CN106640688B - A kind of intelligent diagnosis system and method for output pump unit on-line monitoring failure - Google Patents
A kind of intelligent diagnosis system and method for output pump unit on-line monitoring failure Download PDFInfo
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- CN106640688B CN106640688B CN201611103126.7A CN201611103126A CN106640688B CN 106640688 B CN106640688 B CN 106640688B CN 201611103126 A CN201611103126 A CN 201611103126A CN 106640688 B CN106640688 B CN 106640688B
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D15/00—Control, e.g. regulation, of pumps, pumping installations or systems
- F04D15/0077—Safety measures
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- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Testing Or Calibration Of Command Recording Devices (AREA)
- Testing Of Devices, Machine Parts, Or Other Structures Thereof (AREA)
- Measurement Of Mechanical Vibrations Or Ultrasonic Waves (AREA)
Abstract
The present invention provides the intelligent diagnosis systems and method of a kind of output pump unit on-line monitoring failure, which includes output pump unit, collector, more mouthfuls of transponders, on the spot monitoring unit and remote monitoring unit.The output pump unit includes the motor and output pump being connected, output pump is equipped with detection vibration compound sensor, the detection vibration compound sensor is electrically connected with collector, the collector, on the spot monitoring unit and remote monitoring unit are both electrically connected in more mouthfuls of transponders, which solves the problems, such as outside oil field that defeated main pump unit does not have that single-minded on-line monitoring Fault Intelligent Diagnosis System, Long-term Vibration are exceeded, there are dangerous and waste electric energy, easily cause stopping transportation and cause damages.
Description
Technical field
The present invention relates to output pump units to monitor field on-line, and in particular to a kind of output pump unit on-line monitoring failure intelligence
It can diagnostic system and method.
Background technique
The crucial overwhelming majority of defeated main pump unit involves great expense, unit from esbablished corporation all over the world outside Changqing oilfields
Long-term 24 hours continuous, high rotary speed working, plant maintenance are extremely important, arduous.Once damage or hang-up not only directly damage
Indirect loss that is huge and causing whole line to stop production is lost more to be unable to estimate.Output pump unit does not monitor, and individual pump groups are based on
The acquisition of single data and position limitation protection, without special on-line monitoring Fault Intelligent Diagnosis System；Most of Long-term Vibration is super
Mark, while a large amount of electric energy is wasted, since the degree of correlation of each parameter is not high, also parking can be caused because of wrong report or maloperation sometimes,
And then force completely stopping transportation outside the plan.Once Key generating unit shutdown will also result in significant economic losses, it sometimes can also be with messenger
Member's injures and deaths and serious environmental pollution, previous planned maintenance means are unable to satisfy the production model of equipment high efficiency operation.Pass through
Document Investigation, the results showed that the country not yet carries out further investigation in this field, domestic at present without comprehensively grasping outside oil field
Defeated pump assembly operation information uses for reference identification, judgement and the on-line monitoring system for solving the problems, such as experience of the failure occurred.It is external
It is increasingly becoming mainstream monitoring technology for the continuous on-line monitoring system of fining based on vibration frequency specturm analysis, dimension is predicted with intelligence
Shield is the Typical Representative that leading large scale equipment safety monitoring series instrument system is such product, and the present invention is output pump group
Monitor intelligent fault diagnosis Maintenance Expert System on-line.
In conclusion needing the new output pump unit on-line monitoring intelligent fault diagnosis technology of one kind to meet oil field development
Requirement.
Summary of the invention
The purpose of the present invention is overcome outside oil field defeated main pump unit do not have single-minded on-line monitoring Fault Intelligent Diagnosis System,
Long-term Vibration is exceeded, there are dangerous and waste electric energy, easily cause the problems such as stopping transportation causes damages, and provides a kind of output pump machine
The intelligent diagnosis system and method for group on-line monitoring failure.
