CN116222905A - Fault diagnosis method for online identification and quantitative valve internal leakage - Google Patents

Fault diagnosis method for online identification and quantitative valve internal leakage Download PDF

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Publication number
CN116222905A
CN116222905A CN202310247766.9A CN202310247766A CN116222905A CN 116222905 A CN116222905 A CN 116222905A CN 202310247766 A CN202310247766 A CN 202310247766A CN 116222905 A CN116222905 A CN 116222905A
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valve
internal leakage
acoustic signal
fault
line
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董小倩
钱铭
徐岩
张丽清
林振浩
李文庆
钱锦远
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Valyuan Intelligent Technology Hangzhou Co ltd
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Valyuan Intelligent Technology Hangzhou Co ltd
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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
    • G01M3/00—Investigating fluid-tightness of structures
    • G01M3/02—Investigating fluid-tightness of structures by using fluid or vacuum
    • G01M3/04—Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point
    • G01M3/24—Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point using infrasonic, sonic, or ultrasonic vibrations
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E30/00—Energy generation of nuclear origin
    • Y02E30/30—Nuclear fission reactors

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Abstract

The invention relates to a fault diagnosis method for on-line identification and quantification of internal leakage of a valve, and belongs to the field of valve leakage detection. The method comprises the following steps: firstly, arranging an acoustic signal sensor in a certain range at the upstream and downstream of a valve on a pipeline, locally arranging the acoustic signal sensor, collecting acoustic signals in the valve operation process in real time, transmitting the obtained real-time acoustic signal data to an online diagnosis system through a wireless transmission technology, analyzing and processing the acoustic signals by utilizing an algorithm model, identifying whether an internal leakage fault occurs in the valve, and quantitatively calculating the internal leakage rate of the valve according to a preset leakage rate formula if the internal leakage fault occurs. The invention provides a set of processes for on-line monitoring of the valve acoustic signal, identification and quantitative analysis of the internal leakage condition of the valve, and provides support for on-line state monitoring and fault predictive maintenance of the valve.

