Storage reliability analysis method for coal preparation plant

Abstract

The invention relates to a coal preparation plant storage reliability analysis method. The method comprises the following steps: collecting coal preparation plant storage system data and carrying out preprocessing operation; establishing an equipment operation reliability index, a storage and outward transportation reliability index and a slot available state reliability index; and carrying out quantitative evaluation on an equipment operation reliability index, a storage and outward transportation reliability index and a slot cabin available state reliability index by utilizing statistics and reliability engineering theories. According to the method, data of each link of the coal preparation plant warehousing system is comprehensively considered, the reliability of the system is comprehensively evaluated from multiple dimensions, deviation possibly caused by a single data source is avoided, and it is ensured that the evaluation result is more comprehensive and accurate; and meanwhile, a statistical method and a reliability engineering theory are combined, the overall storage reliability is evaluated by quantitatively analyzing each index, the scientificity of an evaluation result is ensured, a user can conveniently and intuitively know the reliability condition of the storage system through a visual output result, and a scientific basis is provided for storage management of a coal enterprise.

Description

Technical Field

[0001] The invention relates to the technical field of storage management of coal preparation plants, and in particular to a storage reliability analysis method for coal preparation plants. Background Art

[0002] In the coal industry, coal preparation plants are an important part of coal production. The storage system of coal preparation plants is directly related to the storage, allocation and transportation of coal, and its reliability directly affects the production efficiency and economic benefits of coal enterprises. However, the existing storage management methods of coal preparation plants often lack effective evaluation and analysis of the reliability of storage systems, which may lead to various problems in the storage system, such as equipment failure, material shortages, etc., which have an adverse impact on the normal production of coal enterprises.

[0003] At present, the research on the reliability of coal preparation plant storage mainly focuses on equipment maintenance and management, storage capacity planning, and optimization of coal storage environment. At present, the most commonly used methods for establishing reliability analysis models for equipment are fault tree analysis (FAT) and failure mode effect analysis (FMAE). FAT is a model that shows the logical relationship between system structure and faults. It constructs a fault tree, and continuously subdivides the fault type in a tree structure from the top-level event until the leaf node (basic event). FMAE is a systematic analysis method used to identify and evaluate the impact of potential failure modes on the system. It identifies all possible faults of each device, evaluates the impact of each failure mode on the system, finds single point failures, and determines its harmfulness based on the severity, probability of occurrence, and detection capability of the fault. Although these methods can help identify and analyze single fault points in the system, they often ignore the interaction and comprehensive impact between the various parts within the system, and fail to fully reflect the overall reliability of the storage system.

[0004] In addition, existing evaluation methods generally focus on static analysis, that is, evaluating the reliability of the system under fixed conditions, while ignoring the system performance under dynamic operating conditions. In actual operation, the storage system will be affected by a variety of dynamic factors such as changes in coal properties and the availability of coal bunkers, which may cause significant changes in system reliability. Therefore, existing methods are often unable to accurately foresee and solve the actual problems of the storage system in practical applications, thus affecting the overall reliability and production efficiency of the storage system. Summary of the invention

[0005] The technical problem to be solved by the present invention is to overcome the deficiencies in the prior art and provide a method for analyzing the reliability of coal preparation plant storage. By comprehensively analyzing each link of the coal preparation plant storage system, the reliability of the storage system is evaluated, providing a scientific basis for the storage management of coal enterprises.

[0006] The present invention is achieved through the following technical solutions:

[0007] A method for analyzing storage reliability of a coal preparation plant comprises the following steps:

[0008] S1. Collecting coal preparation plant storage system data, the storage system data includes equipment operation data, storage and transportation data, and personnel operation data;

[0009] S2. Preprocessing the data of the storage system;

[0010] S3. Establish equipment operation reliability index, storage and transportation reliability index and tank availability reliability index respectively;

[0011] S4. Use statistics and reliability engineering theory to quantitatively evaluate the equipment operation reliability index, storage and transportation reliability index, and tank availability reliability index.

[0012] According to the above technical solution, preferably, in step S1, the equipment operation data includes the working status, operating time, fault records, and maintenance records of the storage equipment, wherein the storage equipment includes the storage part belt and the coal feeder; the storage and external transportation data includes the coal bunker throughput, planned external transportation volume, actual external transportation volume, the total storage volume of the coal bunker, and the available status of the coal bunker; the personnel operation data includes the operator's working hours and operation records.

