Test device for realizing fault simulation of centrifugal pump

Abstract

The present invention relates to a centrifugal pump fault simulation test device, which is composed of a normal centrifugal pump circulation system and a faulty centrifugal pump circulation system. The normal centrifugal pump circulation system and the faulty centrifugal pump circulation system can operate independently, and are connected and switched in parallel by a three-way valve to realize the switching of the operating states of the two circulation systems, and to realize the simulation of centrifugal pump group and regulating valve failure; the two circulation systems are respectively equipped with a fault diagnosis system. The present invention realizes the simulation and identification of various types of centrifugal pump failures through the adjustment of multiple operating parameters and the replacement of components, and grasps the performance characteristics and vibration characteristic parameters of the pump group under various typical failure modes such as centrifugal pump cavitation, impeller cavitation damage, pump group mass imbalance, pump group misalignment, mouth ring wear, pump group base loosening, pump group filter blockage, pump group bearing failure, motor rotor imbalance, motor bearing abnormality, pump group regulating control valve failure, etc., and realizes centrifugal pump fault diagnosis from the dual levels of performance and vibration characteristics.

Description

Technical Field

[0001] The invention relates to a centrifugal pump test device, in particular to a test device for diagnosing common faults of centrifugal pumps. Background Art

[0002] Centrifugal pumps are a commonly used marine equipment. According to incomplete statistics, among the various auxiliary equipment on ships except the main engine, the total number of marine pumps of various types and uses accounts for about 20%-30% of the total number of ship mechanical equipment. There are many types of centrifugal pump failures, which can be roughly divided into two categories: one is functional failure, abnormal working conditions cause the system to deviate from normal functions, such as damaged parts, improper operation, etc. This type of failure can generally be corrected by correcting parameters or reprocessing parts to enable the system to operate normally; the other is acoustic failure, centrifugal pumps can operate under normal working conditions, but the vibration noise is relatively large. Acoustic failure is a potential manifestation of functional failure of equipment. This type of failure is related to parameters such as the operating conditions of the equipment, pipeline characteristics, equipment processing technology, and functional characteristics of the equipment. If the equipment operates under acoustic failure for a long time, it will eventually lead to functional failure. At present, the judgment of centrifugal pump fault characteristics is generally carried out from the aspects of energy performance such as flow, head, speed and shaft power, while the research on the vibration characteristics of centrifugal pump faults is relatively small, and most of them exist at the mechanism research level. The fault characteristics of centrifugal pumps have not been identified from an engineering perspective, and no judgment standard for centrifugal pump fault identification has been formed. For example, in the document "Research on the Operation Characteristics of Marine Centrifugal Pumps under Typical Fault Conditions", the numerical simulation calculation method is used to study the operating characteristics of a certain type of centrifugal pump under different typical fault forms. For the blade breakage fault form, the ring wear fault form and the concurrent fault form of the two, the external characteristics, internal flow field and vibration characteristics are analyzed respectively, and the operating characteristics of the model pump under the above two fault forms are summarized. However, the number of faults simulated in this document is small, and it is impossible to achieve comprehensive simulation, identification and processing of centrifugal pump faults, and it is impossible to form a standard for centrifugal pump fault diagnosis. Summary of the invention

[0003] In view of the above problems, the present invention proposes a test device for realizing centrifugal pump fault simulation. By adjusting the operating parameters of the pump and replacing the fault simulation components, the fault simulation and characteristic identification of centrifugal pump cavitation, impeller cavitation damage, pump group mass imbalance, pump group misalignment, mouth ring wear, pump group base looseness, pump group blockage, pump group bearing failure, motor rotor imbalance, motor bearing abnormality, pump group regulating control valve failure, etc. are realized, the performance and vibration parameter characteristics of the centrifugal pump under various typical faults are mastered, and the method and standard for centrifugal pump fault diagnosis are formed.

