A method based on health assessment of pump station units

Abstract

The present invention relates to a method based on health assessment of pump station units. First, according to the needs of health assessment of pump station units, a data acquisition front end is established to combine a monitoring network and an overall network system architecture of remote diagnosis, including a perception layer, a network layer and an application layer. Then, the corresponding data of the pump station unit is collected according to the data acquisition device of the perception layer, and the collected data is sent to the server of the application layer through the network layer. After comparing the collected data with a preset alarm threshold value, it is determined whether to perform data analysis and fault diagnosis, and finally the diagnosis result is published. The present invention further analyzes the monitoring results of the pump station unit by comprehensively collecting data parameters such as vibration, swing, and ambient temperature, and objectively evaluates the health status of the pump station unit to ensure the normal operation of the pump station unit and maximize its service life, thereby reducing costs.

Description

Technical Field

[0001] The present invention relates to the field of intelligent operation and maintenance technology, and in particular to a method based on health assessment of pump station units. Background Art

[0002] Traditional pump station maintenance personnel use the four methods of "looking, smelling, touching and listening" to perform daily inspections on unit equipment. It can be seen that traditional daily inspections have great limitations. If the equipment failures found are already irreversible, only experienced maintenance personnel may be able to do it at this time. In addition, traditional maintenance methods also require regular inspections, replacements and repairs. In view of the problems existing in the management of traditional pump station units, the full life cycle management and health assessment of pump station units are defined as follows:

[0003] Full life cycle management: From the start of use to the aging and wear of the equipment, or even the entire process of equipment being unable to continue to be put into use, the equipment can be managed throughout the entire process, and every link of the equipment life cycle can be managed well (such as the management of the initial design defects of the equipment, the management of information such as bumps during transportation, the data management of the installation process, the data management of the operation process, and the management of equipment maintenance and replacement), so as to maximize the extension of equipment life and reduce costs.

[0004] Health assessment: By real-time monitoring of the operating status of the pump station equipment, the health status of the equipment can be understood in real time. When there is an abnormality in the equipment, major incidents caused by equipment failure can be avoided, thereby reducing production costs. Summary of the invention

[0005] The technical problem to be solved by the present invention is to provide a method based on health assessment of pump station units in view of the above-mentioned prior art, so as to ensure the normal operation of the pump station units, maximize their service life, and thus reduce costs.

[0006] The technical solution adopted by the present invention to solve the above-mentioned problem is: a method for health assessment based on the full life cycle management of pump station units. First, according to the needs of full life cycle management and health assessment of pump station units, an overall network system architecture combining a data acquisition front end with a monitoring network and remote diagnosis is established, including a perception layer, a network layer and an application layer. Then, the corresponding data of the pump station unit is collected according to the data acquisition device of the perception layer, and the collected data is sent to the server of the application layer through the network layer. After comparing the collected data with the preset alarm threshold value, it is determined whether data analysis and fault diagnosis are to be performed, and finally the diagnosis results are published.

[0007] Preferably, the server at the application layer stores, analyzes, and manages the real-time data, historical data, and various characteristic value data transmitted from each data acquisition device, analyzes the data and diagnoses faults, that is, performs a health assessment. First, the assessment factors are selected according to the actual situation, and the factors are weighted. A scoring system is established based on the weight division of each factor, and the scores are given according to the assessment calculation rules. The higher the score, the better the health of the equipment. After each unit ends operation, the system automatically updates its health evaluation results based on the operating conditions.

[0008] Preferably, the evaluation calculation rules include:

[0009] 1) No sensor value exceeds the alarm threshold

[0010] Scoring formula: F = PE-KP-[(A 转轮 / A0)×10%+(Apj / A0)×10%+(Bpj / B0)×25%+(C 定子 / C0)×10%+(Cpj / C0)×20%+(Dpj / D0)×15%+(Epj / E0)×10%]×20-M / 10-N-10×ST / 1000

[0011] 2) When the sensor value exceeds the alarm value but does not reach the accident shutdown value:

