System and method for improving reliability of rotating equipment based on vibration diagnosis
By adopting a vibration diagnosis-based system in thermal power plants, the problem of frequent rotating equipment failures is solved, the equipment reliability and maintenance efficiency are improved, maintenance costs are reduced, and technical improvement and maintenance procedures are promoted.
Patent Information
- Application Number
- CN202411194110.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-08-28
- Publication Date
- 2025-02-07
AI Technical Summary
Frequent failure of rotating equipment in thermal power plants leads to low reliability of equipment, affecting production safety and economic losses.
The vibration diagnosis-based system is adopted, including the equipment ledger information module, the vibration diagnosis database module and the fault case library module. The equipment operation status is monitored through vibration signal analysis, fault mode is identified, fault location is located, and maintenance strategies are optimized through the fault case library.
It effectively improves the reliability and maintenance efficiency of rotating equipment, reduces maintenance costs, and promotes the standardization of technological improvement and maintenance processes.
Smart Images
Figure CN119397322A_ABST
Abstract
Description
Technical Field
[0001] The invention belongs to the technical field of thermal power generation rotating equipment, and in particular relates to a system and method for improving the reliability of rotating equipment based on vibration diagnosis. Background Art
[0002] With the rapid development of new energy, the power market system has undergone a very big change. The position of thermal power units in energy supply has changed from the main force to a supporting role. At present, frequent start and stop and deep peak regulation of thermal power units have become the norm, which puts extremely high demands on the reliability of thermal power unit equipment. Rotating equipment is widely present in thermal power plants, such as steam turbine generators, steam pumps, condensate pumps, coal mills, powder exhaust machines, primary fans, suction fans, and blowers. They are all important and key equipment in thermal power plants. Once a failure occurs, it will cause economic losses at the least, affect production safety at the worst, and even cause adverse social impacts. Energy supply requires improving the reliability of rotating equipment.
[0003] Rotating equipment has the characteristics of high occurrence rate, difficulty in finding fault causes, and high maintenance costs, which have a great impact on the safe and stable operation of the unit. A lot of information is hidden in its vibration signal. The application of vibration diagnosis technology can find this information, which can be used to judge the equipment operation status and fault degradation trend, determine the fault type and location, and point out the direction for the rapid solution of the problem. Summary of the invention
[0004] (I) Purpose of the invention
[0005] In order to overcome the above shortcomings, the purpose of the present invention is to provide a system and method for improving the reliability of rotating equipment based on vibration diagnosis, so as to solve the above technical problems.
[0006] (II) Technical solution
[0007] To achieve the above objectives, the technical solutions provided by this application are as follows:
[0008] A system for improving the reliability of rotating equipment based on vibration diagnosis, comprising a rotating equipment ledger information module, a vibration diagnosis database module and a fault case library module.
[0009] The equipment ledger information database module is used to store basic information of the equipment, classify and code the equipment, and also record the use and maintenance of the equipment in detail, providing basic information for the establishment of a vibration diagnosis database and providing the equipment's maintenance status;
[0010] The vibration diagnosis database module collects and stores the vibration spectrum and phase information of the equipment during operation. By analyzing the vibration data, it monitors the equipment operation status and promptly discovers abnormal conditions. It combines the vibration data with the equipment ledger information to diagnose the equipment status and identify possible failure modes. It conducts in-depth analysis of the collected vibration data to determine the fault type, fault location and severity level.
[0011] The fault case module records and stores the diagnosis and analysis of equipment faults, the inspection and repair conditions, and the post-repair effects to form a complete fault case. By collecting various fault cases, it accumulates maintenance experience and technical knowledge, provides a reference for solving similar problems, and allows users to query related cases based on fault type, equipment model and other conditions to quickly find solutions. By analyzing the fault cases in the case library, it identifies common failure modes and causes and optimizes maintenance strategies.
[0012] Preferably, the basic information of the equipment includes the equipment name, model, specifications, purchase date, service life and other information that needs to be recorded.
