CN115127848B - Heat exchanger pipeline blockage detection method - Google Patents
Heat exchanger pipeline blockage detection method Download PDFInfo
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- CN115127848B CN115127848B CN202211050087.4A CN202211050087A CN115127848B CN 115127848 B CN115127848 B CN 115127848B CN 202211050087 A CN202211050087 A CN 202211050087A CN 115127848 B CN115127848 B CN 115127848B
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- 238000001514 detection method Methods 0.000 title claims description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 114
- 229910001868 water Inorganic materials 0.000 claims abstract description 114
- 229910001425 magnesium ion Inorganic materials 0.000 claims abstract description 76
- JLVVSXFLKOJNIY-UHFFFAOYSA-N Magnesium ion Chemical compound [Mg+2] JLVVSXFLKOJNIY-UHFFFAOYSA-N 0.000 claims abstract description 69
- 229910001424 calcium ion Inorganic materials 0.000 claims abstract description 68
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 claims abstract description 64
- 239000011575 calcium Substances 0.000 claims abstract description 64
- 238000011156 evaluation Methods 0.000 claims abstract description 56
- 239000013598 vector Substances 0.000 claims abstract description 33
- 238000000034 method Methods 0.000 claims abstract description 31
- 150000002500 ions Chemical class 0.000 claims description 28
- 238000012546 transfer Methods 0.000 claims description 10
- 238000004364 calculation method Methods 0.000 claims description 8
- ZFXVRMSLJDYJCH-UHFFFAOYSA-N calcium magnesium Chemical compound [Mg].[Ca] ZFXVRMSLJDYJCH-UHFFFAOYSA-N 0.000 claims description 7
- BHPQYMZQTOCNFJ-UHFFFAOYSA-N Calcium cation Chemical compound [Ca+2] BHPQYMZQTOCNFJ-UHFFFAOYSA-N 0.000 claims description 6
- 238000012545 processing Methods 0.000 abstract description 8
- 230000015572 biosynthetic process Effects 0.000 description 8
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 6
- 238000004140 cleaning Methods 0.000 description 4
- 230000005540 biological transmission Effects 0.000 description 3
- 229910000019 calcium carbonate Inorganic materials 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 description 3
- 239000001095 magnesium carbonate Substances 0.000 description 3
- 229910000021 magnesium carbonate Inorganic materials 0.000 description 3
- 230000005236 sound signal Effects 0.000 description 3
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- 229910052791 calcium Inorganic materials 0.000 description 2
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 238000002592 echocardiography Methods 0.000 description 2
- 230000008030 elimination Effects 0.000 description 2
- 238000003379 elimination reaction Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 239000012530 fluid Substances 0.000 description 2
- 238000000691 measurement method Methods 0.000 description 2
- 238000011144 upstream manufacturing Methods 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 229910000975 Carbon steel Inorganic materials 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- BPKGOZPBGXJDEP-UHFFFAOYSA-N [C].[Zn] Chemical compound [C].[Zn] BPKGOZPBGXJDEP-UHFFFAOYSA-N 0.000 description 1
- 230000002159 abnormal effect Effects 0.000 description 1
- 239000003570 air Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000009835 boiling Methods 0.000 description 1
- NKWPZUCBCARRDP-UHFFFAOYSA-L calcium bicarbonate Chemical compound [Ca+2].OC([O-])=O.OC([O-])=O NKWPZUCBCARRDP-UHFFFAOYSA-L 0.000 description 1
- 229910000020 calcium bicarbonate Inorganic materials 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- 239000010962 carbon steel Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 238000006056 electrooxidation reaction Methods 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 238000004880 explosion Methods 0.000 description 1
- 238000009776 industrial production Methods 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- QWDJLDTYWNBUKE-UHFFFAOYSA-L magnesium bicarbonate Chemical compound [Mg+2].OC([O-])=O.OC([O-])=O QWDJLDTYWNBUKE-UHFFFAOYSA-L 0.000 description 1
- 229910000022 magnesium bicarbonate Inorganic materials 0.000 description 1
- 239000002370 magnesium bicarbonate Substances 0.000 description 1
- 235000014824 magnesium bicarbonate Nutrition 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 238000013021 overheating Methods 0.000 description 1
- 238000005057 refrigeration Methods 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M99/00—Subject matter not provided for in other groups of this subclass
- G01M99/002—Thermal testing
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M99/00—Subject matter not provided for in other groups of this subclass
- G01M99/008—Subject matter not provided for in other groups of this subclass by doing functionality tests
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- Testing Of Devices, Machine Parts, Or Other Structures Thereof (AREA)
- Examining Or Testing Airtightness (AREA)
Abstract
The invention relates to the technical field of data processing, in particular to a method for detecting pipeline blockage of a heat exchanger. The method comprises the steps of obtaining the power of a heat exchanger, the content of calcium and magnesium ions and water flow; obtaining the position order difference of the maximum content and the minimum content in the calcium and magnesium ion content sequence; obtaining a scaling rate evaluation index according to the position order difference, the content of calcium and magnesium ions and the change degree of the power of the heat exchanger; obtaining a pipeline danger evaluation index according to the difference of water flow and the scaling rate evaluation index of the adjacent time periods; and extracting sound characteristic vectors in the pipeline, calculating a plurality of heat exchange efficiencies by the similarity of each dimension of sound characteristic vectors and standard characteristic vectors and the danger evaluation index of the pipeline, and further judging whether to remove water scales from the pipeline of the heat exchanger. According to the embodiment of the invention, the heat exchange efficiency of the heat exchanger is determined according to various parameter data in the heat exchanger, and then whether scale is removed from the heat exchanger pipeline is judged, so that the purpose of removing the scale in time is achieved.
