A method for adjusting flow through a constricted orifice and detecting wear of a plug plate based on curve fitting

Abstract

This invention relates to the field of orifice clogging detection and discloses a method for adjusting orifice flow and detecting orifice wear based on curve fitting. The method includes: collecting multiple sets of data during initial installation to construct an initial baseline flow characteristic curve; during operation, using a sliding window to collect data in real time to construct a real-time curve; determining the wear characteristic value through the difference of polynomial constant terms and converting it into dimensionless wear. When wear exceeds a threshold, the area increment is calculated and the orifice opening is adjusted. After adjustment, the baseline curve and basic constant terms are updated. Furthermore, during shutdown maintenance, the actual wear and wear characteristic values ​​are used to update the linear mapping relationship, and the number of samples in the sliding window is fixed. When the Reynolds factor distribution does not meet the requirements, the previous result is used. The orifice opening is adjusted using a stepwise approximation method, ensuring accurate and effective detection and adjustment.

Description

Technical Field

[0001] This invention relates to the field of blockage detection, and in particular to a method for adjusting flow through narrow orifices and detecting blockage wear based on curve fitting. Background Technology

[0002] In industrial fields involving fluid transmission and control, such as power, chemical, and petroleum industries, orifice and plugging plate assemblies are common key equipment. The stability of their flow characteristics and the wear of the plugging plate directly affect the operating efficiency, safety, and reliability of the entire system. The orifice is used to regulate fluid flow, while the plugging plate serves to seal and assist in regulation. With continuous operation, the plugging plate gradually wears down due to fluid erosion, corrosion, and other factors, causing changes in the effective flow area of ​​the orifice. This leads to deviations in parameters such as flow rate and pressure differential, affecting the normal operation of the system.

[0003] Accurately detecting the wear of the plug plate and adjusting the flow through the orifice in a timely manner is crucial for maintaining stable system performance, extending equipment lifespan, and reducing maintenance costs. Traditional detection methods often require downtime for maintenance, determining wear by manually measuring changes in the physical dimensions of the plug plate. This method is not only inefficient and costly but also fails to provide real-time wear information, making it difficult to detect potential faults promptly. Furthermore, some online detection methods based on simple parameter monitoring fail to adequately consider the complex changes in fluid characteristics and operating conditions, resulting in inaccurate detection results and failing to provide a reliable basis for adjusting the flow through the orifice.

[0004] Therefore, we propose a curve fitting-based method for adjusting flow through narrowing holes and detecting wear on plugs to solve the above problems. Summary of the Invention

[0005] This invention provides a method for adjusting flow through a narrowing orifice and detecting the wear of a plug plate based on curve fitting, which is used for detecting the wear of the plug plate.

[0006] The first aspect of this invention provides a method for adjusting flow through a constricted orifice and detecting wear on a plug plate based on curve fitting. The method includes: during the initial installation of the constricted orifice and plug plate assembly, collecting multiple sets of flow rate, pressure difference, fluid density, and fluid viscosity data under different flow conditions to construct an initial reference flow characteristic curve, and recording the polynomial constant term of this curve as a basic constant term; during continuous operation, collecting current data in real time and removing the oldest data within the window, reconstructing the real-time flow characteristic curve using all data within the window, and obtaining the corresponding curve... The polynomial constant term is used to determine the wear characteristic value. The difference between the real-time polynomial constant term and the basic constant term is used as the wear characteristic value. Then, according to the pre-calibrated linear mapping relationship, the wear characteristic value is converted into the wear amount of the plug plate. When the wear amount of the plug plate exceeds a preset threshold, the required area increment is calculated based on the wear amount of the plug plate, and the effective area of ​​the orifice is increased by adjusting the opening of the plug plate. After the area adjustment is completed, the real-time flow characteristic curve is updated to a new reference curve, and the basic constant term is updated to the real-time polynomial constant term. The wear characteristic value is then reset to zero.