[0013] According to the above technical solution, preferably, in step S2, data preprocessing operations are performed on the warehousing and outbound transportation data, and the collected warehousing system data are cleaned and sorted to remove abnormal values ​​and noise.

[0014] According to the above technical solution, preferably, in step S3, the calculation of the equipment operation reliability index includes the following steps: dividing the storage equipment into a front-of-warehouse belt, a coal feeder, and a rear-of-warehouse belt, collecting their failure times and maintenance times respectively, and calculating their failure rates and maintenance rates; establishing a reliability block diagram based on the physical structure of the storage part belts and coal feeders of the coal preparation plant, and calculating the equipment operation reliability index of the entire storage system.

[0015] According to the above technical solution, preferably, in step S3, the storage and outbound transportation reliability index is calculated based on the coal bunker throughput, the planned outbound transportation volume, and the actual outbound transportation volume.

[0016] According to the above technical solution, preferably, in step S3, the calculation of the reliability index of the available state of the tank warehouse includes the following steps: dividing the entire tank warehouse into different storage areas according to the location, and recording the available state, current storage capacity, and available storage capacity of each storage area respectively; calculating the regional utilization rate of each storage area respectively, the regional utilization rate is the ratio of the available storage capacity of the current area to the total storage capacity, and the available state index of the tank warehouse is obtained by weighted averaging the available states of each storage area.

[0017] According to the above technical solution, preferably, in step S4, the equipment operation reliability index, storage and external transportation reliability index, and tank availability reliability index are normalized and standardized, and weighted average is performed to obtain a reliability quantification score for the entire warehousing active transportation system, and the reliability level of the warehousing system is divided.

[0018] The beneficial effects of the present invention are:

[0019] The present invention comprehensively considers the data of each link of the storage system of the coal preparation plant, comprehensively evaluates the reliability of the system from multiple dimensions, avoids the deviation that may be caused by a single data source, and ensures that the evaluation results are more comprehensive and accurate; at the same time, combined with statistical methods and reliability engineering theory, the overall storage reliability is evaluated by quantitative analysis of various indicators, ensuring the scientificity and persuasiveness of the evaluation results; in addition, the visual output results facilitate users to intuitively understand the reliability status of the storage system, providing a scientific basis for the storage management of coal enterprises. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a structural diagram of a coal storage and transportation system in an embodiment of the present invention.

[0021] Figure 2 It is a structural diagram of a series-parallel system in an embodiment of the present invention.

[0022] Figure 3 It is a structural diagram of a parallel-series system in an embodiment of the present invention.

[0023] Figure 4 It is the storage reliability evaluation analysis result in the embodiment of the present invention (the score is too low, and a detailed analysis is given).

[0024] Figure 5 It is the storage reliability evaluation analysis result in the embodiment of the present invention (the score is normal). DETAILED DESCRIPTION

[0025] In order to enable those skilled in the art to better understand the technical solution of the present invention, the present invention is further described in detail below in conjunction with the accompanying drawings and the best embodiment. Based on the embodiments in the invention, all other embodiments obtained by ordinary technicians in the field without making creative work are within the scope of protection of the invention.

[0026] As shown in the figure, the present invention comprises the following steps:

[0027] S1. Collect coal preparation plant storage system data in real time through sensors and monitoring equipment. The storage system data includes equipment operation data, storage and transportation data, and personnel operation data.

[0028] Among them, the equipment operation data includes the working status, operating time, fault records, maintenance records, etc. of the storage equipment (storage part belts and coal feeders), which can be collected and archived through sensors installed on the corresponding equipment; the storage and transportation data includes coal bunker throughput, current tank storage volume, planned external transportation volume, actual external transportation volume, total coal bunker storage volume, coal bunker available status, etc. The tank storage volume related data can be obtained through the installed 3D radar level meter, and the remaining data can be obtained by querying reports; the personnel operation data includes the operator's working hours, operation records and other data.

[0029] S2. Preprocess the warehouse system data to ensure the accuracy and reliability of the data.

[0030] Specifically, the collected data is cleaned and sorted using data processing software to remove outliers and noise to ensure the accuracy and reliability of the data. This part of the data processing mainly checks the incoming belt instantaneous volume, coal bunker storage volume and other data to remove outliers.