[0004] To achieve the above-mentioned purpose, the technical solution of the present invention is: a centrifugal pump fault simulation test device, composed of a normal centrifugal pump circulation system and a faulty centrifugal pump circulation system, the normal centrifugal pump circulation system and the faulty centrifugal pump circulation system can operate independently, and are connected in parallel through a three-way valve, and the operating state of the normal centrifugal pump circulation system and the faulty centrifugal pump circulation system are switched by switching the three-way valve to realize the simulation of centrifugal pump group and regulating valve failure; the normal centrifugal pump circulation system and the faulty centrifugal pump circulation system are respectively equipped with a fault diagnosis system, and the fault diagnosis system completes the simulation test and diagnosis of centrifugal pump group and regulating valve failure.

[0005] Furthermore, the water inlet end of the inlet three-way valve in the faulty centrifugal pump circulation system is connected to a water tank, and the water outlet end is sequentially connected to a true flow meter, an electric regulating valve, a test pipe section, an inlet filter, a flow meter, a flexible connecting pipe, a faulty centrifugal pump, an outlet three-way valve, a three-way valve before the valve, a filter before the valve, an electric regulating valve, a three-way valve after the valve and a water tank.

[0006] Furthermore, a vacuum pressure gauge is provided on the pipeline connecting the inlet three-way valve and the flow meter; an inlet vacuum gauge and an outlet pressure gauge are respectively provided on the pipelines connecting the two ends of the faulty centrifugal pump.

[0007] Furthermore, in the normal centrifugal pump circulation system, the water inlet end of the imported three-way valve is connected to the water tank, and the water outlet end is connected in sequence to the flow meter, electric regulating valve, imported filter, flow meter, imported vacuum gauge, centrifugal pump, outlet three-way valve, three-way valve before the valve, filter before the valve, electric regulating valve, three-way valve after the valve and water tank.

[0008] Furthermore, a vacuum pressure gauge is provided on the pipeline connecting the inlet three-way valve and the flow meter; an inlet vacuum gauge and an outlet pressure gauge are respectively provided on the pipelines connecting the two ends of the centrifugal pump.

[0009] Furthermore, the fault diagnosis system includes a vacuum pressure gauge, a flow meter, a vibration sensor placed on the centrifugal pump, and a current and power measuring instrument for the centrifugal pump motor. The fault diagnosis system identifies the fault of the centrifugal pump based on the test data of the vacuum pressure gauge, the flow meter, the vibration sensor, and the current and power of the centrifugal pump motor, and through a comprehensive judgment of the performance and vibration parameters of the centrifugal pump group, realizes feature extraction and identification of the fault parameters and determines the fault location and type.

[0010] Furthermore, the centrifugal pump fault simulation test device realizes the fault simulation of the centrifugal pump by adjusting the operating parameters of the circulation system of the faulty centrifugal pump or replacing the faulty components.

[0011] Furthermore, the simulation tests of the centrifugal pump group and the regulating valve failures include a centrifugal pump cavitation failure simulation test, an impeller cavitation damage failure simulation test, a centrifugal pump mass imbalance failure simulation test, a centrifugal pump group misalignment failure simulation test, a centrifugal pump group mouth ring wear failure simulation test, a centrifugal pump group base loosening failure simulation test, a centrifugal pump group blockage failure simulation test, a centrifugal bearing failure simulation test, a centrifugal motor rotor imbalance failure simulation test, and a regulating valve failure simulation test.

[0012] The beneficial effects of the present invention are:

[0013] The present invention simulates and identifies various fault types of centrifugal pumps through adjustment of various operating parameters and replacement of components, and grasps the performance characteristics and vibration characteristic parameters of the pump group under various typical fault modes such as centrifugal pump cavitation, impeller cavitation damage, pump group mass imbalance, pump group misalignment, mouth ring wear, pump group base loosening, pump group filter blockage, pump group bearing failure, motor rotor imbalance, motor bearing abnormality, pump group regulating control valve failure, etc., to realize centrifugal pump fault diagnosis from both performance and vibration characteristics. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 It is a schematic diagram of the principle of the test device for realizing centrifugal pump fault simulation of the present invention;