Description
Technical Field
The invention relates to the technical field of data processing, in particular to a method for detecting pipeline blockage of a heat exchanger.
Background
Heat exchangers are important components of refrigeration systems, wherein the heat exchange tubes are usually constructed of hot-dipped zinc carbon steel tubes, aluminum alloy tubes, stainless steel tubes, and the like. Due to long-time or high-power operation, dust in the air and calcium, magnesium ions and the like in water can cause scaling on the surface of the heat exchange tube, affect the heat exchange efficiency and cause the shutdown of the heat exchanger in severe cases. Calcium and magnesium ions in water can form calcium carbonate and magnesium carbonate when being heated, and can be attached to the inner wall of a heat exchanger pipeline without cleaning for a long time, so that the pipeline is easily blocked, the heat exchange effect of the heat exchanger can be reduced, and the industrial production efficiency is further influenced. And the water scale is attached to the heat transfer surface and is difficult to remove, so that the maintenance cost is increased, the manpower and material resources are consumed, the heating surface is damaged, and the service life of the plate heat exchanger is shortened.
At present, the common method of clearing away incrustation scale in the heat exchange tube of heat exchanger is, handle the incrustation scale at fixed time, and the formation of incrustation scale can not accurate detection of this method, can lead to the heat exchange tube to block up and shorten the life-span of heat exchanger to untimely the processing of incrustation scale, and it can lead to the heat exchange efficiency of heat exchanger to clear away the incrustation scale untimely lower.
Disclosure of Invention
In order to solve the technical problems, the invention aims to provide a method for detecting the blockage of a heat exchanger pipeline, which adopts the following technical scheme:
acquiring the power of a heat exchanger, the content of calcium and magnesium ions at a water inlet of a pipeline and the water flow in the pipeline;
obtaining the position order difference of the maximum content and the minimum content in the calcium and magnesium ion content sequence; obtaining the maximum range and the content mean value of the content of calcium and magnesium ions in the calcium and magnesium ion content sequence; obtaining the ion content variation degree by the maximum range and the content mean value; acquiring a maximum power and a power mean value in a heat exchanger power sequence, wherein the difference value of the maximum power and the power mean value is a power change degree; obtaining a scaling rate evaluation index according to the position order difference, the ion content change degree and the power change degree;
obtaining the uniformity degree of the water flow in the pipeline according to the difference of the adjacent water flows in the water flow sequence, and multiplying the uniformity degree by the scaling rate evaluation index to obtain a pipeline danger evaluation index;
collecting sound data in a pipeline, extracting multi-dimensional sound characteristic vectors, and calculating the similarity of each dimension of the sound characteristic vectors and a standard characteristic vector; and calculating a plurality of heat exchange efficiencies according to the similarity and the pipeline danger evaluation index, and judging whether scale removal is carried out on the heat exchanger pipeline according to the heat exchange efficiencies.
Preferably, the method for obtaining the content of calcium and magnesium ions comprises the following steps: and detecting the content of calcium ions and the content of magnesium ions at the water inlet of the pipeline by using a calcium and magnesium ion concentration tester, wherein the sum of the content of the calcium ions and the content of the magnesium ions is the content of the calcium and magnesium ions.
Preferably, the method for obtaining the power of the heat exchanger comprises the following steps: measuring the average temperature difference between a water inlet and a water outlet of the pipeline by using a temperature sensor; and obtaining the area of the heat exchanger, wherein the product of the area, the average temperature difference and the heat transfer coefficient of the heat exchanger is the power of the heat exchanger.
Preferably, the method for acquiring the water flow in the pipeline comprises the following steps: and measuring the water flow in the heat exchanger pipeline by using the surface-mounted pipeline flowmeter.
