CN116359350A - Real-time online monitoring device for active defect acoustic emission of high-temperature tower equipment - Google Patents
Real-time online monitoring device for active defect acoustic emission of high-temperature tower equipment Download PDFInfo
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Abstract
The invention discloses a real-time online monitoring device for active defect acoustic emission of high-temperature tower equipment, and relates to the field of high-temperature tower equipment monitoring. The sensing subsystem detects transient acoustic emission signals of the monitored part and converts the transient acoustic emission signals into analog acoustic emission electric signals; the data processing subsystem collects and processes the analog acoustic emission electric signals to obtain digital acoustic emission electric signals; the remote monitoring subsystem performs cloud storage and positioning on the digital acoustic emission electric signals, displays positioning results in a graph form, and further determines an active defect positioning area and a suspected active defect positioning area in the displayed positioning result graph. The invention adopts the acoustic emission monitoring technology means to collect the acoustic emission signals in the running process of the coke tower in real time, determines the active defect positioning area and the suspected active defect positioning area, and realizes on-line monitoring of the germination and development conditions of the active defects and the health state of the coke tower.
Description
Technical Field
The invention relates to the field of high-temperature tower equipment monitoring, in particular to a real-time online monitoring device for active defect acoustic emission of high-temperature tower equipment.
Background
In the running process of the coke tower, the coke tower is subjected to the influence of factors such as high temperature, high pressure, corrosive medium, external impact and the like, the material organization structure is obviously degraded, typical failure modes such as cracks, corrosion, creep fatigue, leakage and the like are often generated, the coke tower is taken as an example to introduce, the coke tower is one of core equipment of a delayed coking device, the highest temperature in the coke tower can reach about 480 ℃ during the coking operation, the coke tower is heated to the highest operating temperature from normal temperature to the normal temperature in each operating period for 48 hours, the temperature difference exists between the inner wall and the outer wall of the coke tower and the longitudinal direction due to the periodical temperature change, and great thermal stress is generated at the discontinuous parts of the tower body materials and the stress concentration parts of the structure, and the seam of a transition section of a skirt and the seam of a tower joint are easy to crack. In recent years, along with the improvement of the crude oil processing capability, the coking device is always in a full-load operation state, and once accidents occur, huge economic loss and casualties are caused for enterprises, and social influence is bad.
Since the application of the delayed coking coke technology, a great deal of theoretical researches on the aspects of failure modes, defect development, damage generation mechanisms and the like of a coke tower are carried out, and certain research results and operation production experience are obtained. After the delayed coking coke tower is in service for a period of time, the problems of bulging plastic deformation of the tower body, cracking of welding seams of a skirt transition section, cracking of girth welding seams at a tower joint, and the like can occur along with the periodical operation of the coke tower. Starting from the middle 80 th of the last century, each large petrochemical production unit cooperates with related scientific research units, and performs basic research and analysis on plastic deformation, crack initiation development, structural failure mechanisms and the like generated by long-period operation of a delayed coking coke tower, so as to obtain certain theoretical research results. As the Nanjing oil refinery cooperates with Beijing aviation materials institute 621, after analysis and research on the problems of deformation of the coke drum body, weld cracking and the like of the delayed coking coke drum based on the high-temperature strength theory, it is considered that the coke drum failure is mainly caused by cracking of the drum body and the skirt transition section under the conditions of high-temperature creep, low-cycle fatigue and thermal ratchet effect thermal stress, and the cracking is continuously developed until the coke drum is finally broken.
In view of the important role of the coke tower in petrochemical industry and the complex working conditions thereof, domestic research on the coke tower is very important. Because of the increasing size of the coke tower structure and the complexity of working conditions, laboratory simulation and research theory still have a larger gap from engineering practice, and the existing research direction is still mainly focused on aspects of coke tower failure form and failure mechanism, thermal damage mechanism of delayed coking coke tower, calculation method of coke tower change temperature field and stress distribution thereof, safe reliability analysis in continuous working process, prediction of residual life and the like, and cannot well meet evaluation requirements of actual engineering design maintenance. Therefore, the active defect (crack) initiation development condition in the coke tower operation process is necessarily collected in real time, the health state of the coke tower is monitored, and the method has important significance for guaranteeing the safe and healthy operation of equipment, improving the economic benefit of enterprises and preventing accidents.
