An on-line monitoring device for vibration data of high-temperature tower equipment

Abstract

This invention discloses an online vibration data monitoring device for high-temperature tower equipment, relating to the field of vibration data monitoring technology for high-temperature tower equipment. The device includes: a sensing subsystem for collecting vibration data from the high-temperature tower equipment and converting the vibration data into analog signals; a data acquisition and transmission subsystem for converting the acquired analog signals into digital signals; and a data processing subsystem for processing the acquired digital signals to obtain target data. The target data is used to predict the health status and damage level of the high-temperature tower equipment. This invention can collect vibration data during the operation of high-temperature tower equipment in real time.

Description

Technical Field

[0001] This invention relates to the field of vibration data monitoring technology for high-temperature tower equipment, and in particular to an online vibration data monitoring device for high-temperature tower equipment. Background Technology

[0002] During operation, high-temperature tower equipment is subjected to factors such as high temperature, high pressure, corrosive media and external impact, which cause significant degradation of the material structure and often leads to typical failure modes such as cracks, corrosion, creep fatigue and leakage.

[0003] Taking the coke tower as an example, the coke tower is one of the core pieces of equipment in a delayed coking unit. A typical coke tower system includes the tower body (often in a twin-tower configuration), a concrete frame support structure, a steel frame (often a tall structure), and large pipelines. The material reaction and decoking processes inside the coke tower often cause horizontal swaying of the tower itself, its supporting structure, and pipelines. This horizontal swaying involves severe vibrations that can affect structural safety. Furthermore, severe horizontal swaying of pipelines can lead to loose flanges and media leaks, potentially causing production accidents such as fires and explosions. Once such an accident occurs, the consequences are often unimaginable. Summary of the Invention

[0004] The purpose of this invention is to provide an online vibration data monitoring device for high-temperature tower equipment, capable of collecting vibration data in real time during the operation of high-temperature tower equipment.

[0005] To achieve the above objectives, the present invention provides the following solution:

[0006] An online vibration data monitoring device for high-temperature tower equipment, comprising:

[0007] The sensing subsystem is used to collect vibration data of the high-temperature tower equipment and convert the vibration data into analog signals.

[0008] A data acquisition and transmission subsystem is used to convert the acquired analog signals into digital signals;

[0009] The data processing subsystem is used to process the acquired digital signals to obtain target data; the target data is used to predict the health status and damage level of the high-temperature tower equipment.

[0010] Optionally, the sensing subsystem includes at least a vibration sensor and a vibration support;

[0011] The vibration bracket is used to mount the vibration sensor;

[0012] The design principle of the vibration support is that the length of the vibration support is greater than the thickness of the insulation layer of the high-temperature tower equipment, and the temperature at the connection between the vibration support and the vibration sensor is below 50°C.

[0013] Optionally, the vibration sensor is a piezoelectric vibration sensor.

[0014] Optionally, the process for determining the installation location of the vibration sensor is as follows:

[0015] Based on the analysis results of historical inspection data, historical crack data, historical bulging deformation defect data, and the dimensional information of the high-temperature tower equipment, a simulation analysis is performed on the high-temperature tower equipment to determine the installation position of the vibration sensor.

[0016] Optionally, the vibration support is installed on the tower wall of the high-temperature tower equipment by adhesive bonding or welding.

[0017] Optionally, the data acquisition and transmission subsystem includes at least a data transmission cable and a vibration data acquisition instrument; the vibration sensor is connected to the vibration data acquisition instrument via the data transmission cable.

[0018] Optionally, the data transmission cable is a double-shielded multi-strand multi-core cable, and the data transmission cable and the vibration sensor are connected to the same ground.

[0019] Optionally, the vibration data acquisition instrument includes an analog signal conditioning module, an analog signal to digital signal conversion module, and a digital signal processing module;

[0020] The analog signal conditioning module is used to filter the analog signal sent by the vibration sensor; the analog signal to digital signal module is used to convert the filtered analog signal into a digital signal; the digital signal processing module is used to convert the digital signal into a target signal; the target signal is a signal that can be read by a computer.