Preferably, the obtaining of the scaling rate evaluation index according to the position order difference, the ion content change degree and the power change degree comprises:
the calculation formula of the scaling rate evaluation index is as follows:
wherein,
evaluating an index for the fouling rate;
is a natural constant;
is the maximum content in the calcium-magnesium ion content sequence;
is the minimum content in the calcium-magnesium ion content sequence;
is the maximum range;
is the content average value;
is a hyperbolic tangent function;
is the maximum power;
is the power mean;
is a sign function;
the position order of the maximum content in the calcium-magnesium ion content sequence;
the position order of the minimum content in the calcium-magnesium ion content sequence is shown;
is the position order difference.
Preferably, the obtaining the uniformity of the water flow in the pipeline according to the difference between adjacent water flows in the water flow sequence includes:
the calculation formula of the uniformity degree is as follows:
wherein,
the degree of homogeneity;
is the total length of the water flow sequence;
for the second in the water flow sequence
Individual water flow rate;
as the second in the water flow sequence
Individual water flow rate;
as a function of absolute value;
as the second in the water flow sequence
The flow rate of water.
Preferably, the calculating a plurality of heat exchange efficiencies according to the similarity and the pipeline risk evaluation index includes:
1, subtracting the pipeline danger evaluation index to obtain initial efficiency evaluation; and the product of the initial efficiency evaluation and the normalized similarity is the heat exchange efficiency.
Preferably, the judging whether to remove the scale from the heat exchanger pipeline according to the heat exchange efficiency includes:
when any heat exchange efficiency in the heat exchanger efficiencies is smaller than a preset heat exchange efficiency threshold value, scale is removed from the heat exchanger pipeline.
The embodiment of the invention at least has the following beneficial effects:
the embodiment of the invention utilizes a data processing technology, and the method obtains the power of a heat exchanger, the content of calcium and magnesium ions at a water inlet of a pipeline and the water flow in the pipeline; obtaining the position order difference of the maximum content and the minimum content in the calcium and magnesium ion content sequence; obtaining the maximum range and the content mean value of the content of calcium and magnesium ions in the calcium and magnesium ion content sequence; obtaining the ion content variation degree by the maximum range difference and the content mean value; acquiring a maximum power and a power mean value in a heat exchanger power sequence, wherein the difference value of the maximum power and the power mean value is the power change degree; obtaining a scaling rate evaluation index according to the position order difference, the ion content change degree and the power change degree; obtaining the uniformity degree of the water flow in the pipeline according to the difference of the adjacent water flows in the water flow sequence, and multiplying the uniformity degree by the scaling rate evaluation index to obtain a pipeline danger evaluation index; collecting sound data in a pipeline, extracting multi-dimensional sound characteristic vectors, and calculating the similarity of each-dimensional sound characteristic vector and a standard characteristic vector; and calculating a plurality of heat exchange efficiencies according to the similarity and the pipeline danger evaluation index, and judging whether scale removal is carried out on the heat exchanger pipeline according to the heat exchange efficiencies. Because the industrial heat exchanger is large in size, the cleaning of the interior of the heat exchanger or the replacement of the heat exchanger is a huge project, the heat exchange efficiency of the heat exchanger is determined according to various parameter data in the heat exchanger, and when the heat exchange efficiency is lower than a preset heat exchange efficiency threshold value, the normal work of the heat exchanger is influenced by water scale generated in a pipeline, and at the moment, the cleaning operation is carried out.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions and advantages of the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and other drawings can be obtained by those skilled in the art without creative efforts.
Fig. 1 is a flowchart of a method for detecting a heat exchanger pipe blockage according to an embodiment of the present invention.
Detailed Description
The embodiment of the invention provides a specific implementation method of a heat exchanger pipeline blockage detection method, which is suitable for a heat exchanger pipeline blockage detection scene. The temperature difference between the water inlet and the water outlet of the pipeline is measured by using the temperature sensor under the scene, the calcium and magnesium ion content at the water inlet of the pipeline is detected by using the calcium and magnesium ion concentration detector, the water flow in the pipeline is measured by using the surface-mounted pipeline flowmeter, the sound data in the pipeline is measured by using the acoustic instrument, and the problem that the scale cannot be processed timely is solved when the scale is processed by adopting fixed time. According to the embodiment of the invention, the heat exchange efficiency of the heat exchanger is determined according to various parameter data in the heat exchanger, when the heat exchange efficiency is lower than a preset heat exchange efficiency threshold value, the fact that the normal work of the heat exchanger is influenced by the scale generated in the pipeline is reflected, at the moment, the scale removing operation is carried out, and the scale amount in the pipeline and the pipeline blockage degree are judged by calculating and analyzing the scale rate evaluation index, the pipeline danger evaluation index and the heat exchange efficiency, so that the purpose of timely treating the scale is achieved.