[0013] Preferably, the following steps are included:
[0014] Step 1: Establish a rotating equipment ledger information database;
[0015] Step 2: Build a vibration diagnosis database for rotating equipment;
[0016] Step 3: Standardize the collection and diagnosis of vibration information of rotating equipment;
[0017] Step 4: Carry out regular diagnosis and abnormality tracking of rotating equipment;
[0018] Step 5: Form a positive interaction between vibration diagnosis and maintenance;
[0019] Step 6: Conduct statistical analysis on the most frequently occurring fault types of the equipment;
[0020] Step 7: Improve the maintenance process from the perspective of vibration diagnosis.
[0021] Preferably, in step 2, a vibration diagnosis database is established according to the mode of "create factory → create equipment → create measuring point → copy equipment", the selection of vibration measuring points is set according to the national standard GBT 6075, and the measurement range, number of spectral lines, spectrum to be measured, and selected sensor type of each measuring point are set one by one.
[0022] Preferably, the graphs include spectrum graph, time domain waveform graph, demodulation spectrum graph, demodulation waveform graph and axis trajectory graph, Bode graph, polar coordinate graph, vibration trend graph, waterfall graph and other graphs.
[0023] Preferably, the step 3 specifically includes:
[0024] Arrive at the location of the equipment, use an offline vibration analyzer, open the vibration diagnosis database, install vibration sensors according to the measuring point positions in the vibration database, collect vibration information at each measuring point in turn, and preliminarily analyze the vibration fault type based on vibration diagnosis theory. The fault types include mass imbalance, misalignment, mechanical looseness, rotor bending, rotor eccentricity, rotor cracks, rolling bearing failure, sliding bearing failure, rotor friction, beat vibration, resonance, vibration caused by fluid, and electrical failure. Combined with the equipment's operating mode, pressure, flow, and opening, determine the fault type, fault location, and severity level. Analyze the key information and influencing factors involved in the process. Each vibration information collected is saved in the root directory of the equipment, which is convenient for retrieving each vibration information collected. Historical comparison and similar comparison can also be performed to analyze the degradation trend of the equipment and compare with verified equipment failures to improve the accuracy of analysis and diagnosis.
[0025] Preferably, the step 4 specifically includes:
[0026] Perform regular diagnosis on rotating equipment, notify relevant professionals and departments of any abnormal equipment conditions found during the diagnosis, and make suggestions for handling, so as to achieve early detection and early handling of problems. For rotating equipment that cannot be temporarily shut down to eliminate faults, establish file tracking, and reasonably shorten the diagnosis cycle according to the severity of the fault or even conduct continuous tracking and monitoring. When abnormal conditions show a tendency to deteriorate, promptly notify maintenance personnel, carry out equipment maintenance as soon as possible, reduce unplanned shutdowns of rotating equipment, and use vibration diagnosis technology to analyze the type, location, and severity of rotating equipment faults, thereby narrowing the inspection scope, reducing maintenance workload, and improving work efficiency.
[0027] Preferably, the step 5 specifically includes:
[0028] After the faulty equipment is repaired, the maintenance personnel will promptly feedback the equipment maintenance situation to the vibration diagnosis personnel, verify the accuracy of the diagnostic analysis, summarize the experience and lessons, and form a virtuous cycle of vibration diagnosis according to the procedure of "diagnostic analysis-equipment maintenance-verify diagnostic accuracy against maintenance situation-summary and improvement", so as to continuously improve the level of vibration diagnosis.
[0029] Preferably, the step 6 specifically includes:
[0030] For failures occurring in the same type of equipment, we regularly conduct statistical analysis and summarize the types of failures that occur. For common problems that occur frequently, we work with professional technicians to determine the root causes based on the equipment structure and operating principles, and fundamentally improve equipment reliability through technical transformation or preventive maintenance.