Disclosure of Invention
The invention aims to provide a real-time on-line monitoring device for active defect acoustic emission of high-temperature tower equipment, which can be used for acquiring the germination and development conditions of active defects in the running process of a coke tower in real time by adopting an acoustic emission monitoring technology means and monitoring the health state of the coke tower on line.
In order to achieve the above object, the present invention provides the following solutions:
a real-time online monitoring device for active defect acoustic emission of high-temperature tower equipment comprises: the system comprises a sensing subsystem, a data processing subsystem and a remote monitoring subsystem;
the sensing subsystem is arranged on a monitoring part of the coke tower;
the sensing subsystem is connected with the data processing subsystem; the sensing subsystem is used for detecting transient acoustic emission signals of the monitoring part and converting the transient acoustic emission signals into analog acoustic emission electric signals;
the data processing subsystem is connected with the remote monitoring subsystem and is used for collecting and processing the analog acoustic emission electric signals to obtain digital acoustic emission electric signals and sending the digital acoustic emission electric signals to the remote monitoring subsystem;
the remote monitoring subsystem is used for carrying out cloud storage and positioning on the digital acoustic emission electric signals, displaying positioning results in a graph form, and further determining an active defect positioning area and a suspected active defect positioning area in the displayed positioning result graph.
Optionally, the sensing subsystem includes: acoustic emission sensor and waveguide rod;
the acoustic emission sensor is fixed at one end of the waveguide rod, the other end of the waveguide rod is a conical body, and the acoustic emission sensor is welded in a spot welding mode or glued to a monitoring part of the coke tower by adopting high-temperature glue;
the signal output end of the acoustic emission sensor is connected with the data processing subsystem.
Optionally, the length of the waveguide rod is greater than the thickness of the thermal insulation layer of the coke tower, and the temperature at the joint of the waveguide rod and the acoustic emission sensor is reduced to below 60 ℃.
Optionally, the data processing subsystem includes: the system comprises a preamplifier, a signal conditioning module and an analog-to-digital conversion module;
the input end of the preamplifier is connected with the output end of the sensing subsystem, and the output end of the preamplifier is connected with the input end of the signal conditioning module; the pre-amplifier is used for amplifying the analog acoustic emission electric signal;
the output end of the signal conditioning module is connected with the input end of the analog-to-digital conversion module; the signal conditioning module is used for carrying out input impedance matching and signal filtering on the amplified analog acoustic emission electric signals to obtain filtered analog acoustic emission electric signals;
the analog-to-digital conversion module is connected with the remote monitoring subsystem; the analog-to-digital conversion module is used for converting the analog acoustic emission electric signals into digital acoustic emission electric signals and sending the digital acoustic emission electric signals to the remote monitoring subsystem.
Optionally, the data processing subsystem further comprises: a PCI interface module;
the analog-to-digital conversion module is connected with the remote monitoring subsystem through the PCI interface module.
Optionally, the data processing subsystem further comprises: an FPGA control module;
the FPGA control module is respectively connected with the signal conditioning module, the analog-to-digital conversion module and the PCI interface module; the FPGA control module is used for selecting a filter passband, performing analog-to-digital conversion control and performing sampling data transmission control.
Optionally, the data processing subsystem further comprises: a data acquisition and transmission system;
the data acquisition and transmission system comprises a user management module, a system setting module, a data display module and a storage module;
the data display module and the storage module are both connected with the analog-to-digital conversion module;
the data display module is used for displaying digital acoustic emission electric signals; the storage module is used for storing the digital acoustic emission electric signals.
Optionally, the remote monitoring subsystem includes: cloud server and remote monitoring terminal;
the cloud server and the remote monitoring terminal are connected with the data processing subsystem;
the cloud server is used for carrying out cloud storage on the digital acoustic emission electric signals;
the remote monitoring terminal is used for remotely displaying the digital acoustic emission electric signals, positioning the digital acoustic emission electric signals, displaying positioning results in a graphic form, and further determining an active defect positioning area and a suspected active defect positioning area in the displayed positioning result graph.
