment in the data storage module is transmitted to the information preprocessing module, the working state data is converted into an electric signal by the information preprocessing module, and the electric signal is preprocessed. Due to the fact that external interference occurs to the signals acquired through the vibration sensor and the acquisition equipment and the characteristics of non-stationarity and non-smoothness and the like, the signals often deviate from the true values of the signals, and accordingly, errors are increased or even errors are generated in subsequent signal analysis, preprocessing of the signals is necessary before characteristic value extraction, the preprocessing includes zero equalization processing and signal filtering processing, and the zero equalization processing is to enable each value in a group of signals to subtract the average value of the group of signals so as to remove the direct current component of the signals. Meanwhile, due to external interference, noise exists in the acquired signals, and useful signals can be covered by noise signals, so that the signals need to be filtered and denoised, the signal-to-noise ratio is improved, and wavelet packet transformation can be adopted for signal filtering. And preprocessing to obtain a working state signal of the petrochemical equipment to be detected. Different patterns are generated according to the electric signals of the collected working data types, for example, a vibration wave pattern is generated by a vibration signal.
Transmitting a working state signal of petrochemical equipment to be detected to a fault risk evaluation module, wherein the fault risk evaluation module is used for carrying out risk evaluation on possible faults of the petrochemical equipment and comprises a fault type judgment unit, a fault feature extraction unit and a fault risk level evaluation unit, the fault type judgment unit judges which component of the petrochemical equipment has abnormal operating data according to the received fault signal, the fault feature extraction unit extracts diagnosis features required by the fault risk evaluation according to the component with the abnormal operating data and transmits the diagnosis features to the fault risk level evaluation unit to process all operating data of the component with the abnormal operating data, and all operating data are subjected to fusion calculation by using a DS evidence theory to obtain a component basic probability value of the abnormal operating data and compare the basic probability value with the faults in a fault knowledge base module, and obtaining a failure probability risk level. The failure probability risk level comprises four levels of slight failure, common failure, serious failure and critical failure. If the fault occurs for the first time and no corresponding solution is found in the fault knowledge base, the solution is fed back and not found, at the moment, the expert is invited to perform manual processing, and after the fault is relieved, fault information is supplemented into the fault knowledge base to enrich the fault knowledge base. And the fault risk level evaluation unit sends the acquired fault probability risk level to the man-machine interaction device.
The man-machine interaction device comprises a display unit and an alarm unit, wherein at least the display unit displays a fault generation component, a fault risk level and a fault reason, and fonts with different colors are used for displaying according to the fault risk level. The alarm unit adopts the warning prompting device, and the warning prompting device can send out different warning sounds according to the fault risk level, and enables the staff to know the fault level through sound according to the warning sounds. In order to further enrich the fault knowledge base, a maintainer can be connected to the Internet through a man-machine interaction device through a communication module to search fault data of the same type of petrochemical equipment, and the fault data is downloaded and input into the fault knowledge base to enrich the fault knowledge base.
In a further optimized scheme, the human-computer interaction device adopts a high-definition touch screen, and can also adopt a display device and an input device, such as a keyboard.
The invention also provides a petrochemical equipment fault probability risk assessment method, as shown in fig. 2, comprising the following steps:
s101, historical fault data of the petrochemical equipment are obtained, and a fault knowledge base of the petrochemical equipment is constructed.
Collecting historical fault data of petrochemical equipment which is put into use, wherein the historical fault data comprises a fault component and vibration data, pressure data, temperature data, voltage data and current data of the fault component, preprocessing the vibration data, the pressure data, the temperature data, the voltage data and the current data, removing noise information in the preprocessed vibration data, pressure data, temperature data, voltage data and current data, respectively calculating membership values of the vibration data, the pressure data, the temperature data, the voltage data and the current data, taking the membership values of the vibration data, the pressure data, the temperature data, the voltage data and the current data as basic input values of a basic probability distribution function of a D-S evidence theory, calculating to obtain a basic probability value of the fault component after substituting, fusing the vibration data, the pressure data, the temperature data, the voltage data and the current data by adopting a fusion model based on the D-S evidence theory, and acquiring uncertainty of the operation of the fault component, obtaining an uncertainty range according to the uncertainty, and setting a fault probability risk level according to the uncertainty range. Thus, the historical fault database in this embodiment includes faulty components, vibration data, pressure data, temperature data, voltage data, current data, uncertainty in the operation of the faulty component, and fault probability risk level.