[0012] Scoring formula: F = PE1-KP-[(A 转轮 / A0)×10%+(Apj / A1)×10%+(Bpj / B1)×25%+(C 定子 / C0)×10%+(Cpj / C1)×20%+(Dpj / D1)×15%+(Epj / E1)×10%]×20-M / 10-N-10×ST / 1000

[0013] In this case, the score is lower than M1 points;

[0014] 3) When the sensor value exceeds the emergency shutdown value:

[0015] Scoring formula: F = PE2-KP-[(A 转轮 / A0)×10%+(Apj / A1)×10%+(Bpj / B1)×25%+(C 定子 / C0)×10%+(Cpj / C1)×20%+(Dpj / D1)×15%+(Epj / E1)×10%]×20-M / 10-N-10×ST / 1000

[0016] In this case, the score is lower than M2 points;

[0017] in:

[0018] A 转轮 : Reading of the vibration sensor in the runner chamber; take the average value of the maximum values ​​of each measuring point during this operation;

[0019] A 其他 : Vibration sensor readings of other parts;

[0020] B: swing sensor reading;

[0021] C 定子 : The motor stator three-phase temperature sensor reading; take the maximum value during this operation;

[0022] C 其他 : Other temperature sensor readings;

[0023] D: pressure pulsation sensor reading;

[0024] E: Noise sensor reading;

[0025] An: the reading of the vibration sensor numbered n;

[0026] max[An]: the maximum valid value collected by the vibration sensor numbered n# during the operation that just ended;

[0027] Apj: the arithmetic mean of max[An] of all vibration sensors;

[0028] A0: vibration alarm threshold;

[0029] A1: Vibration accident shutdown threshold value;

[0030] K: The range of stable operation under different working conditions, that is, to compare whether the average vibration amplitude A of the runner chamber is close under different working conditions; K = max{A 转轮低扬程 / A 转轮中间扬程 , A 转轮低扬程 / A 转轮最大扬程 , A 转轮中间扬程 / A 转轮最大扬程 , A 转轮中间扬程 / A 转轮低扬程 , A 转轮最大扬程 / A 转轮最小扬程 , A 转轮最大扬程 / A 转轮中间扬程}; Maximum, minimum and intermediate lift refer to the lift during this operation;

[0031] P: Under design conditions, that is, when the measured head = the designed head, the ratio of the measured flow rate to the designed flow rate, P = 100-100*Q 实测 / Q 设计 , if Q 实测 / Q 设计If Q is less than 1, then P is positive; 实测 / Q 设计 If it is greater than 1, P is negative; if the design head is not reached during this operation, Q 设计 Then take the maximum flow rate among all the units started this time;

[0032] M: The number of months since the last major overhaul;

[0033] N: The number of failures that have occurred since the most recent overhaul;

[0034] S: the number of unresolved faults;

[0035] T: operating time since the last overhaul;

[0036] F: health assessment score;

[0037] PE, PE1, PE2: upper limit of scores for each stage.

[0038] Preferably, the server collects the value of the corresponding measuring point by receiving the data collection device, and expresses the current alarm status of the measuring point by combining the changes between different colors:

[0039] When there is no data, the background color of the data display area is gray;

[0040] When the data is within the normal range, the background color will change to green, which means normal;

[0041] When the value of the vibration data exceeds the alarm threshold, the background color will change to yellow, which means high alarm;

[0042] When the value of the vibration data exceeds the danger threshold, the background color will change to red, indicating a high alarm.

[0043] Compared with the prior art, the advantages of the present invention are:

[0044] The present invention realizes the monitoring of the online operation status of the pump station unit by relying on the computer monitoring system. The management of the pump station unit equipment should start from the planning and procurement of the equipment, and comprehensively and reasonably manage the equipment in the whole process until the equipment is scrapped and loses its use value. On the other hand, by comprehensively collecting data parameters such as vibration, swing, and ambient temperature, the monitoring results of the pump station unit are further analyzed, and the health status of the pump station unit is objectively evaluated to ensure the normal operation of the pump station unit and maximize its service life, thereby reducing costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Figure 1 It is an overall architecture diagram of a pump station unit health assessment network system in an embodiment of the present invention. DETAILED DESCRIPTION

[0046] The present invention is further described in detail below with reference to the accompanying drawings.