The following describes a specific scheme of the heat exchanger pipeline blockage detection method provided by the invention in detail with reference to the accompanying drawings.
Referring to fig. 1, a flow chart illustrating steps of a method for detecting a pipe blockage in a heat exchanger according to an embodiment of the present invention is shown, where the method includes the following steps:
and S100, acquiring the power of the heat exchanger, the content of calcium and magnesium ions at the water inlet of the pipeline and the water flow in the pipeline.
In order to timely detect the generation condition of the water scale and timely clean the water scale, the problem that the heat exchanger is low in heat exchange efficiency or even interrupted due to the fact that the water scale causes the heat exchanger pipeline to be blocked is prevented. According to the invention, the evaluation of the blockage degree of the pipeline is realized by analyzing the power of the heat exchanger, the content of calcium and magnesium ions at the water inlet of the pipeline and the water flow in the pipeline to obtain a pipeline danger evaluation index, and the heat exchange efficiency of the heat exchanger is evaluated by combining sound data in the pipeline.
The heat exchanger power can influence the production of incrustation scale, under the condition of high power and heavy load, the water evaporation frequency in the heat exchanger pipeline is very high, calcium sulfate which is difficult to dissolve in water is precipitated, calcium bicarbonate and magnesium bicarbonate which are originally dissolved are decomposed in boiling water to release carbon dioxide, and become calcium carbonate and magnesium carbonate which are difficult to dissolve, and the calcium carbonate and the magnesium carbonate which are difficult to dissolve are also precipitated, so that the incrustation scale generation amount is increased rapidly, and the probability that the heat exchanger pipeline is influenced by the incrustation scale to be blocked is greatly increased. In the embodiment of the invention, the heat exchanger is a plate heat exchanger, and in other embodiments, the heat exchangers such as a spiral plate heat exchanger and a tube heat exchanger can be analyzed. The power of the plate heat exchanger is determined by the amount required at the end, the heat exchanger only plays a role in heat transfer, but the heat transfer of the heat exchanger must follow the principle of conservation of energy.
Method for obtaining power of heat exchanger, in particularThe following steps: measuring the average temperature difference of a water inlet and a water outlet of the pipeline by using a temperature sensor; and obtaining the area of the heat exchanger, wherein the product of the area, the average temperature difference and the heat transfer coefficient of the heat exchanger is the power of the heat exchanger. In the embodiment of the invention, the heat transfer coefficient of the plate heat exchanger is set to 4000W/m 2 The overall heat transfer coefficient of a typical plate heat exchanger is typically 3000W/m 2 ~5000W/m 2 In other embodiments, the heat transfer coefficient may be set by the implementer according to actual conditions. The power of the heat exchanger is measured three times at the beginning of a month, in the middle of the month and at the end of the month respectively every month, so that the condition that the data in the current month is inaccurate due to sudden increase of the power in a certain day is avoided. And taking the average value of the heat exchanger power obtained by three times of measurement at the beginning of the month, in the middle of the month and at the end of the month as the heat exchanger power of the month, acquiring the heat exchanger power of each month, and constructing a heat exchanger power sequence.
The scale is mainly formed by that the salt containing calcium, magnesium and the like in the water is precipitated and adhered to the surface of metal after being heated. The heat conductivity coefficient of the water scale is very small and is about 2% -5% of that of common steel, the heat transfer effect of the water scale on the heating surface of the heat exchanger tube can be greatly deteriorated, the heat exchange efficiency of the heat exchanger is influenced, and metal materials are easily burnt out due to local overheating and even tube explosion accidents occur; the electrochemical corrosion is promoted to be intensified, the scale corrosion of the heat exchanger pipeline is caused, and the damage of the heating surface is accelerated.
The acquisition mode of the content of calcium and magnesium ions is as follows: and detecting the calcium ion content and the magnesium ion content at the water inlet of the pipeline by using a calcium and magnesium ion concentration tester, wherein the sum of the calcium ion content and the magnesium ion content is the calcium and magnesium ion content.
The larger the content of calcium and magnesium ions in water means that the water scale is easier to generate, and the calcium and magnesium ion concentration is obtained once a month to construct a calcium and magnesium ion content sequence.