[0031] S3. Establish equipment operation reliability index, storage and transportation reliability index and tank availability reliability index respectively.

[0032] Specifically, according to the characteristics of the storage system of the coal preparation plant, the storage reliability index is divided into three dimensions: equipment operation reliability index, storage and transportation index, and tank availability index. From the aspects of equipment reliability, dynamic transportation capacity, and storage capacity of the storage active transportation system, the equipment operation reliability index, storage and transportation reliability index, and tank availability reliability index are established respectively.

[0033] (1) Equipment operation reliability indicators:

[0034] The entire coal storage and transportation system equipment is divided into the front belt, coal feeder, and rear belt. The number of failures and maintenance times within a certain period of time are collected, and the failure rate and maintenance rate are calculated. The reliability block diagram of the belt and coal feeder in the storage part of the coal preparation plant is established according to the physical structure. Figure 1This is the structural diagram of the coal storage and transportation system of the coal mine. It can be seen from the figure that the coal bunker and the transportation link before the bunker and the transportation link after the bunker are connected in series in structure. The entire storage active transportation system can be regarded as a series-parallel hybrid repairable system. The series-parallel hybrid repairable system includes a series-parallel repairable system and a parallel-series repairable system. The system structure is as follows Figure 2 , Figure 3 shown.

[0035] According to the series-parallel hybrid system structure Figure 2 and Figure 3 , the whole system consists of n subsystems, each subsystem i has m i components, i = 1, 2, ..., n. In subsystem i, the failure rate and repair rate of each component j are λ ij and μ ij ,j=1,2,…,m i , let A ij is the steady-state availability of component j in subsystem i, then:

[0036]

[0037] Let A i is the steady-state availability of subsystem i. For parallel subsystem i, in most cases, the components are composed of the same type of components, that is, the components have the same failure rate and maintenance rate, which are denoted by λ i =λ ij and μ i =μ ij , that is:

[0038]

[0039] According to the subsystem structure, the availability of parallel subsystem i can be obtained as:

[0040]

[0041] The availability of the series subsystem i is:

[0042]

[0043] According to the system structure, the availability of the entire series-parallel system can be obtained as:

[0044]

[0045] The availability of the entire parallel-series system is:

[0046]

[0047] According to the availability calculation formula of the above series-parallel hybrid system, the equipment operation reliability index of the corresponding warehouse active transportation system can be obtained.

[0048] (2) Storage and transportation reliability indicators:

[0049] The storage and transportation reliability index is calculated based on the coal bunker throughput, plan fulfillment rate and other data. The normal value of the coal bunker throughput is given and combined with the plan fulfillment rate to evaluate the dynamic storage capacity of the coal bunker in the past period of time.

[0050] (3) Reliability index of tank availability:

[0051] The entire silo is divided into different storage areas according to location, and the available status (whether the current area can be used to store coal), current storage capacity, available storage capacity and other data are recorded for each storage area. The regional utilization rate of each area is calculated separately, which is defined as the ratio of the available storage capacity of the current area to the total storage capacity. The available status index of the silo is obtained by weighted average combined with the available status of each area.

[0052] S4. Use statistics and reliability engineering theory to quantitatively evaluate the equipment operation reliability index, storage and transportation reliability index, and tank availability reliability index.

[0053] Specifically, statistics and reliability engineering theory are used to quantitatively evaluate the constructed reliability indicators. The reliability quantitative score of the entire warehouse active transportation system is obtained by weighted averaging the above-constructed reliability indicators, and the reliability level of the warehouse system is divided according to the total score. In order to prevent the excessive weight of a single parameter from affecting the final reliability evaluation results and maintenance strategies, the three indicators obtained need to be normalized and standardized before a comprehensive evaluation. If the reliability level is too low, the corresponding evaluation analysis and improvement suggestions will be output according to the corresponding indicators.

[0054] S5. The evaluation results are presented in a visual way, and the quantitative scores of reliability indicators in three dimensions are presented in charts, so that users can intuitively understand the reliability status of the warehousing system.

[0055] Specifically, the evaluation results are presented to the user in the form of graphs, such as Figure 4 , Figure 5 As shown. A line chart of the quantitative scores of the three dimensional indicators is drawn, and the warehouse reliability evaluation results and detailed analysis are given to help users intuitively understand the reliability status of the warehouse system.