[0047] A method based on health assessment of pump station units in this embodiment mainly includes the following contents:

[0048] 1. Build the network structure

[0049] In response to the needs of full life cycle management and health assessment of pump station units, combined with the "Internet +" technology, an overall network system architecture that combines the data acquisition front end with the monitoring network and remote diagnosis is proposed. The entire system consists of a perception layer, a network layer, and an application layer. Among them, the perception layer realizes intelligent perception, information processing, and automatic control of the physical world, and connects the physical entity to the network layer and the application layer through a communication module. The network layer mainly realizes the transmission, routing, and control of information. The network layer can rely on the public telecommunications network and the Internet. The application layer includes application infrastructure, middleware, and corresponding applications. The overall structure of the pump station is divided into three parts: the data acquisition front end and the remote diagnosis center. The network structure of the host unit's full life cycle monitoring management and health assessment is as follows Figure 1 shown.

[0050] 1) The data acquisition device of each unit in the pump station is responsible for collecting vibration, swing, pressure and other signals of the pump station unit.

[0051] 2) The WEB server is used to store, analyze, and manage real-time data, historical data, and various characteristic value data transmitted from various data acquisition devices, analyze and diagnose faults, and publish data.

[0052] The WEB server collects the values ​​of the corresponding measuring points through the receiving data acquisition device. In the system background, the measuring points for which you want to prompt the alarm can be set. Generally, it depends on whether the data of this object will have any impact after reaching a certain level. If it is felt that there is an impact, the alarm will be turned on and the corresponding alarm limit value will be set. For example, if the noise reaches a certain value, there may be a problem with a certain hardware. At this time, the alarm threshold value can be set. When it exceeds the value, an alarm will be triggered to serve as a reminder to the staff. At the same time, the changes between different colors are combined to express the current alarm status of the measuring point:

[0053] When there is no data, the background color of the data display area is gray;

[0054] When the data is within the normal range, the background color will change to green, which means normal;

[0055] When the value of the vibration data exceeds the alarm threshold, the background color will change to yellow, which means high alarm;

[0056] When the value of the vibration data exceeds the danger threshold, the background color will change to red, indicating a high alarm.

[0057] 2. Health Assessment

[0058] A. Health assessment needs to involve the weight of each factor and score each factor. Because the factors targeted by health assessment are not necessarily the same, factors can be selected according to actual conditions. The general rules are as follows:

[0059] 1) Weight division of each factor (percentage, 100% in total): The weight of the turbine chamber vibration index is 10%, the weight of other vibration indexes is 10%, the weight of the swing index is 25%, the weight of the stator temperature index is 10%, the weight of other temperature indexes is 20%, the weight of the pressure pulsation index is 15%, and the weight of the noise index is 10%.

[0060] 2) The score is based on a 100-point system, with a full score of 100. The higher the score, the better the health of the equipment.

[0061] 3) After each unit operation ends, the system automatically updates its health assessment results based on the operating conditions.

[0062] B. Because there are many symbols involved in the health assessment algorithm, the symbols are explained as follows:

[0063] 1) A 转轮 : Reading of the vibration sensor in the runner chamber; take the average value of the maximum values ​​of each measuring point during this operation;

[0064] 2) A 其他 : Vibration sensor readings of other parts;

[0065] 3) B: swing sensor reading;

[0066] 4) C 定子 : The motor stator three-phase temperature sensor reading; take the maximum value during this operation;

[0067] 5) C 其他 : Other temperature sensor readings;

[0068] 6) D: pressure pulsation sensor reading;

[0069] 7) E: Noise sensor reading;

[0070] 8) An: the reading of the vibration sensor numbered n;

[0071] 9) max[An]: the maximum valid value collected by the vibration sensor numbered n# during the operation just completed;

[0072] 10) Apj: the arithmetic mean of max[An] of all vibration sensors;

[0073] 11) A0: vibration alarm threshold;