Optionally, the remote monitoring terminal includes: structural health monitoring and damage diagnosis system;
the structural health monitoring and damage diagnosis system comprises an operation parameter access module, an acoustic emission data access module, an operation parameter database, an acoustic emission database, a health diagnosis module and a remote display module;
the operation parameter access module is connected with the operation parameter database, and is used for receiving pressure, flow, temperature and operation process parameters in the operation process of the coke tower and transmitting the pressure, flow, temperature and operation process parameters to the operation parameter database;
the acoustic emission data access module is respectively connected with the acoustic emission database and the health diagnosis module, and is used for receiving the digital acoustic emission electric signals and sending the digital acoustic emission electric signals to the acoustic emission database and the health diagnosis module;
the health diagnosis module is connected with the remote display module and is used for analyzing the structural health state of the coke tower in the running process according to the digital acoustic emission electric signals, positioning the digital acoustic emission electric signals and sending the structural health state and the positioning result to the remote display module;
the remote display module is respectively connected with the operation parameter database and the sound emission database, and is used for displaying the structural health state, the pressure, the flow, the temperature and the operation process parameters in the coke tower operation process and displaying the positioning result in a graph.
According to the specific embodiment provided by the invention, the invention discloses the following technical effects:
the invention discloses a real-time online monitoring device for active defect acoustic emission of high-temperature tower equipment, wherein a sensing subsystem detects transient acoustic emission signals of a monitored part and converts the transient acoustic emission signals into analog acoustic emission electric signals; the data processing subsystem collects and processes the analog acoustic emission electric signals to obtain digital acoustic emission electric signals; the remote monitoring subsystem performs cloud storage and positioning on the digital acoustic emission electric signals, displays positioning results in a graph form, and further determines an active defect positioning area and a suspected active defect positioning area in the displayed positioning result graph. The invention adopts the acoustic emission monitoring technology means to collect the acoustic emission signals in the running process of the coke tower in real time, determines the active defect positioning area and the suspected active defect positioning area, and realizes on-line monitoring of the germination and development conditions of the active defects and the health state of the coke tower.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions of the prior art, the drawings that are needed in the embodiments will be briefly described below, it being obvious that the drawings in the following description are only some embodiments of the present invention, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic structural diagram of a real-time online monitoring device for active defect acoustic emission of high-temperature tower equipment, which is provided by the embodiment of the invention;
FIG. 2 is a signal transmission diagram of a real-time online monitoring device for active defect acoustic emission of high-temperature tower equipment, which is provided by the embodiment of the invention;
FIG. 3 is a diagram of an interference signal and a crack propagation signal according to an embodiment of the present invention; fig. 3 (a) is an interference signal diagram, and fig. 3 (b) is a crack propagation signal diagram;
FIG. 4 is a schematic diagram of energy versus time provided by an embodiment of the present invention;
FIG. 5 is a schematic view of an impingement-channel according to an embodiment of the present invention;
fig. 6 is a diagram of a positioning result according to an embodiment of the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
The invention aims to provide a real-time on-line monitoring device for active defect acoustic emission of high-temperature tower equipment, which can be used for acquiring the germination and development conditions of active defects in the running process of a coke tower in real time by adopting an acoustic emission monitoring technology means and monitoring the health state of the coke tower on line.
In order that the above-recited objects, features and advantages of the present invention will become more readily apparent, a more particular description of the invention will be rendered by reference to the appended drawings and appended detailed description.
The invention provides a real-time online monitoring device for active defect acoustic emission of high-temperature tower equipment, which aims at a typical failure mode of coke tower weld cracking, adopts an acoustic emission monitoring technical means to realize the functions of real-time acquisition, storage, remote transmission and the like of acoustic emission parameters in a high-temperature environment, and provides a data basis for coke tower health state diagnosis and damage prediction.
The device for monitoring active defect acoustic emission of high-temperature tower equipment on line in real time provided by the embodiment of the invention, as shown in fig. 1 and 2, comprises: a sensing subsystem, a data processing subsystem and a remote monitoring subsystem.
The sensing subsystem is mounted on a monitoring site of the coke drum. The sensing subsystem is connected with the data processing subsystem; the sensing subsystem is used for detecting transient acoustic emission signals of the monitoring part and converting the transient acoustic emission signals into analog acoustic emission electric signals. The data processing subsystem is connected with the remote monitoring subsystem and is used for collecting and processing the analog acoustic emission electric signals to obtain digital acoustic emission electric signals and sending the digital acoustic emission electric signals to the remote monitoring subsystem. The remote monitoring subsystem is used for carrying out cloud storage and positioning on the digital acoustic emission electric signals, displaying positioning results in a graph form, and further determining an active defect positioning area and a suspected active defect positioning area in the displayed positioning result graph.