[0031] Preferably, the step 7 specifically includes:
[0032] When diagnosing rotating equipment faults, vibration diagnostic personnel should, for example, promptly inform maintenance personnel on-site of the correct maintenance process points when encountering abnormal vibration problems caused by improper maintenance processes. Second, they should notify professional technicians and maintenance teams of the problems with the maintenance process, and suggest that they pay special attention to key points during quality inspection and acceptance. Third, they should make recommendations to professional and maintenance departments, and include non-standard maintenance behaviors in their assessments.
[0033] Beneficial effects:
[0034] The system of the present invention realizes comprehensive monitoring and management of rotating equipment by establishing equipment account information base, vibration diagnosis database and fault case library module. Through hierarchical data collection, standardized vibration information collection and diagnosis, regular equipment diagnosis and abnormality tracking, benign interaction of fault maintenance and diagnosis, as well as statistical analysis of fault types and guidance of maintenance process, the reliability and maintenance efficiency of equipment are effectively improved, maintenance costs are reduced, and technical improvement and standardization of maintenance processes are promoted. BRIEF DESCRIPTION OF THE DRAWINGS
[0035] Figure 1 It is a schematic diagram of the system structure of the present invention. DETAILED DESCRIPTION
[0036] In order to make the purpose, technical scheme and advantages of the present invention clearer, the present invention is further described in detail below in conjunction with specific embodiments. It should be understood that these descriptions are exemplary only and are not intended to limit the scope of the present invention. In addition, in the following description, the description of known structures and technologies is omitted to avoid unnecessary confusion of the concept of the present invention.
[0037] The present invention provides a system for improving the reliability of rotating equipment based on vibration diagnosis, comprising a rotating equipment ledger information module 1, a vibration diagnosis database module 2 and a fault case library module 3.
[0038] The equipment account information base module 1 is used to store basic information of the equipment, including equipment name, model, specification, purchase date, service life and other information that needs to be recorded. The equipment is classified and coded, and the use and maintenance of the equipment are recorded in detail, providing basic information for the construction of the vibration diagnosis database 2, and providing the equipment's previous maintenance information;
[0039] The vibration diagnosis database module 2 collects and stores the vibration spectrum information of the equipment during operation, monitors the equipment operation status by analyzing the vibration data, and promptly discovers abnormal conditions. It combines the vibration data with the equipment ledger information to diagnose the equipment status, identify possible failure modes, and conduct in-depth analysis of the collected vibration data to determine the failure type, failure location, and severity level.
[0040] Fault case module 3 records and stores the diagnosis and analysis of equipment faults, maintenance conditions and post-repair results to form a complete fault case. By collecting various fault cases, it accumulates maintenance experience and technical knowledge, provides a reference for solving similar problems, and allows users to query related cases based on fault type, equipment model and other conditions to quickly find solutions. By analyzing the fault cases in the case library, it identifies common failure modes and causes and optimizes maintenance strategies.
[0041] The equipment ledger information base module 1 provides basic information for the construction of the vibration diagnosis database 2, and provides the equipment's previous maintenance information; the vibration spectrum information is collected using the vibration diagnosis database 2, and the equipment status is diagnosed and analyzed in combination with the equipment's previous maintenance information in the equipment ledger information module, and the fault type, fault location and severity level of the equipment fault are determined; after the equipment fault is resolved, the equipment fault diagnosis and analysis, maintenance status and post-repair effect are formed into an equipment fault case, which is added to the fault case library, and the maintenance status is input into the equipment ledger information module. The equipment ledger information module and the fault case library module supplement information based on the equipment status operation and maintenance status.
[0042] A method for improving the reliability of rotating equipment based on vibration diagnosis comprises the following steps:
[0043] Step 1: Establish a rotating equipment ledger information database;
[0044] A complete rotating equipment is defined as including driving equipment, couplings, driven equipment and foundation parts. The rotating equipment ledger information database contains the following information:
[0045] (1) Basic information of equipment ① Driving equipment, common motors, steam turbines, etc. The motors include information such as name, manufacturer, model, power, motor input voltage, input current, speed, insulation grade, structure, installation form, weight, bearing model, etc.; steam turbine model, type, rated parameters, steam seal system, operation mode, flow level, critical speed, bearing model, etc. ② Couplings, including information such as type, model, input speed, output speed, etc. ③ Driven equipment, including information such as name, model, flow, pressure, head, gear ratio, number of gear teeth, number of blades, bearing model, working medium, etc.