S102, collecting real-time operation data of petrochemical equipment, preprocessing the real-time operation data, and obtaining data to be detected.
The method comprises the steps that various sensors connected with petrochemical equipment are used for collecting operation data of the petrochemical equipment, wherein the operation data at least comprise vibration data, pressure data, temperature data, voltage data and current data, the collected vibration data, pressure data, temperature data, voltage data and current data are preprocessed, noise reduction is carried out through filtering, noise information in the data is removed, and information to be detected is obtained.
S103, comparing the data to be detected with a fault database, evaluating the fault probability risk of the petrochemical equipment, and obtaining a fault probability risk evaluation result.
And fusing the preprocessed vibration data, pressure data, temperature data, voltage data and current data by using a D-S evidence theory, calculating to obtain the uncertainty of the operation of the component to be detected in the petrochemical equipment, comparing the uncertainty of the operation of the component to be detected with the information recorded in the fault database to obtain the result of fault probability risk assessment, and further comparing specific data information to find abnormal data information to know the reason causing the fault.
The calculation process of the operation uncertainty of the component to be detected in the petrochemical equipment comprises the following steps:
the method comprises the steps of respectively calculating membership values of vibration data, pressure data, temperature data, voltage data and current data, taking the membership values of the vibration data, the pressure data, the temperature data, the voltage data and the current data as basic input values of a basic probability distribution function of a D-S evidence theory, carrying the basic input values into the basic probability values to obtain basic probability values of components, and fusing the vibration data, the pressure data, the temperature data, the voltage data and the current data by adopting a fusion model based on the D-S evidence theory to obtain uncertainty of component operation.
And S104, displaying the fault probability risk assessment result, and carrying out early warning prompt according to the fault probability risk assessment result.
In this embodiment, the failure probability risk levels include four levels, namely, a minor failure, a general failure, a major failure, and a critical failure, and different failure probability risk levels are displayed in cooperation with fonts of different colors and emit different warning sounds.
The petrochemical equipment fault probability risk assessment system and the assessment method provided by the invention can be suitable for a large number of petrochemical equipment, when the petrochemical equipment has a fault, noise data can appear on operating parameters such as machine body vibration, voltage, current and the like, the noise data are compared with fault models in a fault knowledge base, the fault probability risk level of the petrochemical equipment can be found in time, if relevant fault information is not recorded in the fault knowledge base, fault detection data and operating video of the petrochemical equipment are sent to an expert, the expert gives a solution, the fault data and the solution are supplemented into the fault knowledge base after the fault is removed, and for the newly-used petrochemical equipment, a maintainer obtains fault data of the type of petrochemical equipment from the Internet or other channels and supplements into the fault knowledge base.
The above-described embodiments are merely illustrative of the preferred embodiments of the present invention, and do not limit the scope of the present invention, and various modifications and improvements of the technical solutions of the present invention can be made by those skilled in the art without departing from the spirit of the present invention, and the technical solutions of the present invention are within the scope of the present invention defined by the claims.