The method for acquiring the water flow in the pipeline specifically comprises the following steps: and measuring the water flow in the heat exchanger pipeline by using the surface-mounted pipeline flowmeter to construct a water flow sequence. The surface-mounted pipeline flowmeter is a measuring mode for measuring the time difference of ultrasonic transmission of upstream and downstream by using an ultrasonic time difference method so as to obtain the flow velocity in a pipeline. The method has the advantages that accurate flow data can be obtained by installing the external clamping type sensor to measure the transmitting and receiving time difference of upstream and downstream transmission signals under the condition of no water cut-off. The ultrasonic time difference measurement method is a measurement method for determining the average flow velocity of a flowing fluid by using the time difference of the propagation time of two ultrasonic signals which propagate in a forward flow and a reverse flow in the same stroke of the flowing fluid.
Step S200, acquiring the position order difference of the maximum content and the minimum content in the calcium and magnesium ion content sequence; obtaining the maximum range and the content mean value of the content of calcium and magnesium ions in the calcium and magnesium ion content sequence; obtaining the ion content variation degree by the maximum range difference and the content mean value; acquiring a maximum power and a power mean value in a heat exchanger power sequence, wherein the difference value of the maximum power and the power mean value is the power change degree; and obtaining a scaling rate evaluation index according to the position sequence difference, the ion content change degree and the power change degree.
And acquiring the position order of the maximum content and the position order of the minimum content in the calcium and magnesium ion content sequence to obtain the position order difference of the maximum content and the minimum content in the calcium and magnesium ion content sequence.
Further, a difference value between the maximum content and the minimum content of the calcium and magnesium ion content in the calcium and magnesium ion content sequence is obtained as a maximum range, a content mean value corresponding to the calcium and magnesium ion content sequence is obtained, and the ion content change degree is obtained from the maximum range and the content mean value. The ion content change degree is the relative change condition of the calcium and magnesium ion content sequence, the larger the relative change of the calcium and magnesium ion content is, the overlarge water quality change is shown, and the change condition of the calcium and magnesium ion content can influence the generation speed of the scale to be faster or slower; on the contrary, the smaller the change of the content of calcium and magnesium ions is, the smaller the change of water quality is, and the change of the scale formation rate is not greatly influenced.
And acquiring the maximum power and the average power value in the heat exchanger power sequence, wherein the difference value of the maximum power and the average power value is the power change degree. The larger the power change degree is, the condition that the power of the heat exchanger is increased suddenly is indicated, the month corresponding to the maximum value of the power of the heat exchanger works under the condition of high power and heavy load, the scaling rate in the pipeline of the heat exchanger is increased, and the pipeline is easier to block. Conversely, the smaller the power change degree is, the more uniform the power of the heat exchanger is, the stable working condition of the heat exchanger is, and the scaling rate in the pipeline is not changed or slightly changed.
Weighting the degree of change of the ion content according to the position order difference between the maximum content and the minimum content, wherein when the position order of the maximum content is greater than the position order of the minimum content, the weight of the degree of change of the ion content is 1; when the position order of the maximum content is equal to the position order of the minimum content, the weight given to the degree of change of the ion content is 0; when the order of positions of the maximum content is smaller than that of the minimum content, a weight of-1 is given to the degree of change in the ion content. Note that, the meaning of weighting the degree of change in ion content according to the difference in position order is:
if the ion content of the calcium and magnesium ions changes to a greater extent and the given weight is 1, reflecting that the content of the calcium and magnesium ions in the water changes faster and at a greater and greater rate, the scale generation rate is faster and faster at the moment;
if the ion content of the calcium and magnesium ions changes to a greater extent and the given weight is-1, reflecting that the content of the calcium and magnesium ions in the water changes faster and at a smaller rate, the scale generation rate is slower and slower;
if the ion content of the calcium and magnesium ions changes to a smaller extent and the given weight is 1, the content of the calcium and magnesium ions in the water is reflected to be larger but the change rate is slow, and the scale generation rate can be ignored at the moment;
if the ion content of calcium and magnesium ions changes to a smaller extent and the weight given thereto is-1, it is reflected that the content of calcium and magnesium ions in water is small and the rate of change is slow, and the rate of scale formation is negligible.
And taking an exponential function taking the natural constant as a base number and the ion content change degree given with the weight as an index as an ion content evaluation index.
The product of the ion content evaluation index and the normalized power change degree is a scaling rate evaluation index, namely the scaling rate evaluation index is obtained according to the position sequence difference, the ion content change degree and the power change degree.
The index for evaluating the fouling rate
The calculation formula of (2) is as follows:
wherein,
is a natural constant;
the maximum content of the calcium and magnesium ion content sequence;
is the minimum content in the calcium and magnesium ion content sequence;
is the maximum range;
is the content average value;
is a hyperbolic tangent function;
maximum power;
is the average power value;
is a sign function;
the position order of the maximum content in the calcium and magnesium ion content sequence;
is the position order of the minimum content in the calcium and magnesium ion content sequence;
is the positional order difference.