[0046] (2) Equipment maintenance and overhaul history.
[0047] (3) Record in detail the abnormal conditions that occur during equipment operation, the maintenance process, the materials and spare parts used for maintenance, the status after maintenance, etc.
[0048] Step 2: Build a vibration diagnosis database for rotating equipment
[0049] The vibration diagnosis database is established in the mode of "create factory → create equipment → create measurement point → copy equipment", and the selection of vibration measurement points is set according to the national standard GB / T 6075. The measurement range, number of spectrum lines, spectrum to be measured, and selected sensor type of each measurement point are set one by one. The spectrum includes spectrum diagram, time domain waveform diagram, demodulation spectrum diagram, demodulation waveform diagram, axis trajectory diagram, Bode diagram, polar coordinate diagram, vibration trend diagram, waterfall diagram and other diagrams.
[0050] The "create factory → create equipment → create measurement points → copy equipment" model is a hierarchical and modular vibration diagnosis database construction method. It first defines one or more factory entities in the database, then creates specific equipment entities under each factory, then defines multiple measurement points for each equipment to collect vibration data, and finally copies equipment functions to quickly create multiple equipment with similar characteristics, thereby achieving data consistency and easy management. This method provides a clear organizational structure that facilitates data expansion, maintenance, and analysis, while supporting rapid deployment and unified equipment management.
[0051] Step 3: Standardize the collection and diagnosis of rotating equipment vibration information
[0052] Arrive at the location of the equipment, use an offline vibration analyzer, open the vibration diagnosis database, install vibration sensors according to the measurement point locations in the vibration database, collect vibration information at each measurement point in turn, and analyze the type of vibration fault according to vibration diagnosis theory. And combine the equipment operation mode, pressure, flow, opening and other operating conditions to determine the fault type, fault location and severity level. Improve the accuracy of diagnosis. The key information and influencing factors involved in the analysis process are solidified into specifications to improve analysis efficiency and accuracy. Each vibration information collected is saved in the root directory of the device. It is easy to retrieve the vibration information collected each time, and historical comparisons and similar comparisons can be performed to analyze the degradation trend of the equipment and compare verified equipment failures to improve the accuracy of analysis and diagnosis.
[0053] Step 4: Conduct regular diagnosis and abnormality tracking of rotating equipment
[0054] Perform regular diagnosis on rotating equipment, notify relevant professionals and departments of any abnormalities found during the diagnosis, and make suggestions for handling, so that problems can be discovered and handled early. For rotating equipment that cannot be temporarily shut down to eliminate faults, establish file tracking, and reasonably shorten the diagnosis cycle or even conduct continuous tracking monitoring according to the severity of the fault. When abnormal conditions show a tendency to deteriorate, promptly notify maintenance personnel, carry out equipment maintenance as soon as possible, and reduce unplanned shutdowns of rotating equipment. Apply vibration diagnosis technology to analyze the type, location, and severity of rotating equipment faults, thereby narrowing the scope of inspection, reducing maintenance workload, and improving work efficiency.
[0055] Step 5: Create a positive interaction between vibration diagnosis and maintenance
[0056] After the faulty equipment is repaired, the maintenance personnel will promptly feedback the equipment maintenance situation to the vibration diagnosis personnel, verify the accuracy of the diagnostic analysis, summarize the experience and lessons, and form a virtuous cycle of vibration diagnosis according to the procedure of "diagnostic analysis-equipment maintenance-verify diagnostic accuracy against maintenance situation-summary and improvement", so as to continuously improve the level of vibration diagnosis.