[0007] Optionally, in the first implementation of the first aspect of the present invention, when the orifice and plugging plate assembly is in a brand new, wear-free state, at least twenty sets of flow rate, pressure difference, fluid density and fluid viscosity data under different flow conditions are collected, and the flow number and Reynolds factor corresponding to each set are calculated respectively. Then, with the Reynolds factor as the independent variable and the flow number as the dependent variable, a third-order polynomial is used for least squares fitting. The polynomial obtained by fitting is the initial reference flow characteristic curve, and the basic constant term is obtained.

[0008] Optionally, in the second implementation of the first aspect of the present invention, a sliding window of fixed size is set, and the latest collected flow rate, pressure difference, fluid density and fluid viscosity data are continuously stored in the window. When a new set of data is collected, the set of data is added to the window and the oldest set of data in the window is removed. Then, with the Reynolds factor corresponding to all the current data in the window as the independent variable and the flow number as the dependent variable, a third-order polynomial is used for least squares fitting. The polynomial obtained by fitting is the real-time flow characteristic curve, and the constant term of the real-time polynomial is obtained.

[0009] Optionally, in a third implementation of the first aspect of the present invention, the difference between the real-time polynomial constant term and the basic constant term is used as the wear characteristic value; the pre-calibrated linear mapping relationship is composed of a proportional coefficient jointly determined by the difference between the basic constant term of the hole-shrinking and plugging plate assembly in a brand-new, wear-free state and the real-time polynomial constant term in a known wear state, and the actual dimensionless wear amount corresponding to the known wear state; the wear characteristic value is multiplied by the proportional coefficient to obtain the current plugging plate wear amount.

[0010] Optionally, in the fourth implementation of the first aspect of the present invention, the calculation of the wear characteristic value is further based on the distribution range of the Reynolds factor within the sliding window. When the difference between the maximum and minimum Reynolds factor values ​​corresponding to all data points within the window is less than a preset span threshold, the calculation of the current wear characteristic value is abandoned, and the wear characteristic value obtained from the most recent valid calculation is used until the distribution range of the Reynolds factor within the window meets the preset span threshold.

[0011] Optionally, in the fifth implementation of the first aspect of the present invention, the calculation of the area increment and the adjustment of the blocking plate opening are further defined as follows: the dimensionless wear amount is directly used as the proportional value of the area increment, that is, the ratio of the required increase in the effective area of ​​the shrinkage hole to the current effective area of ​​the shrinkage hole is equal to the dimensionless wear amount; then, according to the linear relationship between the blocking plate opening and the effective area of ​​the shrinkage hole, the area increment is converted into the adjustment amount of the blocking plate opening, and the axial position of the blocking plate is adjusted by the actuator to increase the effective area of ​​the shrinkage hole by the area increment.

[0012] Optionally, in the sixth implementation of the first aspect of the present invention, the process of adjusting the opening of the plug plate adopts a step-by-step approximation method. After each adjustment, the flow rate is allowed to stabilize, a new set of data is collected and the real-time flow rate is calculated. The real-time flow rate is compared with the flow rate of the initial reference flow characteristic curve under the same Reynolds factor. If the deviation exceeds the allowable range, the opening of the plug plate is finely adjusted until the difference between the real-time flow rate and the corresponding flow rate on the initial reference flow characteristic curve is less than the preset deviation threshold.

[0013] Optionally, in the seventh implementation of the first aspect of the present invention, after the adjustment of the blocking plate opening is completed, the real-time flow characteristic curve obtained by fitting is immediately saved as a new reference curve, and the real-time polynomial constant term corresponding to the real-time flow characteristic curve is assigned to the basic constant term, while the wear characteristic value is set to zero.

[0014] Optionally, in the eighth implementation of the first aspect of the present invention, it further includes: during each shutdown maintenance, obtaining the actual wear amount of the plug plate, and forming a set of calibration points with the actual wear amount and the wear characteristic value calculated last time before the maintenance; when the number of accumulated calibration points reaches two or more, using these calibration points to refit and obtain an updated linear mapping relationship, and replacing the pre-calibrated linear mapping relationship with it.