[0056] This application establishes a mathematical model for reliability analysis of the storage active transportation system by simplifying the analysis of the physical structure of the storage and transportation system of the coal preparation plant. The storage reliability analysis indicators are divided into three dimensions: "equipment operation reliability indicators, storage and transportation indicators, and silo availability indicators". According to the simplified diagram of the physical structure of the storage part of the coal preparation plant, a reliability block diagram of the coal preparation plant storage active transportation system is established. On this basis, based on the reliability model, according to the series-parallel relationship between the belt and the coal feeder, the equipment operation reliability calculation formula is given; the storage and transportation indicators are calculated according to data such as the coal bunker throughput and the plan fulfillment rate; the silo availability indicator is calculated according to the coal bunker availability. Afterwards, the reliability analysis model is used to quantitatively evaluate the constructed reliability indicators, and the above three reliability indicators are combined to obtain the quantitative score of the storage system through weighted average, thereby obtaining the reliability level of the entire storage active transportation system. The present application provides a method for analyzing the reliability of coal preparation plant storage. By comprehensively considering all aspects of the coal preparation plant storage system and constructing appropriate reliability indicators for quantitative evaluation, it can accurately reflect the reliability status of the storage system, help optimize the coal storage operating costs, evaluate the safety and stability of the storage and transportation system, and provide a scientific basis for the storage management of coal enterprises. It has broad application prospects and important practical value.

[0057] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principle of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A method for analyzing storage reliability of a coal preparation plant, characterized in that: The steps include: S1. Collecting coal preparation plant storage system data, the storage system data includes equipment operation data, storage and transportation data, and personnel operation data; S2. Preprocessing the data of the storage system; S3. Establish equipment operation reliability index, storage and transportation reliability index and tank availability reliability index respectively; S4. Use statistics and reliability engineering theory to quantitatively evaluate the equipment operation reliability index, storage and transportation reliability index, and tank availability reliability index.

2. A method for analyzing storage reliability of a coal preparation plant according to claim 1, characterized in that: In step S1, the equipment operation data includes the working status, operation time, fault records, and maintenance records of the storage equipment; The storage and outbound transportation data include coal bunker throughput, planned outbound transportation volume, actual outbound transportation volume, total coal bunker storage volume, and coal bunker availability status; The personnel operation data includes the operator's working hours and operation records.

3. A method for analyzing storage reliability of a coal preparation plant according to claim 2, characterized in that: In step S1, the storage equipment includes a storage belt and a coal feeder.

4. A method for analyzing storage reliability of a coal preparation plant according to claim 1, characterized in that: In step S2, the collected warehouse system data is cleaned and sorted to remove outliers and noise.

5. A method for analyzing storage reliability of a coal preparation plant according to claim 4, characterized in that: In step S2, data preprocessing operations are performed on the warehousing and shipping data.

6. A method for analyzing storage reliability of a coal preparation plant according to claim 3, characterized in that: In step S3, the calculation of the equipment operation reliability index includes the following steps: The storage equipment is divided into the belt in front of the warehouse, the coal feeder, and the belt in the back of the warehouse. The number of failures and maintenance times are collected respectively, and the failure rate and maintenance rate are calculated. According to the physical structure of the belt and coal feeder in the storage part of the coal preparation plant, the reliability block diagram is established, and the equipment operation reliability index of the entire storage system is calculated.

7. A method for analyzing storage reliability of a coal preparation plant according to claim 6, characterized in that: In step S3, the storage and transportation reliability index is calculated according to the coal bunker throughput, the planned transportation volume, and the actual transportation volume.

8. A method for analyzing storage reliability of a coal preparation plant according to claim 7, characterized in that: In step S3, the calculation of the reliability index of the available state of the tank includes the following steps: Divide the entire tank into different storage areas according to location, and record the available status, current storage capacity, and available storage capacity of each storage area; The regional utilization rate of each storage area is calculated respectively, and the regional utilization rate is the ratio of the available storage capacity of the current area to the total storage capacity. The available status of each storage area is combined and weighted averaged to obtain the tank available status index.

9. The method for analyzing storage reliability of a coal preparation plant according to any one of claims 1 to 8, characterized in that: In step S4, the equipment operation reliability index, storage and transportation reliability index, and tank availability reliability index are normalized and standardized, and a weighted average is performed to obtain a reliability quantification score for the entire warehousing active transportation system, and the reliability level of the warehousing system is divided.

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