The output of the sensing subsystem is connected to the data processing subsystem through a cable, and the output of the data processing subsystem is connected to the remote monitoring subsystem through wireless or Ethernet.
The specific structure of each subsystem in the high-temperature tower equipment active defect acoustic emission real-time on-line monitoring device is explained below.
One sensing subsystem
The sensing subsystem includes: acoustic emission sensor and waveguide rod. The acoustic emission sensor is fixed at one end of the waveguide rod, the other end of the waveguide rod is a conical body, and the acoustic emission sensor is welded in a spot welding mode or glued to a monitoring part of the coke tower by adopting high-temperature glue. The signal output end of the acoustic emission sensor is connected with the data processing subsystem.
(1) Acoustic emission sensing technology and sensor
Under the action of external factors such as stress, electromagnetism, temperature and the like, local area stress with micro defects inside the material is highly concentrated, so that strain energy in the area is highly concentrated. The high concentration of local energy promotes further propagation of material defects such as dislocation, slip, cracking, abrupt changes in orientation of grain boundaries, and releases the concentrated excess energy in the form of elastic stress waves, producing an acoustic emission phenomenon, also known as stress wave emission. The localized change in a material that initiates an acoustic emission is referred to as an acoustic emission event, while an acoustic emission source refers to the physical source point of the acoustic emission event or the source of the mechanism that releases the acoustic emission wave. The elastic stress wave released by the acoustic emission source is transmitted to the surface of the object of the detected object through the transmission medium to cause mechanical vibration of the surface of the object, and the acoustic emission sensor converts the detected transient displacement signal into an electric signal.
Aiming at the outstanding problem of coke tower weld cracking, an acoustic emission sensor sensitive to the crack activity defect is selected for monitoring. The commonly used acoustic emission sensor converts surface vibration of a test object caused by acoustic emission waves into an electrical signal based on the piezoelectric effect of a crystal element.
Acoustic emission sensor performance parameters:
(1) resonant frequency: 150kHz
(2) Operating frequency: 50 kHz-200 kHz
(3) Operating temperature: 65 ℃ below zero to 175 DEG C
(4) The installation mode is as follows: waveguide rod auxiliary installation
(2) High-temperature waveguide rod
Because the surface temperature of the coke tower is higher, the acoustic emission sensor cannot be directly contacted with the surface of equipment, and therefore, the coupling temperature of the sensor is improved by adopting an acoustic emission waveguide rod. The design principle of the waveguide rod is that the length is larger than the thickness of the thermal insulation layer of the coke tower, the temperature of the joint of the waveguide rod and the sensor is reduced to below 60 ℃, as shown in fig. 3, the acoustic emission sensor is fixed at one end of the waveguide rod through a clamping groove at the left side of the waveguide rod, and a gasket at the upper end of the clamping groove is screwed up through threads in the clamping groove, so that the sensor is well coupled with the bottom end of the clamping groove; the other end of the waveguide rod is a conical body, and the conical body is welded by spot welding or glued to the body to be measured by adopting high-temperature glue.
(II) data processing subsystem
The data processing subsystem includes: the system comprises a preamplifier, a signal conditioning module and an analog-to-digital conversion module.
The input end of the preamplifier is connected with the output end of the sensing subsystem, and the output end of the preamplifier is connected with the input end of the signal conditioning module; the pre-amplifier is used for amplifying the analog acoustic emission electric signal. The output end of the signal conditioning module is connected with the input end of the analog-to-digital conversion module; the signal conditioning module is used for carrying out input impedance matching and signal filtering on the amplified analog acoustic emission electric signals to obtain filtered analog acoustic emission electric signals. The analog-to-digital conversion module is connected with the remote monitoring subsystem; the analog-to-digital conversion module is used for converting the analog acoustic emission electric signals into digital acoustic emission electric signals and sending the digital acoustic emission electric signals to the remote monitoring subsystem.
The data acquisition and transmission subsystem is used for acquiring acoustic emission signals of key positions of the coke tower structure (such as cylinder circumferential weld, skirt weld and the like) in real time, and carrying out operations such as local storage and remote transmission on the acoustic emission signals.