[0015] Optionally, in the ninth implementation of the first aspect of the present invention, the step of refitting the calibration points to obtain the updated linear mapping relationship specifically involves: using the wear characteristic value as the independent variable and the actual wear amount as the dependent variable, fitting two or more calibration points using the least squares method to obtain a straight line passing through the origin, and using the slope of the straight line as the updated proportional coefficient to replace the pre-calibrated proportional coefficient.

[0016] Beneficial effects: By using a sliding window to collect multiple sets of data such as flow rate and differential pressure in real time during continuous operation, a real-time flow characteristic curve is constructed. The wear characteristic value is accurately determined by the change of the polynomial constant term, and then the dimensionless wear amount is calculated. This can detect early wear problems in time, avoid the equipment from operating under severe wear, reduce the risk of failure, reduce unplanned downtime, and ensure production continuity.

[0017] Based on the detected wear, the required area increment is scientifically calculated, and the effective area of ​​the shrinkage hole is precisely increased by adjusting the opening of the plug plate. This can promptly compensate for the impact of plug plate wear, maintain stable system flow, improve equipment operating efficiency and product quality, and reduce production losses caused by flow fluctuations.

[0018] When adjusting the opening of the blocking plate, a gradual approximation method is adopted. After each adjustment, the flow rate is allowed to stabilize. Data is then collected again and compared with the initial reference value. If the deviation exceeds the range, fine-tuning continues until the deviation is less than the preset threshold. This ensures the accuracy of the blocking plate opening adjustment, avoids over-adjustment or under-adjustment, and further optimizes the flow adjustment effect of the narrowing orifice. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of an embodiment of the method for adjusting flow through a constricted orifice and detecting wear of a plug plate based on curve fitting in this invention. Detailed Implementation

[0020] This invention provides a method for adjusting flow through a narrowing orifice and detecting the wear of a plug plate based on curve fitting, used for detecting the wear of the plug plate. The terms "first," "second," "third," "fourth," etc. (if present) in the specification, claims, and accompanying drawings are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments described herein can be implemented in a sequence other than that illustrated or described herein. Furthermore, the terms "comprising" or "having" and any variations thereof are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0021] For ease of understanding, the specific process of the embodiments of the present invention is described below. Please refer to [link / reference]. Figure 1 One embodiment of the method for adjusting flow through a constricted orifice and detecting wear of a plug plate based on curve fitting in this invention includes: 101. During the initial installation of the orifice and plugging plate assembly, collect multiple sets of flow rate, pressure difference, fluid density and fluid viscosity data under different flow conditions. Construct an initial reference flow characteristic curve by fitting a third-order polynomial, and record the polynomial constant term of the curve as the basic constant term.

[0022] It is understood that the executing entity of this invention can be a curve fitting-based orifice flow adjustment and plug wear detection device, or it can be a terminal or a server; the specific implementation is not limited here. This embodiment of the invention will be described using a server as an example.

[0023] Specifically, the process of constructing the initial reference flow characteristic curve is further defined as follows: when the orifice and plugging plate assembly is in a brand new, wear-free state, at least twenty sets of flow rate, pressure difference, fluid density and fluid viscosity data under different flow conditions are collected, and the flow number and Reynolds factor corresponding to each set are calculated respectively. Then, with the Reynolds factor as the independent variable and the flow number as the dependent variable, a third-order polynomial is used for least squares fitting. The polynomial obtained by fitting is the initial reference flow characteristic curve, and the constant term of the polynomial is the basic constant term.

[0024] It should be noted that in the cooling water circulation network of a chemical plant, a brand-new, wear-free set of orifice and plug plate components was installed for the first time, and the system server began to construct the initial reference flow characteristic curve.