[0015] In the figure: 10. vacuum pressure gauge, 11. flow meter, 12. electric regulating valve, 13. test pipe section, 14. inlet filter, 15. flow meter, 16. flexible pipe, 17. inlet vacuum gauge, 18. centrifugal pump, 19. outlet pressure gauge, 20. vacuum pressure gauge, 21. flow meter, 22. electric regulating valve, 23. inlet filter, 24. flow meter, 25. inlet vacuum gauge, 26. centrifugal pump, 27. outlet pressure gauge, 30. pre-valve filter, 31. electric regulating valve, 40. pre-valve filter, 41. electric regulating valve, 5. inlet three-way valve, 6. outlet three-way valve, 7. pre-valve three-way valve, 8. post-valve three-way valve, 9. water tank. DETAILED DESCRIPTION

[0016] The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0017] like Figure 1 As shown, the centrifugal pump fault simulation test device of the present invention is composed of a normal centrifugal pump circulation system and a faulty centrifugal pump circulation system, and the two systems can operate independently. By switching the three-way valve, the system normal / fault state is switched to achieve the simulation of system faults.

[0018] The faulty centrifugal pump circulation system consists of a vacuum pressure gauge 10, a flow meter 11, an electric regulating valve 12, a test pipe section 13, an inlet filter 14, a flow meter 15, a flexible pipe 16, an inlet vacuum gauge 17, a centrifugal pump 18, an outlet pressure gauge 19, a pre-valve filter 30, an electric regulating valve 31, an inlet three-way valve 5, an outlet three-way valve 6, a pre-valve three-way valve 7, a post-valve three-way valve 8, a water tank 9 and an associated vibration measurement system; the water inlet end of the inlet three-way valve 5 is connected to the water tank 9, and the water outlet end is connected in sequence to the vacuum flow meter 11, the electric regulating valve 12, the test pipe section 13, the inlet filter 14, the flow meter 15, the flexible pipe 16, the centrifugal pump 18, the outlet three-way valve 6, the pre-valve three-way valve 7, the pre-valve filter 30, the electric regulating valve 31, the post-valve three-way valve 8 and the water tank 9. A vacuum pressure gauge 10 is provided on the pipeline connecting the inlet three-way valve 5 and the flow meter 11, and an inlet vacuum gauge 17 and an outlet pressure gauge 19 are provided on the pipelines connecting the two ends of the centrifugal pump 18, respectively.

[0019] The normal centrifugal pump circulation system is composed of a vacuum pressure gauge 20, a flow meter 21, an electric regulating valve 22, an inlet filter 23, a flow meter 24, an inlet vacuum gauge 25, a centrifugal pump 26, an outlet pressure gauge 27, a pre-valve filter 40, an electric regulating valve 41, an inlet three-way valve 5, an outlet three-way valve 6, a pre-valve three-way valve 7, a post-valve three-way valve 8, a water tank 9 and an auxiliary vibration measurement system; the inlet end of the inlet three-way valve 5 is connected to the water tank 9, and the outlet end is connected in sequence to the flow meter 21, the electric regulating valve 22, the inlet filter 23, the flow meter 24, the inlet vacuum gauge 25, the centrifugal pump 26, the outlet three-way valve 6, the pre-valve three-way valve 7, the pre-valve filter 40, the electric regulating valve 41, the post-valve three-way valve 8 and the water tank 9. The pipeline connecting the inlet three-way valve 5 and the flow meter 21 is provided with a vacuum pressure gauge 20, and the pipelines connecting the two ends of the centrifugal pump 26 are respectively provided with an inlet vacuum gauge 25 and an outlet pressure gauge 27.

[0020] The fault simulation of the system is realized by adjusting the operating parameters of the faulty centrifugal pump circulation system or replacing the faulty parts. When the system is running, the system's electrical parameters such as current and power, performance parameters such as speed, flow, pressure, inlet and outlet pressure, vibration parameters such as machine foot vibration acceleration and rotor vibration displacement are monitored and identified. Through comprehensive judgment of the performance and vibration parameters of the centrifugal pump group, the feature extraction and identification of the fault parameters are realized, and the location and type of the system fault are determined.