Description

Fault diagnosis method for online identification and quantitative valve internal leakage
Technical Field
The invention belongs to the field of valve leakage detection, and particularly relates to a fault diagnosis method for online identification and quantification of internal leakage of a valve.
Background
The valve is a pivot for connecting and controlling the material transmission in industry, and the internal sealing surface of the valve is not tight due to corrosion, aging, friction and other reasons, so that the internal leakage of the valve is caused. The leakage process of the valve is not directly observed unlike the leakage process of the valve, and the early valve leakage detection method mainly comprises a pressurization detection method, a vacuum detection method and a bubble method. These methods require that the valve must be shut down and removed from the line for testing. The off-line detection mode is quite inefficient, and the disassembly process is prone to causing additional damage to the valve.
Aiming at the online nondestructive detection of the internal leakage of the industrial field valve, the existing method comprises the following steps: pressure drop method, vibration method, thermal infrared method, ultrasonic detection method, optical fiber leak detection method, and acoustic emission detection method. The principle of the ultrasonic detection method is that when the valve leaks internally, multiphase turbulent flow is formed at the leakage hole, the high-speed jet impacts the pipe wall to excite elastic waves, namely, sound signals are emitted, and the sound signals are received by the sound emission sensor for monitoring and analyzing, so that the purpose of detecting the internal leakage of the valve can be achieved. In the existing application of the ultrasonic detection method, the detection result only relates to two states of leakage or no leakage, and the quantitative analysis of the leakage degree is not carried out.
Therefore, there is a need for a fault diagnosis method for online identification and quantification of leaks in valves to solve the above problems.
Disclosure of Invention
Aiming at the problems that in the prior art, in the detection process of the internal leakage fault of the valve, the traditional internal leakage detection mode of the valve is low in efficiency, the existing online internal leakage detection technology is not quantitative and the like, the invention provides an online identification and quantitative fault diagnosis method for the internal leakage of the valve, which is used for improving the diagnosis effect of the internal leakage fault of the valve to a certain extent and providing basis for predictive fault diagnosis and maintenance of the valve.
The specific technical scheme adopted by the invention is as follows:
the invention provides a fault diagnosis method for on-line identification and quantification of internal leakage of a valve, which comprises the following steps:
s1: an acoustic signal sensor is arranged at the upstream and downstream of the valve;
s2: the two acoustic signal sensors acquire acoustic signals of the valve in real time to obtain real-time acoustic signal data;
s3: the acoustic signal sensor transmits the real-time acoustic signal data to an online diagnostic system;
s4: the on-line diagnosis system analyzes and processes the received sound signals to identify the internal leakage faults of the valve on line; if the internal leakage fault of the valve is confirmed, the step S5 is carried out, otherwise, the received sound signal is continuously analyzed and processed;
s5: and quantitatively calculating the internal leakage rate of the valve according to a preset leakage rate formula.
Preferably, in the step S1, the acoustic signal sensor is disposed at a position that is one pipe diameter from the valve.
Preferably, in the step S2, the signal acquisition state of the acoustic signal sensor is real-time continuous acquisition.
Preferably, in the step S3, data transmission is implemented through a 5G or transmission protocol; the transmission protocol includes one of HART, modbus, profibus, FF fieldbuses.
Preferably, in the step S4, the analysis processing of the acoustic signal includes the steps of:
s41: the on-line diagnosis system performs preliminary filtering processing on the received sound signals to filter out basic environmental noise;
s42: the online diagnosis system extracts available parameters from the data according to the data characteristics of the acoustic signals; parameters include frequency, amplitude, energy, ringing count, and average signal level;
s43: the online diagnosis system analyzes and processes each parameter in the step S42 as a characteristic value, and compares the energy distribution difference of the acoustic signals obtained before and after the valve;
s44: the actual difference value X and the standard difference value X of the preset internal leakage fault are compared 0 Comparing, wherein X is the characteristic value of the valve back sound signal minus the characteristic value of the valve front sound signal, X 0 Is obtained through the research of an internal leakage fault mechanism; degree of deviation
Figure BDA0004126596760000021
If the absolute value of P is smaller than 10%, the actual difference value is considered to be the same as the standard difference value of the preset internal leakage fault, and the internal leakage fault of the valve is indicated.
Preferably, in the step S5, the preset leakage rate formula is logv=alogq+b; wherein V is the amplitude of the acoustic signal, Q is the leakage rate, and a and b are both coefficients.
Compared with the prior art, the invention has the following beneficial effects:
1) The invention provides a set of processes for on-line monitoring of the valve acoustic signal, identification and quantitative analysis of the internal leakage condition of the valve, and provides support for on-line state monitoring and fault predictive maintenance of the valve.
2) The invention provides an acoustic signal data processing mode of internal leakage faults, which utilizes the comparison between the difference of acoustic signal energy distribution at the upstream and downstream of a valve and the preset difference of internal leakage faults to realize the scientific identification of the internal leakage faults of the valve.
3) The invention provides a set of algorithm model for quantitatively calculating the internal leakage degree, and the algorithm model can be used for calculating the value of the leakage rate after the front and back acoustic signals of a valve are measured.
Drawings
FIG. 1 is a schematic flow chart of a method for diagnosing faults of on-line identifying and quantifying internal leakage of a valve according to an embodiment of the present invention;
FIG. 2 is a graph showing the amplitude versus leak rate of a double logarithmic relationship provided by an embodiment of the invention.
Detailed Description