[0025] Engineers controlled a variable frequency water pump to gradually change the fluid velocity in the pipeline, stabilizing the system under 20 different flow conditions. Under each condition, the transmitter synchronously collected data. For example, under the first low-flow condition, a flow rate of 50 m³ / h was collected. 3 / h, the pressure difference before and after the shrinkage is 12kPa, and the fluid density is 998kg / m³. 3 The fluid viscosity is 1 mPa·s; under the 10th group of medium flow conditions, the flow rate is increased to 100 m³ / s. 3 / h, the pressure difference reaches 48kPa; under the 20th high-flow-rate condition, the flow rate reaches 150m³ / h. 3 / h, with a pressure difference of 108kPa.

[0026] After receiving the data, intermediate parameters are calculated. The Reynolds factor for group 1 is 12000, and the flow number is 0.612; the Reynolds factor for group 10 is 24000, and the flow number is 0.625; the Reynolds factor for group 20 is 36000, and the flow number is 0.632. After acquiring 20 pairs of data, the server linearly normalizes the Reynolds factor values ​​(12000 to 36000) to the range of 0 to 1, eliminating the potential for truncation errors caused by excessively large values. Then, using the normalized Reynolds factor as the independent variable on the x-axis and the flow number as the dependent variable on the y-axis, a third-order polynomial curve fitting is performed. The fitting generates a curve reflecting the hydraulic characteristics of the component in its new state, with a constant term calculated to be 0.598. This polynomial is archived, and 0.598 is permanently recorded as the "basic constant term" as the initial benchmark for future wear assessments.

[0027] 102. During continuous operation, the current data is collected in real time using a sliding window method and the oldest data in the window is removed. A real-time flow characteristic curve is reconstructed using all the data in the window, and the polynomial constant term corresponding to the curve is obtained.

[0028] Specifically, the construction process of the real-time flow characteristic curve is further defined as follows: a fixed-size sliding window is set, which continuously stores the latest collected flow rate, pressure difference, fluid density, and fluid viscosity data. Each time a new set of data is collected, the set is added to the window, and the oldest set of data in the window is removed. Then, using the Reynolds factor corresponding to all current data in the window as the independent variable and the flow number as the dependent variable, a third-order polynomial is used for least-squares fitting. The resulting polynomial is the real-time flow characteristic curve, and the constant term of this polynomial is the real-time polynomial constant term. Furthermore, the number of samples in the sliding window is fixed at thirty data sets. When the number of currently valid data sets in the window is less than thirty, real-time flow characteristic curve fitting is not performed; instead, the most recently fitted real-time flow characteristic curve and its real-time polynomial constant term are used until the number of data sets in the window reaches thirty.

[0029] It should be noted that after the pipeline network has been in continuous operation for several months, it enters the real-time monitoring phase. The system memory is set with a fixed sliding window capacity of 30 data sets. When there are only 25 sets of valid data in the window during the initial restart after maintenance, the system does not perform fitting and uses the previously saved curve and constant terms.

[0030] When the latest monitoring data of Group 31 (flow rate 95m) 3 / h, pressure difference 44kPa, density 998kg / m³ 3 When the viscosity (1 mPa·s) is returned, the server stores it in a window and removes the oldest data set (the first set) while maintaining 30 sets of the latest continuous data.

[0031] The flow numbers and Reynolds factors (ranging from 18,000 to 28,000) were calculated for the updated 30 sets of original data. The system substituted these Reynolds factors into the normalization module to map them to the interval between 0 and 1. Then, using these as independent variables and the corresponding 30 flow numbers as dependent variables, the least squares method was used to perform third-order polynomial fitting.

[0032] Due to the slight change in the effective flow cross-section of the component caused by long-term fluid erosion, the latest constant term calculated in this fitting deviates from the initial value to 0.605. The server uses 0.605 as the current "real-time polynomial constant term" cache, preparing to enter the wear assessment stage.

[0033] 103. The difference between the real-time polynomial constant term and the basic constant term is determined as the wear characteristic value. Then, based on the pre-calibrated linear mapping relationship, the wear characteristic value is converted into the wear amount of the plug plate.