The aim of giving weight to the ion content change degree according to the position order difference is fulfilled through a symbolic function; the purpose of normalizing the power change degree is realized through the hyperbolic tangent function.
Wherein,
is an ion content evaluation index;
is the normalized power variation degree.
The scale formation rate evaluation index is obtained for analyzing the possible scale formation of the inner wall of the heat exchanger pipeline and the change speed of the scale formation rate, and is convenient for determining the pipeline blockage degree and the subsequent treatment process according to different scale formation rates.
And step S300, obtaining the uniformity of the water flow in the pipeline according to the difference of the adjacent water flows in the water flow sequence, and multiplying the uniformity by the scaling rate evaluation index to obtain a pipeline risk evaluation index.
When the pipeline is good and has no scale residue or is hollow due to corrosion, the water flow in the pipeline is almost kept unchanged, namely the difference between the adjacent water flow at the current moment and the previous moment is zero, and the obtained difference between the adjacent water flows is 0, so that the uniformity of the water flow in the pipeline is better.
And obtaining the uniformity of the water flow in the pipeline according to the difference of the adjacent water flow in the water flow.
The uniformity degree
The calculation formula of (2) is as follows:
wherein,
is the total length of the water flow sequence;
as the second in the water flow sequence
Individual water flow rate;
for the second in the water flow sequence
Individual water flow rate;
as a function of absolute value;
as the second in the water flow sequence
The flow rate of water.
Wherein, in the calculation formula of the uniformity degree,
the difference value of the water flow at the current moment and the water flow at the previous moment is represented;
means representing the mean value of water flow at the present moment and all moments before, and the previous momentAnd the difference value of the average value of the water flow at all the moments before the previous moment.
Furthermore, the evaluation index of the fouling rate of the pipeline is also an important factor for determining the blockage degree in the pipeline. The high scaling rate means that the water circulation volume in the pipeline is large, which indirectly causes the increase of calcium and magnesium ions contained in the water with the flow, the scale formation volume is increased, and at the moment, the danger degree that the heat exchanger pipeline is blocked by the scale is high. On the contrary, the slow scaling rate reflects that the water circulation quantity passing through the heat exchanger pipeline does not change too much, the heat exchanger keeps working stably, and the danger degree that the scale blocks the heat exchanger pipeline is lower at the moment.
If the scaling rate evaluation index corresponding to the pipeline is larger but the water flow uniformity degree is also larger, the fact that the scale in the pipeline is leveled is reflected, the influence on the heat exchange efficiency of the heat exchanger is smaller, and the danger degree that the scale blocks the pipeline of the heat exchanger is lower; if the scaling rate evaluation index corresponding to the pipeline is smaller but the water flow uniformity degree is smaller, the overlapping of the scale at a certain position in the pipeline is reflected, and the danger degree that the heat exchanger pipeline is blocked by the scale is high.
And multiplying the uniformity and the scaling rate evaluation index to obtain a pipeline danger evaluation index.
S400, collecting sound data in a pipeline, extracting multi-dimensional sound characteristic vectors, and calculating the similarity between each-dimensional sound characteristic vector and a standard characteristic vector; and calculating a plurality of heat exchange efficiencies according to the similarity and the pipeline danger evaluation index, and judging whether scale removal is carried out on the heat exchanger pipeline according to the heat exchange efficiencies.
Usually the incrustation scale presents graininess and powdered, when the pipeline is strikeed by rivers to the bold incrustation scale, the incrustation scale card is in the heat exchanger pipeline, rivers will send the noise through meetting the obstacle, especially the sound at the terminal that hot water used is most obvious, the problem of handling the noise to the incrustation scale in the pipeline can only be alleviated this moment, the incrustation scale condition in the pipeline can further be judged according to the sound data in the pipeline, the sound data in its current pipeline and the standard sound data similarity under the no incrustation scale condition are less, the difference is the bigger, it is more serious to reflect the incrustation scale condition, the heat exchange efficiency influence to the heat exchanger is big more.
An acoustic instrument is placed in a pipeline, data acquisition and signal processing equipment is arranged outside the pipeline, the tail end of the pipeline is semi-closed, sound is reflected, refracted and scattered when encountering the tail end of the pipeline in the transmission process of the pipeline, a large number of information reflection echoes carrying pipeline scaling defects are generated, and the data acquisition and signal processing equipment acquires the reflected echoes to obtain sound signal data of the pipeline. The data acquisition and signal processing equipment processes signal data, sound signal data are decomposed and reconstructed by adopting a dual-tree complex wavelet transform algorithm to obtain components of each frequency band, the components of each frequency band are respectively represented by a time domain diagram, the time domain diagram is observed, the frequency band component represented by the time domain diagram with large noise is removed, the components of other frequency bands are used as effective frequency band components, sound pressure level transformation is carried out on the effective frequency band components to obtain sound pressure level signals of each effective frequency band component, and sound intensity can be further obtained through the sound pressure level signals.