[0057] Step 6: Perform statistical analysis on the most frequently occurring fault types of the equipment
[0058] For failures occurring in the same type of equipment, we regularly conduct statistical analysis and summarize the types of failures that occur. For common problems that occur frequently, we work with professional technicians to determine the root causes based on the equipment structure and operating principles, and fundamentally improve equipment reliability through technical transformation or preventive maintenance.
[0059] Step 7: Improve the maintenance process from the perspective of vibration diagnosis
[0060] When diagnosing rotating equipment faults, vibration diagnostic personnel will promptly inform maintenance personnel of the correct maintenance process points on site for abnormal vibration problems caused by improper maintenance processes; second, notify professional technicians and maintenance teams of the problems in the maintenance process and suggest that they pay special attention to key points during quality inspection and acceptance; third, make suggestions to professional and maintenance departments to include non-standard maintenance behaviors in the assessment. Through these three measures, the maintenance process can be standardized, the maintenance quality of rotating equipment can be improved, and the reliability of equipment can be ensured.
[0061] The system of the present invention realizes comprehensive monitoring and management of rotating equipment by establishing equipment account information base, vibration diagnosis database and fault case library module. Through hierarchical data collection, standardized vibration information collection and diagnosis, regular equipment diagnosis and abnormality tracking, benign interaction of fault maintenance and diagnosis, as well as statistical analysis of fault types and guidance of maintenance process, the reliability and maintenance efficiency of equipment are effectively improved, maintenance costs are reduced, and technical improvement and standardization of maintenance processes are promoted.
[0062] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the sentence "comprise a ..." do not exclude the existence of other identical elements in the process, method, article or device including the elements.
[0063] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features may be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.
Claims
1. A system for improving the reliability of rotating equipment based on vibration diagnosis, characterized in that: It includes the rotating equipment ledger information module, the vibration diagnosis database module and the fault case library module. The equipment ledger information library module is used to store the basic information of the equipment, classify and encode the equipment, and also record the use and maintenance of the equipment in detail, providing basic information for the establishment of the vibration diagnosis database and providing the equipment's previous maintenance information; The vibration diagnosis database module collects and stores the vibration spectrum and phase information of the equipment during operation. By analyzing the vibration data, it monitors the equipment operation status and promptly discovers abnormal conditions. It combines the vibration data with the equipment ledger information to diagnose the equipment status and identify possible failure modes. It conducts in-depth analysis of the collected vibration data to determine the fault type, fault location and severity level. The fault case module records and stores the diagnosis and analysis of equipment faults, the inspection and repair conditions, and the post-repair effects to form a complete fault case. By collecting various fault cases, it accumulates maintenance experience and technical knowledge, provides a reference for solving similar problems, and allows users to query related cases based on fault type, equipment model and other conditions to quickly find solutions. By analyzing the fault cases in the case library, it identifies common failure modes and causes and optimizes maintenance strategies.
2. A system for improving the reliability of rotating equipment based on vibration diagnosis according to claim 1, characterized in that: The basic information of the equipment includes the equipment name, model, specifications, purchase date, service life and other information that needs to be recorded.
3. A method for improving the reliability of rotating equipment based on vibration diagnosis, characterized in that: The following steps are involved: Step 1: Establish a rotating equipment ledger information database; Step 2: Build a vibration diagnosis database for rotating equipment; Step 3: Standardize the collection and diagnosis of vibration information of rotating equipment; Step 4: Carry out regular diagnosis and abnormality tracking of rotating equipment; Step 5: Form a positive interaction between vibration diagnosis and maintenance; Step 6: Conduct statistical analysis on the most frequently occurring fault types of the equipment; Step 7: Improve the maintenance process from the perspective of vibration diagnosis.
4. A method for improving the reliability of rotating equipment based on vibration diagnosis according to claim 3, characterized in that: In step 2, a vibration diagnosis database is established according to the mode of "create factory → create equipment → create measuring point → copy equipment". The selection of vibration measuring points is set according to the national standard GB / T 6075, and the measurement range, number of spectral lines, spectrum to be measured, and selected sensor type of each measuring point are set one by one.