[0021] Method for simulating cavitation failure of a centrifugal pump: a. Adjust the directions of the inlet three-way valve 5, the outlet three-way valve 6, the three-way valve before the valve 7, and the three-way valve after the valve 8 to switch the test device pipeline to the pump failure simulation mode, even if the system is working in the faulty centrifugal pump and normal regulating valve mode; b. Start the pump group, adjust the operating state of the centrifugal pump 18 to the rated operating condition, adjust the opening of the electric regulating valve 12, so that the centrifugal pump 18 is in the cavitation state, and the supporting fault diagnosis system will identify the pump group cavitation failure based on the vacuum pressure gauge 15, the flow meter 17, the vibration sensor placed on the pump group, and the test data of the motor current and power; c. Restore the opening of the electric regulating valve 12, shut down the centrifugal pump 18, and complete the centrifugal pump cavitation failure simulation test.

[0022] Impeller cavitation damage fault simulation method: a. Replace the impeller of the centrifugal pump 18 with a simulated impeller with cavitation damage; b. Adjust the direction of the inlet three-way valve 5, the outlet three-way valve 6, the pre-valve three-way valve 7, and the post-valve three-way valve 8 to switch the test device pipeline to the pump fault simulation mode, and operate in the faulty centrifugal pump and normal regulating valve mode; c. Start the centrifugal pump 18 to perform the impeller cavitation damage fault simulation test. The supporting fault diagnosis system will identify the impeller cavitation damage fault based on the vacuum pressure gauge 15, the flow meter 17, the outlet pressure gauge 19, the vibration sensor placed on the pump group, and the test data of the motor current and power; d. Shut down the centrifugal pump 18, replace the impeller with cavitation damage, restore the state of the centrifugal pump 18 to normal, and complete the impeller cavitation damage fault simulation test.

[0023] Method for simulating mass imbalance failure of the pump group: a. Adjust the directions of the inlet three-way valve 5, the outlet three-way valve 6, the three-way valve before the valve 7, and the three-way valve after the valve 8 to switch the test device pipeline to the pump failure simulation mode, even if the system is in the faulty centrifugal pump and normal regulating valve mode; b. Add a counterweight bolt at the coupling position of the centrifugal pump 18 to put the pump group in a mass imbalance state; c. Start the pump group and adjust the operating state of the centrifugal pump 18 to the rated operating condition. The matching fault diagnosis system will identify the mass imbalance failure of the pump group based on the vacuum pressure gauge 15, the flow meter 17, the outlet pressure gauge 19, the vibration sensor placed on the pump group, and the test data of the motor current and power; d. Shut down the centrifugal pump 18, remove the counterweight bolt, and complete the centrifugal pump mass imbalance failure simulation test.

[0024] Method for simulating pump group misalignment fault: a. Raise the installation foot of the centrifugal pump 18 by 2mm to simulate the pump group misalignment fault; b. Adjust the direction of the inlet three-way valve 5, the outlet three-way valve 6, the three-way valve before the valve 7, and the three-way valve after the valve 8 to switch the test device pipeline to the pump fault simulation mode and operate in the faulty centrifugal pump and normal regulating valve mode; c. Start the centrifugal pump 18 to perform the pump group misalignment fault simulation test. The matching fault diagnosis system will identify the pump group misalignment fault based on the vacuum pressure gauge 15, the flow meter 17, the outlet pressure gauge 19, the vibration sensor placed on the pump group, and the test data of the motor current and power; d. Shut down the centrifugal pump 18, remove the heightening gasket, and complete the pump group misalignment fault simulation test.

[0025] Simulation method of mouth ring wear failure: a. Replace the mouth ring of the centrifugal pump 18 with a worn mouth ring; b. Adjust the direction of the inlet three-way valve 5, the outlet three-way valve 6, the three-way valve before the valve 7, and the three-way valve after the valve 8 to switch the test device pipeline to the pump failure simulation mode, and work in the faulty centrifugal pump and normal regulating valve mode; c. Start the centrifugal pump 18 to perform the mouth ring wear failure simulation test. The supporting fault diagnosis system will identify the mouth ring wear failure based on the vacuum pressure gauge 15, the flow meter 17, the outlet pressure gauge 19, the vibration sensor placed on the pump group, and the test data of the motor current and power; d. Shut down the centrifugal pump 18, replace the worn mouth ring, restore the state of the centrifugal pump 18 to normal, and complete the mouth ring wear failure simulation test.