Claims (9)
1. A petrochemical equipment fault probability risk assessment system is characterized in that: comprises a working state information acquisition module, an information storage module, an information preprocessing module, a fault risk evaluation module, a fault knowledge base module, a man-machine interaction device and a communication module,
the working state information acquisition module is used for acquiring working data of petrochemical equipment;
the information storage module is used for storing the working data of the petrochemical equipment;
the information preprocessing module is used for preprocessing the working data of the petrochemical equipment;
the fault risk assessment module is used for diagnosing and assessing fault risks possibly existing in petrochemical equipment and grading the fault risks;
the fault knowledge base module is used for storing the fault type of the petrochemical equipment, the fault risk level and the judgment standard of the fault risk level;
the human-computer interaction device is used for displaying the fault risk, the fault risk level and input information;
the communication module is used for the petrochemical equipment fault probability risk assessment system to perform information interaction with the Internet;
the working state information acquisition module, the information storage module, the information preprocessing module, the fault risk assessment module and the human-computer interaction device are sequentially connected, the fault risk assessment module is connected with the fault knowledge base module, the human-computer interaction device is connected with the fault knowledge base module, and the human-computer interaction device is connected with the internet through the communication module.
2. The petrochemical device failure probability risk assessment system of claim 1, wherein: the working state information acquisition module comprises a vibration data acquisition unit, a pressure data acquisition unit, a temperature data acquisition unit, a voltage data acquisition unit and a current data acquisition unit, and the vibration data acquisition unit, the pressure data acquisition unit, the temperature data acquisition unit, the voltage data acquisition unit and the current data acquisition unit are all connected with the information storage module.
3. The petrochemical device failure probability risk assessment system of claim 2, wherein: the vibration data acquisition unit with acceleration sensor on the petrochemical equipment is connected, pressure data acquisition unit with pressure sensor on the petrochemical equipment is connected, temperature data acquisition unit with temperature sensor on the petrochemical equipment is connected, voltage data acquisition unit with voltage sensor on the petrochemical equipment is connected, current data acquisition with current sensor on the petrochemical equipment is connected.
4. The petrochemical device failure probability risk assessment system of claim 1, wherein: and the information preprocessing module converts the petrochemical equipment working data into an electric signal, and performs filtering and noise reduction to obtain data to be detected.
5. The petrochemical device failure probability risk assessment system of claim 1, wherein: the fault risk assessment module comprises a fault risk type judgment unit, a fault feature extraction unit and a fault risk level assessment unit, wherein the fault risk type judgment unit is used for judging components with abnormal operation data, the fault feature extraction unit is used for acquiring feature information required by fault diagnosis, the fault risk level assessment unit is used for assessing fault risk levels, the fault risk type judgment unit, the fault feature extraction unit and the fault risk level assessment unit are sequentially connected, the fault risk level assessment unit is connected with the fault knowledge base module, and the fault risk level assessment unit is connected with the human-computer interaction device.
6. The petrochemical device failure probability risk assessment system of claim 1, wherein: the man-machine interaction device comprises a display unit and an alarm unit, wherein the display unit is used for displaying a fault occurrence position, a fault risk level and a fault reason.
7. The petrochemical plant failure probability risk assessment system of claim 1 or 6, wherein: the alarm unit adopts an alarm which can send out different alarm sounds according to the fault grade.
8. A petrochemical equipment fault probability risk assessment method is characterized by comprising the following steps: the method comprises the following steps:
acquiring historical fault data of petrochemical equipment, and constructing a fault knowledge base of the petrochemical equipment;
acquiring real-time operation data of the petrochemical equipment, and preprocessing the real-time operation data to obtain data to be detected;
comparing the data to be detected with the fault database, evaluating the fault probability risk of the petrochemical equipment, and obtaining a fault probability risk evaluation result;
and displaying the fault probability risk assessment result, and carrying out early warning prompt according to the fault probability risk assessment result.
9. The petrochemical device fault probability risk assessment method of claim 8, wherein: the preprocessing comprises the steps of converting the real-time operation data into electric signals, generating a signal wave pattern based on the electric signals, and filtering and denoising the signal wave pattern.
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| CN113936441A (en) * | 2021-11-15 | 2022-01-14 | 河北金融学院 | Power station risk automatic identification and early warning device |
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