[0021] Optionally, the data processing subsystem is used to process the target signal sent by the data acquisition and transmission subsystem and extract the feature values ​​of the target signal; the feature values ​​include peak acceleration, RMS acceleration passband value, RMS acceleration value, RMS velocity value, absolute acceleration value, acceleration skewness index value, acceleration kurtosis index value, RMS acceleration root amplitude value, acceleration margin index value, and peak acceleration index value; the target data are the feature values ​​of the target signal.

[0022] Optionally, the data processing subsystem is further configured to determine the status information of the high-temperature tower equipment based on the characteristic values ​​of the target signal.

[0023] According to specific embodiments provided by the present invention, the present invention discloses the following technical effects:

[0024] This invention targets high-temperature tower equipment and employs vibration monitoring technology to design a dedicated online vibration data monitoring device for high-temperature tower equipment. This device enables real-time acquisition, storage, and remote transmission of vibration data under high-temperature environments, providing a data foundation for health status diagnosis and damage prediction of high-temperature tower equipment. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 The structural block diagram of the online vibration data monitoring device for high-temperature tower equipment provided in the embodiments of the present invention is shown. Detailed Implementation

[0027] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0028] This invention employs vibration monitoring technology to collect vibration data in real time during the operation of high-temperature tower equipment, and monitors the health status of the high-temperature tower equipment online. This is of great significance for ensuring the safe and healthy operation of high-temperature tower equipment, improving the economic benefits of enterprises, and preventing accidents.

[0029] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0030] Example 1

[0031] like Figure 1 As shown in the figure, the online monitoring device for vibration data of high-temperature tower equipment provided in this embodiment consists of a sensing subsystem, a data acquisition and transmission subsystem, and a data processing subsystem.

[0032] The sensing subsystem is used to collect vibration data of the high-temperature tower equipment and convert the vibration data into analog signals.

[0033] The data acquisition and transmission subsystem is used to convert the acquired analog signals into digital signals.

[0034] The data processing subsystem is used to process the acquired digital signals to obtain target data; the target data is used to predict the health status and damage level of the high-temperature tower equipment.

[0035] The sensing subsystem mainly consists of a vibration sensor and a vibration bracket. The vibration bracket is used to mount the vibration sensor.

[0036] (1) Vibration sensor

[0037] In this embodiment, a piezoelectric vibration sensor is used as the vibration sensor.

[0038] Piezoelectric vibration sensors utilize the piezoelectric effect of crystals to perform vibration measurements. When the vibration of the object being measured exerts pressure on the piezoelectric vibration sensor, the crystal element generates a corresponding charge, and the charge count can be converted into vibration data.

[0039] Compared with other types of vibration sensors, piezoelectric vibration sensors have the following advantages:

[0040] 1) It has better all-around characteristics, with a very wide frequency and dynamic range, and good linearity throughout the entire range;

[0041] 2) Relatively sturdy and reliable;

[0042] 3) Piezoelectric accelerometers are self-generating and do not require a power source;

[0043] 4) There are no wearable moving parts, and the output signal, which is proportional to acceleration, can be integrated into velocity and displacement signals.

[0044] The process for determining the installation location of the vibration sensor is as follows:

[0045] Based on the analysis results of historical inspection data, historical crack data, historical bulging deformation defect data, and the dimensional information of the high-temperature tower equipment, a simulation analysis is performed on the high-temperature tower equipment to determine the installation position of the vibration sensor.

[0046] (2) Vibration support

[0047] Because the surface temperature of high-temperature tower equipment is high, taking a coke tower as an example, the surface temperature of its tower wall is about 500°C. Vibration sensors cannot directly contact the surface of the coke tower. Therefore, vibration supports are used to improve the working temperature of vibration sensors.

[0048] The design principle of the vibration support is that the length of the vibration support should be greater than the thickness of the insulation layer of the high-temperature tower equipment, and the temperature at the connection between the vibration support and the vibration sensor should be reduced to below 50°C. At the same time, after the vibration support is designed, it is necessary to perform simulation analysis to ensure that the vibration data will not be seriously distorted due to the vibration support.

[0049] The vibration support is installed on the tower wall of the high-temperature tower equipment by bonding or welding.

[0050] The data acquisition and transmission subsystem is used to acquire vibration signals at key locations of the high-temperature tower equipment structure in real time, and to perform operations such as local storage and remote transmission of the signals.

[0051] The data acquisition and transmission subsystem consists of data transmission cables and a vibration data acquisition instrument.