The electric signal output by the acoustic emission sensor is connected to a data acquisition and transmission subsystem through a cable, the data acquisition and transmission subsystem firstly conditions the electric signal, mainly performs impedance matching, filtering treatment and the like, then performs analog-to-digital conversion, and finishes filter passband selection, analog-to-digital conversion control, sampling data transmission control and the like through FPGA control. And finally, transmitting the data to a computer host through a PCI interface.
The signal conditioning module mainly refers to a part between the output of the amplifier and the analog-to-digital conversion module, and mainly comprises input impedance matching and signal filtering. Because the amplitude of the input acoustic emission signal is possibly exceeding the range of the A/D converter after being amplified by the preamplifier, the amplitude of the signal is necessarily limited for protecting a later-stage circuit; in addition, acoustic emission signals are sensitive to noise and require filtering of the signal to be sampled.
The analog-to-digital conversion module is used for completing the design of a multi-path A/D chip application circuit, the design of a reference voltage source circuit and the like, and is a core component for realizing the conversion from an analog acoustic emission signal to a digital quantity.
The PCI interface is a channel for transmitting data issued and acquired by the acquisition instruction to the PC computer, and the interface module mainly comprises a configuration circuit and an application circuit of the PCI chip.
The FPGA control module is respectively connected with the signal conditioning module, the analog-to-digital conversion module and the PCI interface module to complete the control of the whole sampling process such as filter passband selection, analog-to-digital conversion control, sampling data transmission control and the like, and concretely comprises two parts of a control circuit and a control logic of the FPGA, wherein the control circuit comprises an FPGA configuration circuit, a clock circuit, a pin distribution circuit and the like.
The data acquisition and transmission software mainly comprises a user management module, a system setting module, a data display module, a storage module and the like, and achieves the functions of local storage, remote wireless transmission and the like of the active defect monitoring data.
The main performance indicators of the data acquisition and transmission subsystem (acoustic emission acquisition module in fig. 1) are as follows:
(1) and (3) an acquisition channel: 8 channels;
(2) acquisition card bandwidth: 1khz-400khz;
(3) sampling rate: 2MSPS;
(4) operating temperature: -35 ℃ -70 ℃.
(III) remote monitoring subsystem
The system mainly comprises a cloud server, a remote monitoring terminal (PC end or mobile end) and the like, and achieves the functions of cloud storage, remote checking, analysis and the like of the coking tower structure health monitoring data.
The cloud server and the remote monitoring terminal are connected with the data processing subsystem. The cloud server is used for carrying out cloud storage on the digital acoustic emission electric signals. The remote monitoring terminal is used for remotely displaying the digital acoustic emission electric signals, positioning the digital acoustic emission electric signals, displaying positioning results in a graphic form, and further determining an active defect positioning area and a suspected active defect positioning area in the displayed positioning result graph.
The remote monitoring terminal includes: the structural health monitoring and damage diagnosis system (high-temperature tower type equipment structural health monitoring and damage diagnosis software system) integrates data analysis, graphic display and data management, has a concise and attractive interface, is convenient to operate, and completely and intuitively displays structural health monitoring contents. The software can continuously monitor the running condition of the structure for 24 hours, record the state parameters of the coke tower structure by using the storage space of the computer, diagnose the health state of the equipment, predict the damage trend, evaluate the residual life of the equipment and the like. The main functions are as follows:
(1) Real-time monitoring of multiple parameters
The method can realize real-time online monitoring of acoustic emission parameters of the coke tower, establish a database to store monitoring data and analyze historical data.
(2) Health diagnosis
Based on acoustic emission sensing technology, the structural operation state parameters of the coke tower are monitored on line in real time, structural health states of the coke tower in the operation process are analyzed by fusing various damage evaluation algorithms, and various real-time early warning functions such as APP, short messages, popup windows and the like are provided.
(3) Operating parameter access
The system is provided with a special interface aiming at multiple operation parameters such as pressure, flow, temperature, operation technological parameters and the like in the operation process of the coke tower, and a special database is designed for storing operation parameter data.
The structural health monitoring and damage diagnosis system comprises an operation parameter access module, an acoustic emission data access module, an operation parameter database, an acoustic emission database, a health diagnosis module and a remote display module.
The operation parameter access module is connected with the operation parameter database, and is used for receiving pressure, flow, temperature and operation process parameters in the operation process of the coke tower and transmitting the pressure, flow, temperature and operation process parameters to the operation parameter database.