[0034] Specifically, the determination of wear characteristic values ​​and the conversion of wear amount are further defined as follows: the difference between the real-time polynomial constant term and the basic constant term is used as the wear characteristic value; the pre-calibrated linear mapping relationship is composed of the ratio coefficient determined by the difference between the basic constant term of the hole and plug assembly in a brand-new, wear-free state and the real-time polynomial constant term in a known wear state, and the actual dimensionless wear amount corresponding to the known wear state; multiplying the wear characteristic value by this ratio coefficient yields the current wear amount of the plug. Furthermore, the calculation of wear characteristic values ​​is also based on the distribution range of the Reynolds factor within the sliding window. When the difference between the maximum and minimum Reynolds factor values ​​corresponding to all data points within the window is less than a preset span threshold, the calculation of the current wear characteristic value is abandoned, and the most recently valid calculated wear characteristic value is used, until the distribution range of the Reynolds factor within the window meets the preset span threshold.

[0035] It should be noted that after extracting the constant term of the real-time polynomial, the validity of the data is first verified. The maximum Reynolds factor for the current 30 data sets is 28000, the minimum is 18000, and the distribution span is 10000. The system's preset span threshold is 5000; 10000 is greater than 5000, indicating that the data covers a sufficiently wide range of operating conditions, the fit is reliable, and the calculation can be performed.

[0036] The "basic constant term" 0.598 from step 101 is retrieved and calculated with the "real-time polynomial constant term" 0.605 from step 102. Subtracting 0.598 from 0.605 yields a difference of 0.007, which is the current component's "wear characteristic value".

[0037] Read the pre-calibrated proportional coefficient from the database. Historical calibration shows that when the actual wear of the plug plate reaches 0.05, the difference in the constant term is 0.020, thus establishing the linear proportional coefficient as 2.5 (i.e., 0.05 divided by 0.020).

[0038] Multiplying the current wear characteristic value of 0.007 by the preset scaling factor of 2.5 yields a result of 0.0175. This indicates that, under the current condition, the effective cross-sectional area of ​​the plug plate has increased by 1.75% relative to the wear rate.

[0039] 104. When the wear exceeds the preset threshold, calculate the required area increment based on the wear and increase the effective area of ​​the shrinkage hole by adjusting the opening of the blocking plate.

[0040] Specifically, the calculation of the area increment and the adjustment of the plug opening are further defined as follows: the dimensionless wear amount is directly used as the proportional value of the area increment, that is, the ratio of the required increase in the effective area of ​​the orifice to the current effective area of ​​the orifice is equal to the dimensionless wear amount; then, based on the linear relationship between the plug opening and the effective area of ​​the orifice, the area increment is converted into the adjustment amount of the plug opening, and the axial position of the plug is adjusted by the actuator to increase the effective area of ​​the orifice by the area increment. The adjusted plug opening position serves as the base state for subsequent operation. Furthermore, the process of adjusting the plug opening adopts a stepwise approximation method. After each adjustment, the flow rate is allowed to stabilize, a new set of data is collected and the real-time flow rate is calculated. The real-time flow rate is compared with the flow rate of the initial reference flow characteristic curve under the same Reynolds factor. If the deviation exceeds the allowable range, the plug opening is finely adjusted until the difference between the real-time flow rate and the corresponding flow rate on the initial reference flow characteristic curve is less than the preset deviation threshold. The plug opening position at this point is taken as the final position after adjustment.

[0041] It should be noted that the preset safe allowable wear threshold is 0.015 (i.e., 1.5%). The currently detected dimensionless wear is 0.0175, which exceeds the limit, and the system automatically triggers the closed-loop adjustment program.

[0042] Wear has caused the original design cross-sectional area to increase. To restore the original fluid throttling resistance, the cross-sectional area must be reduced. The current rated effective cross-sectional area is 10000 mm². 2 The system calculated that the area to be compensated for is 10000 multiplied by 0.0175, which is 175mm. 2 .

[0043] According to the mechanical parameters, a 1mm axial movement of the blocking plate corresponds to a 50mm change in area. 2 175mm 2 Dividing by 50, the required axial adjustment is 3.5mm. The actuator then advances the stop plate 3.5mm in the direction of decreasing the opening.