While the valve leak diagnosis method of the present invention may be implemented in a variety of different ways, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings, without intending to limit the scope of the invention to the exemplary embodiments. Accordingly, the drawings and description of the embodiments are to be regarded as illustrative in nature, and not as restrictive.
Further description will be made below by way of specific embodiments.
The invention provides a fault diagnosis method for on-line identification and quantitative valve internal leakage, which aims at pipeline valves in the fluid industry, arranges an acoustic signal sensor in a certain range before and after the valve, acquires acoustic signal data before and after the valve in real time, transmits the acquired data to an on-line diagnosis system, diagnoses the valve internal leakage fault by utilizing an algorithm model in the system, quantitatively calculates the valve internal leakage rate according to a preset leakage rate formula, thereby improving the diagnosis effect of the valve internal leakage fault to a certain extent and providing basis for the valve predictive fault diagnosis and maintenance.
As shown in FIG. 1, the method for on-line identification and quantification of the internal leakage of the valve provided by the invention mainly comprises the following steps:
s1: arrangement sensor
For pipeline valves in the fluid industry, an acoustic signal sensor is arranged in a certain range before and after the valve. Regarding the selection of the arrangement distance of the sensor, as the pipe diameter is larger, the flow passing through the sensor is larger, and when the arrangement position of the sensor is far away from the valve, the clear acoustic signal is not collected; when the sensor is arranged too close to the valve, vibration of the valve during operation can affect sound signal acquisition. Therefore, through comparison calculation, the arrangement position of the sensor is preferably the length distance from one pipe diameter of the valve. Regarding the selection of the acoustic signal sensor, a wireless transmission function is required, and the collected data can be transmitted to the on-line diagnosis software through a 5G or transmission protocol.
S2: collecting data in real time
The acoustic signal sensor collects acoustic signal data before and after the valve in real time in the valve operation process.
S3: transmitting data
The acoustic signal sensor transmits the acquired acoustic signal data to the on-line diagnostic software through a 5G or transmission protocol, the transmission protocol comprising: HART, modbus, profibus, FF fieldbus, etc.
S4: analyzing and processing data
The valve leakage acoustic emission signal belongs to a secondary acoustic emission source and is a continuous acoustic emission signal. The on-line diagnosis system analyzes and processes the received sound signals to identify the internal leakage faults of the valve on line; if the internal leakage fault of the valve is confirmed, the step S5 is carried out, otherwise, the received sound signals are continuously analyzed and processed, and the purpose of identifying the internal leakage fault of the valve in real time is achieved. The method comprises the following steps:
the first step is to perform preliminary filtering processing on the signals acquired by the acoustic signal sensor, and filter out basic environmental noise.
The second step is to extract available parameters from the data according to the data characteristics, including: frequency, amplitude, energy, ringing count, and average signal level. The frequency is the number of times the acoustic emission signal completes periodic variation in unit time, and the unit is Hz; the amplitude is the maximum value of the acoustic emission signal sampling point in unit time, and the unit is dB; the energy is the area enveloped by the cubic spline interpolation line of the extremum and the time axis after the acoustic emission signal takes the absolute value in unit time, and has no dimension; the ringing count is the number of times that the waveform of the acoustic emission signal exceeds a preset threshold value in unit time, and is dimensionless; the average signal level is the microcell area of the digital waveform signal per unit time and the unit is dB.
And thirdly, analyzing and processing each parameter extracted in the second step into a characteristic value by the online diagnosis system, and comparing the energy distribution difference of the acoustic signals obtained before and after the valve.
Fourth, the actual difference value X is compared with the standard difference value X of the preset internal leakage fault 0 Comparing, wherein X is the characteristic value of the valve back sound signal minus the characteristic value of the valve front sound signal, X 0 Is obtained by researching an internal leakage fault mechanism. Because the on-line valve is in an operating state, vibration and environmental noise of the valve and the pipeline can interfere the acoustic emission signals, if the energy distribution of the acoustic emission signals before and after the valve is different, the internal leakage fault can not be judged directly at the moment. Therefore, the actual difference value needs to be compared with the standard difference value of the preset internal leakage fault. Degree of deviation
Figure BDA0004126596760000051
If the absolute value of P is smaller than 10%, the actual difference value is considered to be the same as the standard difference value of the preset internal leakage fault, and the internal leakage fault of the valve is indicated.
S5: quantitative calculation of leak Rate
If it is confirmed that the valve has an internal leakage fault in step S4, the following operations are performed to quantitatively calculate the leakage rate:
theoretical analysis and formula deduction are carried out based on turbulence knowledge, so that when a certain pressure difference is kept unchanged, the acoustic signal increases along with the increase of the leakage rate, the double-logarithmic relation between the amplitude of the acoustic signal and the leakage rate is shown in fig. 2, and the general curve form is as follows: logv=analogue q+b.
Wherein V is the amplitude, Q is the leakage rate, a and b are coefficients which change with the leakage sound source signal and the change of valve pressure drop, leakage port size, leakage rate, medium property and the like.
Therefore, the value of the leakage rate at the moment can be calculated by knowing the valve acoustic signal amplitude according to the double-logarithmic relation of the acoustic signal amplitude and the leakage rate.
The above embodiment is only a preferred embodiment of the present invention, but it is not intended to limit the present invention. Various changes and modifications may be made by one of ordinary skill in the pertinent art without departing from the spirit and scope of the present invention. Therefore, all the technical schemes obtained by adopting the equivalent substitution or equivalent transformation are within the protection scope of the invention.