The acoustic emission data access module is respectively connected with the acoustic emission database and the health diagnosis module, and is used for receiving the digital acoustic emission electric signals and sending the digital acoustic emission electric signals to the acoustic emission database and the health diagnosis module.
The health diagnosis module is connected with the remote display module and is used for analyzing the structural health state of the coke tower in the running process according to the digital acoustic emission electric signals, positioning the digital acoustic emission electric signals and sending the structural health state and the positioning result to the remote display module.
The remote display module is respectively connected with the operation parameter database and the sound emission database, and is used for displaying the structural health state, the pressure, the flow, the temperature and the operation process parameters in the coke tower operation process and displaying the positioning result in a graph.
The technical scheme of the invention is exemplified below.
1) Determining the mounting position and mounting mode of a sensor
And (3) preliminarily determining the mounting position of the sensor according to analysis of coke tower historical inspection data, historical crack and bulge deformation defect conditions and research results of related literature data. On a coke tower of a petrochemical company, acoustic emission sensors are arranged on the upper part and the lower part of a cylinder ring weld joint.
In order to adapt to the high-temperature working environment of tower equipment, the acoustic emission sensor is installed in an auxiliary mode through a waveguide rod, the length of the waveguide rod is customized according to different working temperatures of monitoring objects, the temperature of a non-welding end of the waveguide rod is reduced to be lower than 60 ℃, and the shortest length of the waveguide rod is required to be larger than the thickness of the heat preservation layer. The acoustic emission sensor is fixed at one end of the waveguide rod through the clamping groove and the spring, the other end of the waveguide rod is a conical body, and the acoustic emission sensor is coupled to the body to be measured through spot welding or bonding.
According to the requirements of a high-temperature tower type equipment management unit, two waveguide rods with different coupling modes such as spot welding, bonding and the like are designed; (1) For enterprises allowing welding on high-temperature tower equipment, spot welding a conical body at the top end of a waveguide rod onto a tower body; (2) Aiming at enterprises which are not allowed to weld on high-temperature tower equipment, the conical body at the top end of the waveguide rod is adhered to the tower body by adopting high-temperature glue, and meanwhile, the waveguide rod is well coupled with the tested body by fixing the waveguide rod to an auxiliary mechanism (such as an auxiliary bracket, a pedestrian ladder and the like) of the tested equipment through a bracket.
2) Installation mode of data acquisition cabinet
The data acquisition device is mainly used for acquiring acoustic emission signals of key positions of the coke tower structure in real time, and carrying out operations such as local storage, remote transmission and the like on the acquired signals. The explosion-proof cabinet is arranged on the coke drum skirt platform and is 8 meters away from the coke drum. The cabinet ground platform is 30cm in height, a cable is fed into the cabinet through a thickened aluminum groove box, and the cabinet is arranged in a lifting mode of an automobile crane.
3) Central control room cloud platform arrangement
And placing the cloud platform with the double-screen host in a coking central control room. The host computer displays the cloud platform interface and the monitoring system interface.
4) In-situ cable laying
(1) The method comprises the steps of surveying a scene, determining the cable length, and determining the trend position of a steel pipe groove box and the placement position of a cabinet;
(2) Building a scaffold around a coke tower, laying a pipeline along the line, fixing a steel pipe at the edge of a fence, carrying the cable to the site, laying the cable by a constructor matched with a responsible person, smoothening the cable, marking the cable, transferring the cable into a groove box, and reserving wires with enough lengths at two ends;
(3) Determining the position point position of the sensor and dismantling the heat preservation layer;
(4) And hoisting the explosion-proof cabinet, and arranging and fastening the explosion-proof cabinet.
(5) Installing a sensor and wiring;
(6) Monitoring data analysis:
(7) After the wiring is finished, whether the wiring is correct or not, whether the wiring is attractive or not, whether the grounding wire is connected correctly or not according with the electrical technical requirements or not is checked, impurities such as copper wires and the like in the switch are cleaned up by using a hairbrush, whether a short circuit phenomenon exists or not is detected by using a universal meter, then the power can be transmitted, a UPS (uninterrupted Power supply) is connected, and an instrument switch is turned on to supply power to the sensor.