[0044] After the movement is completed, wait 3 minutes for the flow rate to stabilize again. The sensor data calculated the real-time flow rate to be 0.613. Under the corresponding operating conditions with the normalized Reynolds factor, the baseline flow rate should be 0.611. The actual deviation is 0.002.

[0045] The preset allowable deviation threshold is 0.001, and 0.002 has been exceeded, indicating that the mechanical dead zone caused the initial adjustment to be inadequate. Considering the mechanical sensitivity characteristic of correcting a 0.007 drift with a previous 3.5mm adjustment (i.e., approximately 0.002 flow rate per 1mm), the server issued a precise fine-tuning command: continue to advance 1mm towards reducing the opening. After stabilization, the real-time flow rate dropped back to 0.611, with the difference from the baseline value reaching 0, less than the threshold of 0.001. The adjustment was deemed satisfactory, and the system locked the blockage position as the new baseline for subsequent operation.

[0046] 105. After completing the area adjustment, update the real-time flow characteristic curve to the new reference curve, update the basic constant term to the real-time polynomial constant term, and reset the wear characteristic value to zero for subsequent wear detection reference.

[0047] Specifically, the update of the reference curve and the basic constant term is further defined as follows: after the adjustment of the baffle opening is completed, the real-time flow characteristic curve obtained by fitting is immediately saved as the new reference curve, and the real-time polynomial constant term corresponding to the real-time flow characteristic curve is assigned to the basic constant term, while the wear characteristic value is set to zero; the updated reference curve and the basic constant term serve as the reference for calculating the wear characteristic value in the subsequent sliding window detection process.

[0048] It should be noted that after the mechanical adjustment successfully compensated for the cross-sectional area, the hydraulic system returned to a design flow resistance state similar to "wear-free". To ensure that no logical errors occur in the next stage of monitoring, the server immediately captures the latest data within the sliding window after the adjustment has stabilized and generates a "real-time flow characteristic curve".

[0049] After performing a third-order fit on the current stable operating conditions, the latest real-time polynomial constant term is obtained as 0.599. This value is extremely close to the absolute reference of 0.598 at the time of initial installation, perfectly confirming that the physical compensation action successfully eliminated the hydraulic deviation caused by wear, and achieved a logically self-consistent closed loop in terms of fluid dynamics performance.

[0050] The server then archives the old "initial baseline curve," activates the latest curve as the "new baseline curve," and forcibly updates the "basic constant term" in system memory to 0.599. Simultaneously, because physical compensation has offset the cross-sectional expansion, the system completely clears the recorded "wear characteristic value" of 0.007 that triggered this adjustment. After completing the state reversal, the system seamlessly switches back to step 102 to continue monitoring. The specific parameter conversion logic is shown in Table 1 below: Table 1 106. It also includes: during each shutdown maintenance, obtaining the actual wear of the plug plate, and forming a set of calibration points with the wear characteristic value calculated last time before maintenance; when the number of accumulated calibration points reaches more than two, using these calibration points to refit and obtain an updated linear mapping relationship, and using this to replace the pre-calibrated linear mapping relationship for subsequent wear amount conversion.

[0051] Furthermore, an updated linear mapping relationship is obtained by refitting the calibration points. Specifically, the wear characteristic value is used as the independent variable and the actual wear amount is used as the dependent variable. The least squares method is used to fit two or more calibration points to obtain a straight line passing through the origin. The slope of this straight line is used as the updated proportional coefficient to replace the pre-calibrated proportional coefficient.

[0052] It should be noted that this pipeline network has been in operation for many years and has undergone three annual overhauls. Each time the pipeline was completely emptied and components disassembled, engineers used a coordinate measuring machine to precisely measure the "actual dimensionless wear" of the plugs. The server extracted the "wear characteristic value" output just moments before shutdown, and the two were paired and entered into the optimization database. The effective historical calibration points accumulated over three years are shown in Table 2 below: Table 2 After the third set of data was entered, the number of calibration points reached the algorithm trigger threshold (more than two). The system used x as the independent variable and y as the dependent variable in the table, and forced the straight line to pass through the origin (physically and logically without feature values, i.e., without wear) to perform rigorous least squares calculation.