The method comprises the steps of obtaining the intensity of sound in a heat exchanger pipeline, namely obtaining the sound energy value of the sound in the heat exchanger pipeline, collecting sound data when the sound energy value is larger than a set value, and carrying out analog-to-digital conversion on the sound data. The collected sound data is processed to extract relevant sound characteristics, the extracted sound characteristics are compared with the sound characteristics under the normal scale-free condition stored in a database, and the similarity of the sound characteristics is calculated to determine whether the sound signal is abnormal caused by the scale generated by water flow collision.
Collecting sound data in a pipeline, extracting multi-dimensional sound characteristic vectors, and calculating the similarity between each-dimensional sound characteristic vector and a standard characteristic vector. Specifically, the method comprises the following steps: detecting the sound energy in the pipeline at set time intervals, and acquiring sound data when the sound energy is greater than a set value; and converting the collected sound data into digital signals through analog signals, and extracting the characteristics of the digital signals to obtain characteristic parameters. Wherein, the extracted characteristic parameters comprise: sound amplitude maximum, minimum, mean, variance, energy histogram. Note that the frequency domain characteristics of the sound are obtained by using a fast fourier transform. Combining the characteristic parameters together to form a high-dimensional sound characteristic vector, and calculating the following formula for each dimension of sound characteristic vector in order to eliminate the magnitude difference:
wherein,
the ith original sound characteristic vector corresponding to the ith actually obtained characteristic parameter is obtained;
the maximum value of the ith sound characteristic vector prestored in the database;
the minimum value of the ith sound characteristic vector prestored in the database is obtained;
the feature vector of the voice to be recognized after the ith elimination order is obtained.
Calculating the voice characteristic vector to be recognized after eliminating the magnitude order
Standard characteristic vector corresponding to scale-free time prestored in database
The similarity of (c). The similarity in the embodiment of the invention is calculated by adopting an Euclidean distance formula. And after the similarity corresponding to each dimension of sound feature vector is obtained, normalizing the similarity.
And obtaining the heat exchange efficiency of the plurality of heat exchangers according to the pipeline danger evaluation indexes of the heat exchanger pipeline blocked by the water scale and the plurality of similarities corresponding to the sound characteristic vectors. Specifically, the method comprises the following steps: 1, subtracting a pipeline danger evaluation index to obtain an initial efficiency evaluation; and the product of the initial efficiency evaluation and the normalized similarity is the heat exchange efficiency.
The heat exchange efficiency of the heat exchanger corresponding to the ith characteristic parameter
The calculation formula of (2) is as follows:
wherein,
is a pipeline danger evaluation index;
for the sound characteristic vector to be identified after the ith elimination order of magnitude
Standard feature vector corresponding to scale-free time prestored in database
The normalized similarity of (a);
is an initial efficiency evaluation.
The heat exchange efficiency reflects the influence degree of the current heat exchanger on the scale. The more the scale exists, the greater the influence on the operation effect of the heat exchanger is, and the lower the corresponding heat exchange efficiency is.
A plurality of sound characteristic parameters correspond the heat exchange efficiency of a plurality of heat exchangers, and when any heat exchange efficiency is less than a preset heat exchange efficiency threshold value in the obtained heat exchange efficiency of a plurality of heat exchangers, the incrustation scale is removed from the heat exchanger pipeline. In the embodiment of the invention, the value of the preset heat exchange efficiency threshold is 0.8, and in other embodiments, an implementer can adjust the value according to actual conditions.
In summary, in the embodiments of the present invention, a data processing technology is used, and the method obtains the power of the heat exchanger, the content of calcium and magnesium ions at the water inlet of the pipeline, and the water flow rate in the pipeline; obtaining the position order difference of the maximum content and the minimum content in the calcium and magnesium ion content sequence; obtaining the maximum range and the content mean value of the content of calcium and magnesium ions in the calcium and magnesium ion content sequence; obtaining the ion content variation degree by the maximum range difference and the content mean value; acquiring a maximum power and a power mean value in a heat exchanger power sequence, wherein the difference value of the maximum power and the power mean value is the power change degree; obtaining a scaling rate evaluation index according to the position order difference, the ion content change degree and the power change degree; obtaining the uniformity degree of the water flow in the pipeline according to the difference of the adjacent water flows in the water flow sequence, and multiplying the uniformity degree by the scaling rate evaluation index to obtain a pipeline danger evaluation index; collecting sound data in a pipeline, extracting multi-dimensional sound characteristic vectors, and calculating the similarity between each-dimensional sound characteristic vector and a standard characteristic vector; and calculating a plurality of heat exchange efficiencies according to the similarity and the pipeline danger evaluation index, and judging whether scale removal is carried out on the heat exchanger pipeline according to the heat exchange efficiencies. Because the industrial heat exchanger is large in size, the cleaning of the interior of the heat exchanger or the replacement of the heat exchanger is a huge project, the heat exchange efficiency of the heat exchanger is determined according to various parameter data in the heat exchanger, and when the heat exchange efficiency is lower than a preset heat exchange efficiency threshold value, the fact that scale generated in a pipeline influences the normal work of the heat exchanger is reflected, and at the moment, scale removing operation is carried out.