5) Acoustic emission monitoring data analysis
The acoustic emission signal also has certain regularity, takes 24 hours as a period, and appears periodically, and the acoustic emission signal is found to have consistency after being compared with the working flow of an actual coke tower. During decoking, the flow of water and impingement with the vessel walls can create a number of interfering signals due to the injection of water into the vessel, as shown in FIG. 3. The data of the decoking process were thus all filtered out at the time of analysis.
As can be seen from the graph of energy over time (fig. 4), the signal energy values monitored when no active defects are generated or spread are substantially below 1000, and therefore a period of greater energy value is of concern. Meanwhile, the time point of the sudden event rate needs to be concerned, and whether field construction or other interference signals exist around the time is determined. When monitoring, the monitoring needs to continuously pay attention to the area with concentrated positioning, and as can be seen from fig. 5, more signals are received by the 3# sensor and the 4# sensor, and the signals are consistent with the phenomenon that fatigue cracks exist near the 3# sensor reflected by a user.
Because the stress of the local area with micro defects in the material is highly concentrated, the concentrated excess energy is released in the form of elastic stress wave, the acoustic emission signals detected by the acoustic emission sensor are more, and the number of finally obtained positioning points is more. Therefore, in the acoustic emission monitoring localization map shown in fig. 6, it can be seen that there are 3 active defect localization areas, where the C area is the area where fatigue cracks reflected by the company security manager are located; the A area and the B area are newly discovered acoustic emission source areas and suspected defect source areas, and cracks can be initiated or expanded, so that the change condition of each area and whether a new positioning area is generated or not are closely concerned.
The positioning method of the acoustic emission signal comprises the following steps: according to the time difference positioning algorithm, when the time difference of the acoustic emission signals sent by the same acoustic emission source reaching different sensors, the accurate position of the acoustic source is determined through measurement of parameters such as wave speed, sensor spacing and the like and algorithm operation.
The activity and the existence area of the crack can be confirmed through the monitoring for more than ten days, a reference standard for near-one-step crack monitoring is established, and a foundation is laid for the long-term health monitoring of the coke tower.
The invention has the beneficial effects that:
aiming at the cracking failure mode of a coke tower weld of high-temperature tower equipment, an acoustic emission monitoring technology is adopted to research the online monitoring technology of the high-temperature tower equipment, active defect germination development parameters in the running process of the coke tower are collected in real time based on an active defect acoustic emission real-time online monitoring device of the high-temperature tower equipment, the health state of the coke tower is monitored online, the fault development trend of the coke tower equipment is predicted in time, and the method has important significance for guaranteeing the safe and healthy running of the equipment, improving the economic benefit of enterprises and preventing accidents.
In the present specification, each embodiment is described in a progressive manner, and each embodiment is mainly described in a different point from other embodiments, and identical and similar parts between the embodiments are all enough to refer to each other.
The principles and embodiments of the present invention have been described herein with reference to specific examples, the description of which is intended only to assist in understanding the methods of the present invention and the core ideas thereof; also, it is within the scope of the present invention to be modified by those of ordinary skill in the art in light of the present teachings. In view of the foregoing, this description should not be construed as limiting the invention.
Claims (9)
1. The utility model provides a real-time on-line monitoring device of active defect acoustic emission of high temperature tower equipment which characterized in that includes: the system comprises a sensing subsystem, a data processing subsystem and a remote monitoring subsystem;
the sensing subsystem is arranged on a monitoring part of the coke tower;
the sensing subsystem is connected with the data processing subsystem; the sensing subsystem is used for detecting transient acoustic emission signals of the monitoring part and converting the transient acoustic emission signals into analog acoustic emission electric signals;
the data processing subsystem is connected with the remote monitoring subsystem and is used for collecting and processing the analog acoustic emission electric signals to obtain digital acoustic emission electric signals and sending the digital acoustic emission electric signals to the remote monitoring subsystem;
the remote monitoring subsystem is used for carrying out cloud storage and positioning on the digital acoustic emission electric signals, displaying positioning results in a graph form, and further determining an active defect positioning area and a suspected active defect positioning area in the displayed positioning result graph.
2. The real-time online monitoring device for active defect acoustic emission of high-temperature tower equipment according to claim 1, wherein the sensing subsystem comprises: acoustic emission sensor and waveguide rod;
the acoustic emission sensor is fixed at one end of the waveguide rod, the other end of the waveguide rod is a conical body, and the acoustic emission sensor is welded in a spot welding mode or glued to a monitoring part of the coke tower by adopting high-temperature glue;
the signal output end of the acoustic emission sensor is connected with the data processing subsystem.