[0053] According to the formula for fitting a straight line through the origin, the numerator is the sum of the products of the independent and dependent variables: (0.008 × 0.022) + (0.012 × 0.033) + (0.015 × 0.040) = 0.001172; the denominator is the sum of the squares of the independent variables: (0.008 2 )+(0.012 2 )+(0.015 2 =0.000433.

[0054] Dividing the two yields the true, precise mathematical slope: 0.001172 / 0.000433 = 2.706697... The server rounds the result to three decimal places, determining the new slope of the line to be 2.707.

[0055] The old laboratory ratio of 2.5, which has been used for a long time, will be discarded and archived. The global ratio of 2.707, which incorporates the actual physical characteristics of the site, will be used instead. After the pipeline network is restarted, the system's calculations and conversions will uniformly use 2.707, making subsequent automated wear assessments more accurate and error-free.

[0056] The present invention also provides a curve fitting-based device for adjusting flow through a concave orifice and detecting wear on a plug plate. The device includes a memory and a processor. The memory stores computer-readable instructions. When the computer-readable instructions are executed by the processor, the processor performs the steps of the curve fitting-based method for adjusting flow through a concave orifice and detecting wear on a plug plate in the above embodiments.

[0057] The present invention also provides a computer-readable storage medium, which can be a non-volatile computer-readable storage medium or a volatile computer-readable storage medium, wherein the computer-readable storage medium stores instructions that, when the instructions are executed on a computer, cause the computer to perform the steps of the curve fitting-based orifice flow adjustment and plug wear detection method.

[0058] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0059] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0060] The above-described embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for adjusting flow through a constricted orifice and detecting wear of a plug plate based on curve fitting, characterized in that, include: During the initial installation of the orifice and plugging plate assembly, multiple sets of data on flow rate, pressure difference, fluid density, and fluid viscosity under different flow conditions were collected to construct an initial reference flow characteristic curve, and the polynomial constant term of the curve was recorded as the basic constant term. During continuous operation, the current data is collected in real time and the oldest data in the window is removed. The real-time flow characteristic curve is reconstructed using all the data in the window, and the polynomial constant term corresponding to the curve is obtained. The difference between the real-time polynomial constant term and the basic constant term is determined as the wear characteristic value. Then, based on the pre-calibrated linear mapping relationship, the wear characteristic value is converted into the wear amount of the plug plate. When the wear of the blocking plate exceeds a preset threshold, the required area increment is calculated based on the wear of the blocking plate, and the effective area of ​​the shrinkage hole is increased by adjusting the opening of the blocking plate. After the area adjustment is completed, the real-time flow characteristic curve is updated to the new reference curve, the basic constant term is updated to the real-time polynomial constant term, and the wear characteristic value is reset to zero.

2. The method for adjusting flow through a narrow orifice and detecting wear of a plug plate based on curve fitting according to claim 1, characterized in that, When the orifice and plugging plate assembly is in a brand new, wear-free state, at least twenty sets of flow rate, pressure difference, fluid density and fluid viscosity data under different flow conditions are collected. The flow number and Reynolds factor corresponding to each set are calculated. Then, with the Reynolds factor as the independent variable and the flow number as the dependent variable, a third-order polynomial is used for least squares fitting. The polynomial obtained by fitting is the initial reference flow characteristic curve, and the basic constant term is obtained.

3. The method for adjusting flow through narrowing orifices and detecting wear of plugging plates based on curve fitting according to claim 1, characterized in that, A fixed-size sliding window is set up to continuously store the latest collected flow rate, pressure difference, fluid density, and fluid viscosity data. Each time a new set of data is collected, the set of data is added to the window and the oldest set of data in the window is removed. Then, using the Reynolds factor corresponding to all the current data in the window as the independent variable and the flow number as the dependent variable, a third-order polynomial is used for least squares fitting. The polynomial obtained by fitting is the real-time flow characteristic curve, and the constant term of the real-time polynomial is obtained.