[0026] Method for simulating a loose base failure of a pump group: a. Loosen the bolts of the base of the centrifugal pump 18 to simulate a loose base failure of the pump group; b. Adjust the directions of the inlet three-way valve 5, the outlet three-way valve 6, the three-way valve before the valve 7, and the three-way valve after the valve 8 to switch the test device pipeline to the pump failure simulation mode and operate in the faulty centrifugal pump and normal regulating valve modes; c. Start the centrifugal pump 18 to perform a simulation test on the loose base of the pump group. The matching fault diagnosis system will identify the fault based on the vacuum pressure gauge 15, the flow meter 17, the outlet pressure gauge 19, the vibration sensor placed on the pump group, and the test data of the motor current and power; d. Shut down the centrifugal pump 18, tighten the base bolts, restore the state of the centrifugal pump 18 to normal, and complete the simulation test on the loose base failure of the pump group.

[0027] Pump group blockage failure simulation method: a. Place gauze and stones at the inlet filter 14 to simulate the pump group filter blockage failure; b. Adjust the direction of the inlet three-way valve 5, the outlet three-way valve 6, the three-way valve before the valve 7, and the three-way valve after the valve 8 to switch the test device pipeline to the pump failure simulation mode, and work in the faulty centrifugal pump and normal regulating valve mode; c. Turn on the centrifugal pump 18 for a simulation test. The matching fault diagnosis system will identify the fault based on the vacuum pressure gauge 10, the flow meter 11, the vacuum pressure gauge 15, the flow meter 17, the outlet pressure gauge 19, the vibration sensor placed on the pump group, and the test data of the motor current and power; d. Shut down the centrifugal pump 18, remove the gauze and other debris, restore the state of the centrifugal pump 18 to normal, and complete the pump group blockage failure simulation test.

[0028] Pump group bearing failure simulation method: a. Replace the support bearing of the centrifugal pump 18 with a bearing with rolling element failure; b. Adjust the direction of the inlet three-way valve 5, the outlet three-way valve 6, the three-way valve before the valve 7, and the three-way valve after the valve 8 to switch the test device pipeline to the pump failure simulation mode and operate in the faulty centrifugal pump and normal regulating valve mode; c. Start the centrifugal pump 18 to perform a fault simulation test. The matching fault diagnosis system will identify the bearing fault based on the vacuum pressure gauge 15, the flow meter 17, the outlet pressure gauge 19, the vibration sensor placed on the pump group, and the test data of the motor current and power; d. Shut down the centrifugal pump 18, replace the damaged bearing, restore the state of the centrifugal pump 18 to normal, and complete the bearing failure simulation test.

[0029] Method for simulating motor rotor unbalance fault: a. Add a counterweight bolt at the motor fan position to put the motor in a mass unbalanced state; b. Adjust the direction of the inlet three-way valve 5, the outlet three-way valve 6, the three-way valve before the valve 7, and the three-way valve after the valve 8 to switch the test device pipeline to the pump fault simulation mode, even if the system is working in the faulty centrifugal pump and normal regulating valve mode; c. Turn on the pump group and adjust the operating state of the centrifugal pump 18 to the rated operating condition. The matching fault diagnosis system will identify the motor mass imbalance fault based on the vacuum pressure gauge 15, the flow meter 17, the outlet pressure gauge 19, the vibration sensor placed on the pump group, and the test data of the motor current and power; d. Shut down the centrifugal pump 18, remove the counterweight bolt, and complete the motor rotor unbalance fault simulation test.