[0074] 12) A1: Vibration accident shutdown threshold value;

[0075] 13) K: The range of stable operation under different working conditions. That is, to compare whether the average vibration amplitude A of the runner chamber is close under different working conditions. K = max{A 转轮低扬程 / A 转轮中间扬程 , A 转轮低扬程 / A 转轮最大扬程 , A 转轮中间扬程 / A 转轮最大扬程 , A 转轮中间扬程 / A 转轮低扬程 , A 转轮最大扬程 / A 转轮最小扬程 , A 转轮最大扬程 / A 转轮中间扬程}; Maximum, minimum and intermediate lift refer to the lift during this operation;

[0076] 14) P: The ratio of the measured flow rate to the designed flow rate under the design working condition (when the measured head = the designed head). P = 100-100*Q 实测 / Q 设计 , if Q 实测 / Q 设计 If Q is less than 1, then P is positive. 实测 / Q 设计 If it is greater than 1, P is negative; if the design head is not reached during this operation, Q 设计 Then take the maximum flow rate among all the units started this time;

[0077] 15) M: The number of months since the last major overhaul

[0078] 16) N: Number of failures that have occurred since the last overhaul

[0079] 17) S: Number of unresolved faults

[0080] 18) T: operating time from the last overhaul to the present (directly divided by 1000 when calculating);

[0081] 19) F: Health Assessment Score

[0082] C: Evaluation calculation

[0083] 1) No sensor value exceeds the alarm threshold:

[0084] Rating calculation formula: F = 100-KP-[(A 转轮 / A0)×10%+(Apj / A0)×10%+(Bpj / B0)×25%+(C 定子 / C0)×10%+(Cpj / C0)×20%+(Dpj / D0)×15%+(Epj / E0)×10%]×20-M / 10-N-10×ST / 1000

[0085] in:

[0086] A 转轮 Refers to the maximum value of each vibration measuring point on the rotor during this operation;

[0087] C 定子 , swing Bpj, and noise Epj also take the maximum value;

[0088] For other Apj, Cpj, and Dpj, take the average of the maximum values.

[0089] 2) When the sensor value exceeds the alarm value but does not reach the accident shutdown value:

[0090] Rating calculation formula: F = 80-KP-[(A 转轮 / A0)×10%+(Apj / A1)×10%+(Bpj / B1)×25%+(C 定子 / C0)×10%+(Cpj / C1)×20%+(Dpj / D1)×15%+(Epj / E1)×10%]×20-M / 10-N-10×ST / 1000

[0091] In this case, the score is less than 80 points.

[0092] 3) When the sensor value exceeds the emergency shutdown value:

[0093] Scoring formula: F = 60-KP-[(A 转轮 / A0)×10%+(Apj / A1)×10%+(Bpj / B1)×25%+(C 定子 / C0)×10%+(Cpj / C1)×20%+(Dpj / D1)×15%+(Epj / E1)×10%]×20-M / 10-N-10×ST / 1000

[0094] In this case, the score is less than 60 points.

[0095] The meaning of the calculation of the final score range is defined as follows:

[0096] 85-100 points: Good

[0097] 70-85 points: Available

[0098] 60-70 points: Abnormal

[0099] Below 60 points: Stopping required

[0100] Based on the above final score range, the health assessment results of the pump station units are divided into: good (green), available (orange), abnormal (yellow), and shutdown required (red).

[0101] In addition to the above embodiments, the present invention also includes other implementation modes. Any technical solutions formed by equivalent transformation or equivalent replacement should fall within the protection scope of the claims of the present invention.