[0052] (1) Data transmission cable

[0053] Due to its inherent limitations, vibration sensors are restricted by high output impedance and require low-noise cables and charge amplifiers to adapt the signal. Therefore, during data acquisition and transmission, the data transmission cable needs to be set as a double-shielded multi-strand multi-core cable. At the same time, during data acquisition and transmission, the data transmission cable and the vibration sensor need to be connected to the same ground to ensure data stability.

[0054] (2) Vibration data acquisition instrument

[0055] The vibration data acquisition instrument mainly includes an analog signal conditioning module, an analog-to-digital signal conversion module, and a digital signal processing module. The analog signal conditioning module is primarily used to filter the analog signals sent by the vibration sensor to remove some high- and low-frequency interference. The analog-to-digital signal conversion module converts the filtered analog signals into recognizable digital signals. The digital signal processing module converts the digital signals into a target signal; the target signal is a signal that can be read by a computer.

[0056] Data processing subsystem

[0057] The digital processing section is mainly handled by the host computer. The data processing subsystem analyzes the acquired signal (i.e., the target signal sent by the data acquisition and transmission subsystem) and extracts the feature values ​​of the target signal (including but not limited to peak acceleration, RMS acceleration frequency, RMS acceleration, RMS velocity, absolute acceleration, acceleration skewness index, acceleration kurtosis index, RMS acceleration amplitude, acceleration margin index, and peak acceleration index). The target data refers to these feature values ​​of the target signal.

[0058] The data processing subsystem is also used to analyze the feature values ​​of the target signal to determine the status information of the high-temperature tower equipment. The feature value analysis mainly involves big data analysis of vibration signals from previous high-temperature tower equipment, organizing the feature values ​​of vibration signals from different process stages to determine the rate of change and high / low thresholds of the vibration feature values ​​at different process stages; then, it compares the feature values ​​with the vibration signals collected in real time by the field equipment to determine the current status of the high-temperature tower equipment.

[0059] The following uses a coke tower as an example to introduce the technical solution provided by this invention, which specifically includes the following steps:

[0060] 1) Determine the layout and installation of vibration sensors

[0061] Based on the analysis results of historical inspection data, historical crack data, historical bulging deformation defects, and relevant literature review of the coke tower, and combined with the dimensional information of the coke tower, a simulation analysis of the coke tower was conducted to determine the monitoring points; finally, vibration sensors were installed on the three lower sections of the coke tower.

[0062] To adapt to the high-temperature working environment of the coking tower, the vibration sensor is installed with the aid of a vibration bracket, which is installed on the tower wall by bonding or welding.

[0063] Because the temperature of the coking tower wall reaches 500℃, ordinary high-strength adhesives cannot withstand this temperature. Therefore, high-temperature resistant inorganic adhesives are used for bonding. However, high-temperature resistant inorganic adhesives have relatively low strength, so various methods need to be adopted to improve the bonding strength during the design and bonding process of the vibratory support. First, the contact area between the vibratory support and the coking tower wall needs to be as large as possible, and as thin as possible while ensuring structural stability, thereby reducing the weight of the vibratory support. Second, the contact area between the vibratory support and the coking tower wall needs to be processed according to the structure of the coking tower. Since the surface of the coking tower wall is curved, the contact area between the vibratory support and the coking tower wall needs to be processed according to the curvature of the coking tower wall. Therefore, knurling is performed on the contact area between the vibratory support and the coking tower wall to increase the roughness of the bonding surface and improve the bonding strength. When bonding on site, the contact area between the vibratory support and the coking tower wall needs to be ground until the entire metal luster is exposed, while the contact area is made as rough as possible to increase the bonding strength.

[0064] When installing the vibratory support using welding, the base material at the installation location on the coke tower wall must be considered. The vibratory support must be made from the same base material as the tower wall, and welding must be performed according to the corresponding process to ensure welding quality and minimize damage to the coke tower caused by welding. During both bonding and welding, the vibratory support must be installed perpendicular to the coke tower wall to ensure the accuracy of subsequent data.

[0065] 2) Data transmission and acquisition subsystem

[0066] The implementation of the data transmission and acquisition section mainly includes the laying of data transmission cables and the installation of the vibration data acquisition device. When laying and connecting the data transmission cables, attention must be paid to the cable trays, ensuring they are kept away from power cables and equipment that may vibrate, and adhering to electrical connection and grounding specifications. The vibration data acquisition device is installed together with the data processing equipment.