[0030] Method for simulating failure of regulating control valve of pump group: a. Adjust the direction of inlet three-way valve 5, outlet three-way valve 6, pre-valve three-way valve 7 and post-valve three-way valve 8 to switch the pipeline of test device to the failure simulation mode of regulating valve, even if the system is working in normal centrifugal pump and failure regulating valve mode; b. Replace the valve plate of regulating valve 31 with a corroded and damaged valve plate, and conduct a failure simulation test of regulating control valve; c. Start the pump group, adjust the operating state of centrifugal pump 26 to rated working condition, and the matching fault diagnosis system will identify the fault according to the test data of vacuum pressure gauge 24, flow meter 25, outlet pressure gauge 27, vibration sensor placed on valve group and motor current and power; d. Shut down centrifugal pump 26, replace the damaged valve plate, and complete the failure simulation test of regulating valve.

[0031] By injecting the above-mentioned faults simultaneously, the simulated diagnosis of the centrifugal pump compound faults can be realized.

Claims

1. A centrifugal pump fault simulation test device, consisting of a normal centrifugal pump circulation system and a faulty centrifugal pump circulation system, characterized in that: The normal centrifugal pump circulation system and the faulty centrifugal pump circulation system can operate independently and are connected in parallel through a three-way valve. By switching the three-way valve, the operating states of the normal centrifugal pump circulation system and the faulty centrifugal pump circulation system are switched to simulate the failure of the centrifugal pump group and the regulating valve. The normal centrifugal pump circulation system and the faulty centrifugal pump circulation system are respectively equipped with a fault diagnosis system, and the fault diagnosis system completes the simulation test and diagnosis of the centrifugal pump group and the regulating valve failure. The water inlet end of the imported three-way valve in the faulty centrifugal pump circulation system is connected to the water inlet end of the imported three-way valve in the faulty centrifugal pump circulation system. The water outlet is connected to a water tank, and the water outlet is connected in sequence to a true flow meter, an electric regulating valve, a test pipe section, an inlet filter, a flow meter, a flexible pipe, a faulty centrifugal pump, an outlet three-way valve, a three-way valve before the valve, a filter before the valve, an electric regulating valve, a three-way valve after the valve and a water tank; the water inlet end of the inlet three-way valve in the normal centrifugal pump circulation system is connected to the water tank, and the water outlet end is connected in sequence to a flow meter, an electric regulating valve, an inlet filter, a flow meter, an inlet vacuum meter, a centrifugal pump, an outlet three-way valve, a three-way valve before the valve, a filter before the valve, an electric regulating valve, a three-way valve after the valve and a water tank; The fault diagnosis system includes a vacuum pressure gauge, a flow meter, a vibration sensor placed on the centrifugal pump, and a current and power measuring instrument for the centrifugal pump motor. The fault diagnosis system identifies the fault of the centrifugal pump group based on the test data of the vacuum pressure gauge, the flow meter, the vibration sensor, and the current and power of the centrifugal pump motor, and realizes feature extraction and identification of the fault parameters and determines the fault location and type through comprehensive judgment of the performance and vibration parameters of the centrifugal pump group; the centrifugal pump fault simulation test device realizes the fault simulation of the centrifugal pump by adjusting the operating parameters of the faulty centrifugal pump circulation system or replacing the faulty parts; the simulation tests of the centrifugal pump group and the regulating valve fault include the centrifugal pump cavitation fault simulation test, the impeller cavitation damage fault simulation test, the centrifugal pump mass imbalance fault simulation test, the centrifugal pump group misalignment fault simulation test, the centrifugal pump group mouth ring wear fault simulation test, the centrifugal pump group base loose fault simulation test, the centrifugal pump group blockage fault simulation test, the centrifugal bearing fault simulation test, the centrifugal motor rotor imbalance fault simulation test, and the regulating valve fault simulation test.

2. The centrifugal pump fault simulation test device according to claim 1, characterized in that: A vacuum pressure gauge is provided on the pipeline connecting the inlet three-way valve and the flow meter; an inlet vacuum gauge and an outlet pressure gauge are respectively provided on the pipelines connecting the two ends of the faulty centrifugal pump.

3. The centrifugal pump fault simulation test device according to claim 1, characterized in that: A vacuum pressure gauge is provided on the pipeline connecting the inlet three-way valve and the flow meter; an inlet vacuum gauge and an outlet pressure gauge are respectively provided on the pipelines connecting the two ends of the centrifugal pump.

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