3. The real-time online monitoring device for active defect acoustic emission of high-temperature tower equipment according to claim 2, wherein the length of the waveguide rod is greater than the thickness of the thermal insulation layer of the coke tower, and the temperature at the joint of the waveguide rod and the acoustic emission sensor is reduced to below 60 ℃.
4. The real-time online monitoring device for active defect acoustic emission of high-temperature tower equipment according to claim 1, wherein the data processing subsystem comprises: the system comprises a preamplifier, a signal conditioning module and an analog-to-digital conversion module;
the input end of the preamplifier is connected with the output end of the sensing subsystem, and the output end of the preamplifier is connected with the input end of the signal conditioning module; the pre-amplifier is used for amplifying the analog acoustic emission electric signal;
the output end of the signal conditioning module is connected with the input end of the analog-to-digital conversion module; the signal conditioning module is used for carrying out input impedance matching and signal filtering on the amplified analog acoustic emission electric signals to obtain filtered analog acoustic emission electric signals;
the analog-to-digital conversion module is connected with the remote monitoring subsystem; the analog-to-digital conversion module is used for converting the analog acoustic emission electric signals into digital acoustic emission electric signals and sending the digital acoustic emission electric signals to the remote monitoring subsystem.
5. The real-time online monitoring device for active defect acoustic emissions of high-temperature tower equipment according to claim 4, wherein the data processing subsystem further comprises: a PCI interface module;
the analog-to-digital conversion module is connected with the remote monitoring subsystem through the PCI interface module.
6. The real-time online monitoring device for active defect acoustic emissions of high-temperature tower equipment according to claim 5, wherein the data processing subsystem further comprises: an FPGA control module;
the FPGA control module is respectively connected with the signal conditioning module, the analog-to-digital conversion module and the PCI interface module; the FPGA control module is used for selecting a filter passband, performing analog-to-digital conversion control and performing sampling data transmission control.
7. The real-time online monitoring device for active defect acoustic emissions of high-temperature tower equipment according to claim 6, wherein the data processing subsystem further comprises: a data acquisition and transmission system;
the data acquisition and transmission system comprises a user management module, a system setting module, a data display module and a storage module;
the data display module and the storage module are both connected with the analog-to-digital conversion module;
the data display module is used for displaying digital acoustic emission electric signals; the storage module is used for storing the digital acoustic emission electric signals.
8. The real-time online monitoring device for active defect acoustic emission of high-temperature tower equipment according to claim 1, wherein the remote monitoring subsystem comprises: cloud server and remote monitoring terminal;
the cloud server and the remote monitoring terminal are connected with the data processing subsystem;
the cloud server is used for carrying out cloud storage on the digital acoustic emission electric signals;
the remote monitoring terminal is used for remotely displaying the digital acoustic emission electric signals, positioning the digital acoustic emission electric signals, displaying positioning results in a graphic form, and further determining an active defect positioning area and a suspected active defect positioning area in the displayed positioning result graph.
9. The real-time online monitoring device for active defect acoustic emission of high-temperature tower equipment according to claim 8, wherein the remote monitoring terminal comprises: structural health monitoring and damage diagnosis system;
the structural health monitoring and damage diagnosis system comprises an operation parameter access module, an acoustic emission data access module, an operation parameter database, an acoustic emission database, a health diagnosis module and a remote display module;
the operation parameter access module is connected with the operation parameter database, and is used for receiving pressure, flow, temperature and operation process parameters in the operation process of the coke tower and transmitting the pressure, flow, temperature and operation process parameters to the operation parameter database;
the acoustic emission data access module is respectively connected with the acoustic emission database and the health diagnosis module, and is used for receiving the digital acoustic emission electric signals and sending the digital acoustic emission electric signals to the acoustic emission database and the health diagnosis module;
the health diagnosis module is connected with the remote display module and is used for analyzing the structural health state of the coke tower in the running process according to the digital acoustic emission electric signals, positioning the digital acoustic emission electric signals and sending the structural health state and the positioning result to the remote display module;
the remote display module is respectively connected with the operation parameter database and the sound emission database, and is used for displaying the structural health state, the pressure, the flow, the temperature and the operation process parameters in the coke tower operation process and displaying the positioning result in a graph.
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