[0067] 3) Data processing subsystem

[0068] The data processing subsystem mainly analyzes the collected signals. It is generally installed in a cabinet. When the cabinet is located outdoors or in an explosion-proof area, the cabinet must meet the relevant requirements of the installation area. The cabinet should not be placed too far away from the sensing equipment to prevent excessive signal noise caused by excessively long signal lines, which would affect data quality.

[0069] This invention primarily collects vibration data of high-temperature tower equipment in real time, providing data support for subsequent health monitoring and analysis of high-temperature tower equipment. It also lays the foundation for future damage identification and bolt loosening issues of high-temperature tower equipment, which is of great significance for ensuring the safe and healthy operation of high-temperature tower equipment, improving enterprise economic benefits, and preventing accidents.

[0070] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0071] This document uses specific examples to illustrate the principles and implementation methods of the present invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of the present invention. Furthermore, those skilled in the art will recognize that, based on the ideas of the present invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. An online monitoring device for vibration data of high-temperature tower equipment, characterized in that, include: The sensing subsystem is used to collect vibration data of the high-temperature tower equipment and convert the vibration data into analog signals. The sensing subsystem includes at least a vibration sensor and a vibration support; The vibration bracket is used to mount the vibration sensor; The design principle of the vibration support is that the length of the vibration support is greater than the thickness of the insulation layer of the high-temperature tower equipment, and the temperature at the connection between the vibration support and the vibration sensor is below 50°C. The contact area between the vibration support and the coking tower wall should be as large as possible, and it should be processed according to the curvature of the coking tower wall. When bonding on site, the contact area between the vibration support and the coking tower wall should be knurled and polished. When installing the vibration support by welding, the same base material as the tower wall should be used. During the bonding and welding process, the vibration support should be installed perpendicular to the coking tower wall. The process for determining the installation location of the vibration sensor is as follows: Based on the analysis results of historical inspection data, historical crack data, historical bulging deformation defect data, and the dimensional information of the high-temperature tower equipment, a simulation analysis is performed on the high-temperature tower equipment to determine the installation position of the vibration sensor. A data acquisition and transmission subsystem is used to convert the acquired analog signal into a digital signal. The data acquisition and transmission subsystem includes at least a data transmission cable and a vibration data acquisition instrument. The vibration sensor is connected to the vibration data acquisition instrument through the data transmission cable. The vibration data acquisition instrument includes an analog signal conditioning module, an analog signal to digital signal conversion module, and a digital signal processing module. The analog signal conditioning module is used to filter the analog signal sent by the vibration sensor; the analog signal to digital signal conversion module is used to convert the filtered analog signal into a digital signal; the digital signal processing module is used to convert the digital signal into a target signal; the target signal is a signal that can be read by a computer. The data processing subsystem is used to process the acquired digital signals to obtain the target data, specifically including: The data processing subsystem is used to process the target signal sent by the data acquisition and transmission subsystem and extract the feature values ​​of the target signal. The characteristic values ​​include peak acceleration, RMS acceleration passband, RMS acceleration, RMS velocity, absolute acceleration, acceleration skewness index, acceleration kurtosis index, RMS acceleration root amplitude, acceleration margin index, and peak acceleration index; the target data are the characteristic values ​​of the target signal; the target data are used to predict the health status and damage level of high-temperature tower equipment.

2. The online monitoring device for vibration data of high-temperature tower equipment according to claim 1, characterized in that, The vibration sensor is a piezoelectric vibration sensor.

3. The online monitoring device for vibration data of high-temperature tower equipment according to claim 1, characterized in that, The vibration support is installed on the tower wall of the high-temperature tower equipment by bonding or welding.

4. The online monitoring device for vibration data of high-temperature tower equipment according to claim 1, characterized in that, The data transmission cable is a double-shielded multi-strand multi-core cable, and the data transmission cable and the vibration sensor are connected to the same ground.

5. The online monitoring device for vibration data of high-temperature tower equipment according to claim 1, characterized in that, The data processing subsystem is also used to determine the status information of the high-temperature tower equipment based on the characteristic values ​​of the target signal.

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