Claims (6)

1. The fault diagnosis method for on-line identification and quantification of the internal leakage of the valve is characterized by comprising the following steps of:
s1: an acoustic signal sensor is arranged at the upstream and downstream of the valve;
s2: the two acoustic signal sensors acquire acoustic signals of the valve in real time to obtain real-time acoustic signal data;
s3: the acoustic signal sensor transmits the real-time acoustic signal data to an online diagnostic system;
s4: the on-line diagnosis system analyzes and processes the received sound signals to identify the internal leakage faults of the valve on line; if the internal leakage fault of the valve is confirmed, the step S5 is carried out, otherwise, the received sound signal is continuously analyzed and processed;
s5: and quantitatively calculating the internal leakage rate of the valve according to a preset leakage rate formula.
2. The method for on-line detecting and quantifying the internal leakage of a valve according to claim 1, wherein in the step S1, the acoustic signal sensor is disposed at a position that is one pipe diameter from the valve.
3. The method for diagnosing a fault in an on-line detecting and quantifying valve leakage according to claim 1, wherein in the step S2, the signal acquisition status of the acoustic signal sensor is real-time continuous acquisition.
4. The method for diagnosing a fault in an on-line leak in a valve according to claim 1, wherein in step S3, data transmission is performed by a 5G or transmission protocol; the transmission protocol includes one of HART, modbus, profibus, FF fieldbuses.
5. The method for diagnosing a failure in on-line recognition and quantification of an internal leak of a valve according to claim 1, wherein the analyzing process of the acoustic signal in the step S4 includes the steps of:
s41: the on-line diagnosis system performs preliminary filtering processing on the received sound signals to filter out basic environmental noise;
s42: the online diagnosis system extracts available parameters from the data according to the data characteristics of the acoustic signals; parameters include frequency, amplitude, energy, ringing count, and average signal level;
s43: the online diagnosis system analyzes and processes each parameter in the step S42 as a characteristic value, and compares the energy distribution difference of the acoustic signals obtained before and after the valve;
s44: the actual difference value X and the standard difference value X of the preset internal leakage fault are compared 0 Comparing, wherein X is the characteristic value of the valve back sound signal minus the characteristic value of the valve front sound signal, X 0 Is obtained through the research of an internal leakage fault mechanism; degree of deviation
Figure FDA0004126596750000021
If the absolute value of P is smaller than 10%, the actual difference value is considered to be the same as the standard difference value of the preset internal leakage fault, and the internal leakage fault of the valve is indicated.
6. The method for online identifying and quantifying valve internal leakage fault diagnosis according to claim 1, wherein in step S5, the preset leakage rate formula is logv=alogq+b; wherein V is the amplitude of the acoustic signal, Q is the leakage rate, and a and b are both coefficients.
CN202310247766.9A 2023-03-15 2023-03-15 Fault diagnosis method for online identification and quantitative valve internal leakage Pending CN116222905A (en)

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Application Number Priority Date Filing Date Title
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Application Number Priority Date Filing Date Title
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