Claims

1. A method based on health assessment of pump station units, characterized in that: First, according to the needs of health assessment of pump station units, the overall network system architecture combining data acquisition front-end with monitoring network and remote diagnosis is established, including perception layer, network layer and application layer. Then, the corresponding data of the pump station units is collected by the data acquisition device of the perception layer, and the collected data is sent to the server of the application layer through the network layer. After comparing the collected data with the preset alarm threshold value, it is determined whether data analysis and fault diagnosis are to be performed, and finally the diagnosis results are published. The server at the application layer stores, analyzes, and manages the real-time data, historical data, and various characteristic value data transmitted from various data acquisition devices, analyzes the data and diagnoses faults, that is, performs health assessment. First, the assessment factors are selected according to the actual situation, and the weights of the factors are divided. A scoring system is established based on the weight division of each factor, and the scoring is performed according to the evaluation calculation rules. The higher the score, the better the health of the equipment. After each unit ends operation, the system automatically updates its health assessment results based on the operation status; The evaluation calculation rules include: 1) No sensor value exceeds the alarm threshold Scoring formula: F = PE-KP-[(A 转轮 / A0)×10%+(Apj / A0)×10%+(Bpj / B0)×25%+(C 定子 / C0)×10%+(Cpj / C0)×20%+(Dpj / D0)×15%+(Epj / E0)×10%]×20-M / 10-N-10×ST / 1000 PE: The upper limit of the score in this stage; 2) When the sensor value exceeds the alarm value but does not reach the accident shutdown value: Rating calculation formula: F = 80-KP-[(A 转轮 / A0)×10%+(Apj / A1)×10%+(Bpj / B1)×25%+(C 定子 / C0)×10%+(Cpj / C1)×20%+(Dpj / D1)×15%+(Epj / E1)×10%]×20-M / 10-N-10×ST / 1000 In this case, the score is less than 80 points; 3) When the sensor value exceeds the emergency shutdown value: Scoring formula: F = 60-KP-[(A 转轮 / A0)×10%+(Apj / A1)×10%+(Bpj / B1)×25%+(C 定子 / C0)×10%+(Cpj / C1)×20%+(Dpj / D1)×15%+(Epj / E1)×10%]×20-M / 10-N-10×ST / 1000 In this case, the score is less than 60 points; in: A 转轮 : Reading of the vibration sensor in the runner chamber; take the average value of the maximum values ​​of each measuring point during this operation; A 其他 : Vibration sensor readings of other parts; B: swing sensor reading; C 定子 : The motor stator three-phase temperature sensor reading; take the maximum value during this operation; C 其他 : Other temperature sensor readings; D: pressure pulsation sensor reading; E: Noise sensor reading; An: the reading of the vibration sensor numbered n; max[An]: the maximum valid value collected by the vibration sensor numbered n# during the operation that just ended; Apj: the arithmetic mean of max[An] of all vibration sensors; A0: vibration alarm threshold; A1: Vibration accident shutdown threshold value; K: The range of stable operation under different working conditions, that is, to compare whether the average vibration amplitude A of the runner chamber is close under different working conditions; K = max{A 转轮低扬程 / A 转轮中间扬程 , A 转轮低扬程 / A 转轮最大扬程 , A 转轮中间扬程 / A 转轮最大扬程 , A 转轮中间扬程 / A 转轮低扬程 , A 转轮最大扬程 / A 转轮最小扬程 , A 转轮最大扬程 / A 转轮中间扬程 }; Maximum, minimum and intermediate lift refer to the lift during this operation; P: Under design conditions, that is, when the measured head = the designed head, the ratio of the measured flow rate to the designed flow rate, P = 100-100*Q 实测 / Q 设计 , if Q 实测 / Q 设计 If Q is less than 1, then P is positive; 实测 / Q 设计 If it is greater than 1, P is negative; if the design head is not reached during this operation, Q 设计 Then take the maximum flow rate among all the units started this time; M: The number of months since the last major overhaul; N: The number of failures that have occurred since the most recent overhaul; S: The number of unresolved faults; T: operating time since the last overhaul; F: Health assessment score.

2. A method based on health assessment of pump station units according to claim 1, characterized in that: The server collects the values ​​of the corresponding measuring points through the receiving data acquisition device, and expresses the current alarm status of the measuring point by combining the changes between different colors: When there is no data, the background color of the data display area is gray; When the data is within the normal range, the background color will change to green, which means normal; When the value of the vibration data exceeds the alarm threshold, the background color will change to yellow, which means high alarm; When the value of the vibration data exceeds the danger threshold, the background color will change to red, indicating a high alarm.

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