4. The method for adjusting flow through a narrow orifice and detecting wear of a plug plate based on curve fitting according to claim 1, characterized in that, The difference between the real-time polynomial constant term and the basic constant term is used as the wear characteristic value. The linear mapping relationship obtained by pre-calibration is composed of the ratio coefficient determined by the difference between the basic constant term of the hole and plug plate assembly in a brand new, wear-free state and the real-time polynomial constant term in a known wear state, as well as the actual dimensionless wear amount corresponding to the known wear state. The current wear amount of the plug plate is obtained by multiplying the wear characteristic value by the ratio coefficient.

5. The method for adjusting flow through a narrow orifice and detecting wear of a plug plate based on curve fitting according to claim 4, characterized in that, The calculation of the wear characteristic value is also based on the distribution range of the Reynolds factor within the sliding window. When the difference between the maximum and minimum Reynolds factor values ​​corresponding to all data points within the window is less than the preset span threshold, the calculation of the wear characteristic value is abandoned, and the wear characteristic value obtained from the most recent valid calculation is used until the distribution range of the Reynolds factor within the window meets the preset span threshold.

6. The method for adjusting flow through a narrow orifice and detecting wear of a plug plate based on curve fitting according to claim 1, characterized in that, The calculation of the area increment and the adjustment of the blocking plate opening are further defined as follows: the dimensionless wear amount is directly used as the proportional value of the area increment, that is, the ratio of the required increase in the effective area of ​​the shrinkage hole to the current effective area of ​​the shrinkage hole is equal to the dimensionless wear amount; then, according to the linear relationship between the blocking plate opening and the effective area of ​​the shrinkage hole, the area increment is converted into the adjustment amount of the blocking plate opening, and the axial position of the blocking plate is adjusted by the actuator to increase the effective area of ​​the shrinkage hole by the area increment.

7. The method for adjusting flow through a narrow orifice and detecting wear of a plug plate based on curve fitting according to claim 6, characterized in that, The process of adjusting the opening of the baffle plate adopts a step-by-step approximation method. After each adjustment, the flow rate is allowed to stabilize, a new set of data is collected and the real-time flow rate is calculated. The real-time flow rate is compared with the flow rate of the initial reference flow characteristic curve under the same Reynolds factor. If the deviation exceeds the allowable range, the opening of the baffle plate is finely adjusted until the difference between the real-time flow rate and the corresponding flow rate on the initial reference flow characteristic curve is less than the preset deviation threshold.

8. The method for adjusting flow through narrowing orifices and detecting wear of plugging plates based on curve fitting according to claim 1, characterized in that, After completing the adjustment of the baffle opening, immediately save the currently fitted real-time flow characteristic curve as a new reference curve, assign the real-time polynomial constant term corresponding to the real-time flow characteristic curve to the basic constant term, and reset the wear characteristic value to zero.

9. The method for adjusting flow through a narrow orifice and detecting wear of a plug plate based on curve fitting according to claim 1, characterized in that, Also includes: During each shutdown maintenance, the actual wear of the plug plate is obtained, and the actual wear is combined with the wear characteristic value calculated at the last time before the maintenance to form a set of calibration points. When the number of accumulated calibration points reaches two or more, these calibration points are used to refit and obtain an updated linear mapping relationship, which replaces the pre-calibrated linear mapping relationship.

10. The method for adjusting flow through a narrow orifice and detecting wear of a plug plate based on curve fitting according to claim 9, characterized in that, The method of refitting the calibration points to obtain the updated linear mapping relationship is as follows: using the wear characteristic value as the independent variable and the actual wear amount as the dependent variable, the least squares method is used to fit two or more calibration points to obtain a straight line passing through the origin. The slope of this straight line is used as the updated proportional coefficient to replace the pre-calibrated proportional coefficient.

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