5. A method for improving the reliability of rotating equipment based on vibration diagnosis according to claim 4, characterized in that: The graphs include spectrum graph, time domain waveform graph, demodulation spectrum graph, demodulation waveform graph and axis trajectory graph, Bode graph, polar coordinate graph, vibration trend graph and waterfall graph.
6. The method for improving the reliability of rotating equipment based on vibration diagnosis according to claim 3, characterized in that: The step 3 specifically includes: Arrive at the location of the equipment, use an offline vibration analyzer, open the vibration diagnosis database, install vibration sensors according to the measuring point positions in the vibration database, collect vibration information at each measuring point in turn, and analyze the vibration fault type according to the vibration diagnosis theory. The fault types include mass imbalance, misalignment, mechanical looseness, rotor bending, rotor eccentricity, rotor cracks, rolling bearing failure, sliding bearing failure, rotor friction, beat vibration, resonance, vibration caused by fluid, and electrical failure. Combined with the equipment's operating mode, pressure, flow, and opening, determine the fault type, fault location, and severity level. Analyze the key information and influencing factors involved in the process. Each vibration information collected is saved in the root directory of the equipment, which is convenient for retrieving each vibration information collected. Historical comparison and similar comparison can also be performed to analyze the degradation trend of the equipment and compare with verified equipment failures to improve the accuracy of analysis and diagnosis.
7. The method for improving the reliability of rotating equipment based on vibration diagnosis according to claim 3, characterized in that: The step 4 specifically includes: Perform regular diagnosis on rotating equipment, notify relevant professionals and departments of any abnormal equipment conditions found during the diagnosis, and make suggestions for handling, so as to achieve early detection and early handling of problems. For rotating equipment that cannot be temporarily shut down to eliminate faults, establish file tracking, and reasonably shorten the diagnosis cycle according to the severity of the fault or even conduct continuous tracking and monitoring. When abnormal conditions show a tendency to deteriorate, promptly notify maintenance personnel, carry out equipment maintenance as soon as possible, reduce unplanned shutdowns of rotating equipment, and use vibration diagnosis technology to analyze the type, location, and severity of rotating equipment faults, thereby narrowing the inspection scope, reducing maintenance workload, and improving work efficiency.
8. The method for improving the reliability of rotating equipment based on vibration diagnosis according to claim 3, characterized in that: The step 5 specifically includes: After the faulty equipment is repaired, the maintenance personnel will promptly feedback the equipment maintenance situation to the vibration diagnosis personnel, verify the accuracy of the diagnostic analysis, summarize the experience and lessons, and form a virtuous cycle of vibration diagnosis according to the procedure of "diagnostic analysis-equipment maintenance-verify diagnostic accuracy against maintenance situation-summarize and improve", so as to continuously improve the level of vibration diagnosis.
9. The method for improving the reliability of rotating equipment based on vibration diagnosis according to claim 3, characterized in that: The step 6 specifically includes: For failures occurring in the same type of equipment, we regularly conduct statistical analysis and summarize the types of failures that occur. For common problems that occur frequently, we work with professional technicians to determine the root causes based on the equipment structure and operating principles, and fundamentally improve equipment reliability through technical transformation or preventive maintenance.
10. The method for improving the reliability of rotating equipment based on vibration diagnosis according to claim 3, characterized in that: The step 7 specifically includes: When diagnosing rotating equipment faults, vibration diagnostic personnel should, for example, promptly inform maintenance personnel on-site of the correct maintenance process points when encountering abnormal vibration problems caused by improper maintenance processes. Second, they should notify professional technicians and maintenance teams of the problems with the maintenance process, and suggest that they pay special attention to key points during quality inspection and acceptance. Third, they should make recommendations to professional and maintenance departments, and include non-standard maintenance behaviors in their assessments.