Claims (4)
1. A heat exchanger pipeline blockage detection method is characterized by comprising the following steps:
acquiring the power of a heat exchanger, the content of calcium and magnesium ions at a water inlet of a pipeline and the water flow in the pipeline;
obtaining the position order difference of the maximum content and the minimum content in the calcium and magnesium ion content sequence; obtaining the maximum range and the content mean value of the content of calcium and magnesium ions in the calcium and magnesium ion content sequence; obtaining the ion content variation degree by the maximum range and the content mean value; acquiring the maximum power and the average power value in the heat exchanger power sequence, wherein the difference value of the maximum power and the average power value is the power change degree; obtaining a scaling rate evaluation index according to the position order difference, the ion content change degree and the power change degree;
obtaining the uniformity degree of the water flow in the pipeline according to the difference of the adjacent water flows in the water flow sequence, and multiplying the uniformity degree by the scaling rate evaluation index to obtain a pipeline danger evaluation index;
collecting sound data in a pipeline, extracting multi-dimensional sound characteristic vectors, and calculating the similarity of each dimension of the sound characteristic vectors and a standard characteristic vector; calculating a plurality of heat exchange efficiencies according to the similarity and the pipeline danger evaluation index, and judging whether scale removal is carried out on the heat exchanger pipeline or not according to the heat exchange efficiencies;
wherein, the calculation formula of the scaling rate evaluation index is as follows:
wherein,
evaluating an index for the fouling rate;
is a natural constant;
is the maximum content in the calcium-magnesium ion content sequence;
is the minimum content in the calcium-magnesium ion content sequence;
is the maximum range;
is the content average value;
is a hyperbolic tangent function;
is the maximum power;
is the power mean;
is a sign function;
the position order of the maximum content in the calcium and magnesium ion content sequence is shown;
the position order of the minimum content in the calcium-magnesium ion content sequence is shown;
is the position order difference;
wherein, the calculation formula of the uniformity degree is as follows:
wherein,
the degree of homogeneity;
is the total length of the water flow sequence;
is waterIn the flow sequence
Individual water flow rate;
as the second in the water flow sequence
Individual water flow rate;
as a function of absolute value;
as the second in the water flow sequence
Individual water flow rate;
and calculating a plurality of heat exchange efficiencies according to the similarity and the pipeline danger evaluation index, wherein the method for judging whether scale removal is carried out on the heat exchanger pipeline according to the heat exchange efficiencies comprises the following steps: 1, subtracting the pipeline danger evaluation index to obtain initial efficiency evaluation; the product of the initial efficiency evaluation and the normalized similarity is the heat exchange efficiency; when any heat exchange efficiency in the heat exchanger efficiencies is smaller than a preset heat exchange efficiency threshold value, scale is removed from the heat exchanger pipeline.
2. The method for detecting the pipe blockage of the heat exchanger according to claim 1, wherein the method for acquiring the content of calcium and magnesium ions comprises the following steps: and detecting the content of calcium ions and the content of magnesium ions at a water inlet of the pipeline by using a calcium and magnesium ion concentration tester, wherein the sum of the content of the calcium ions and the content of the magnesium ions is the content of the calcium and magnesium ions.
3. The method for detecting the pipe blockage of the heat exchanger as claimed in claim 1, wherein the method for acquiring the power of the heat exchanger comprises the following steps: measuring the average temperature difference between a water inlet and a water outlet of the pipeline by using a temperature sensor; and obtaining the area of the heat exchanger, wherein the product of the area, the average temperature difference and the heat transfer coefficient of the heat exchanger is the power of the heat exchanger.
4. The method for detecting the blockage of the pipeline of the heat exchanger according to claim 1, wherein the method for acquiring the water flow in the pipeline comprises the following steps: and measuring the water flow in the heat exchanger pipeline by using the surface-mounted pipeline flowmeter.
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