The technical solution of the present invention is to provide a kind of intelligent diagnosis systems of output pump unit on-line monitoring failure, including
Output pump unit, collector, more mouthfuls of transponders, on the spot monitoring unit and remote monitoring unit.The output pump unit includes phase
The motor and output pump of connection, output pump are equipped with detection vibration compound sensor, and the detection is vibrated compound sensor and adopted
Storage electrical connection, the collector, on the spot monitoring unit and remote monitoring unit are both electrically connected in more mouthfuls of transponders.
The monitoring unit on the spot includes Central Control Room computer and engineer station's host computer, the Central Control Room computer and work
Cheng Shizhan host computer is all used for data storage and monitoring, Central Control Room computer can also be diagnosed to be output pump unit failure on the spot, and
Data are uploaded in digitalized network.
The remote monitoring unit includes Web server and remote diagnostic center, and the Web server is for remotely monitoring
Output pump unit operating condition and storing data, carry out Web publication, and the remote diagnostic center is used for remote data storage and prison
It surveys, and diagnoses output pump unit fail result in time.
The Central Control Room computer and remote diagnostic center are both provided with Database Unit, data acquisition unit, state prison
Survey unit, dynamic balance calculation unit and analyzing and diagnosing unit.
The output pump unit can be single group or multiple groups.
Detection vibration compound sensor, the inspection are equipped in the horizontal direction of the output pump front and back end and disposition direction
It includes vibration acceleration sensor, temperature sensor, speed probe and pressure sensor that compound sensor is moved in vibration measuring, is a kind of
Amplitude, acceleration, temperature, revolving speed and pressure integrated special type compound sensor can be detected simultaneously, by ATEX certification of explosion protection.
Explosion-proof tank is provided on the collector.
A kind of intelligent diagnosing method of output pump unit on-line monitoring failure, it is characterised in that: the following steps are included:
Step 1) loads onto detection vibration compound sensor on the output pump of defeated pump assembly outside, will test vibration composite sensing
Device is electrically connected to collector, and collector, on the spot monitoring unit and remote monitoring unit are both electrically connected in more mouthfuls of transponders；
Step 2 collector collects the signal of detection vibration compound sensor and is translated into data, is transmitted to more
Mouth transponder；
More mouthfuls of transponders of step 3) send data to monitoring unit on the spot, Central Control Room computer and engineer station's host computer
Data storage and monitoring can be carried out simultaneously, and engineer station's host computer can also be diagnosed to be the various events of output pump unit on the spot
Barrier, and data are uploaded in digitalized network, while local operation personnel according to the fail result being diagnosed to be and instruct
Property maintenance；
Data are also uploaded to remote monitoring unit, Web clothes by oil field private network optical fiber simultaneously by more mouthfuls of transponders of step 4)
Business device and remote diagnostic center carry out data storage and monitoring simultaneously, and Web server can also carry out Web publication to data, remotely
Diagnostic center is able to achieve the monitoring of output pump set state, data analysis and Remote Fault Diagnosis result.
Data in the step 2 include the real-time operating conditions of output pump front-end and back-end, specifically include vibration amplitude
Data, acceleration information, rotary speed data, pressure data and temperature data.
Beneficial effects of the present invention:
(1) intelligent diagnosis system of this output pump unit on-line monitoring failure provided by the invention and method may be implemented
The timely discovery and the analysis of causes of monitoring, the equipment fault of the operating status of output pump unit and the finger of precognition equipment maintenance
It leads, thoroughly solves the existing failure problems of output pump unit.
(2) intelligent diagnosis system of this output pump unit on-line monitoring failure provided by the invention and method use remote
The journey diagnostic center operating status different for unit, is automatically stored related data, forms various databases.Equipment may be implemented
The timely discovery and the analysis of causes and the guidance of precognition equipment maintenance of monitoring, the equipment fault of operating status.
(3) intelligent diagnosis system of this output pump unit on-line monitoring failure provided by the invention and method can be simultaneously
Monitor single group or multiple groups output pump unit, by output pump front and back end horizontally and vertically on be equipped with detection vibration
Dynamic compound sensor, can find and diagnose in time mass unbalance existing for output pump unit, initial bending, thermal flexure, leaf
Piece falls off, misaligns, oil whip, steam flow excitation, electromagnetic exciting, friction, bearing shell loosen and fault conditions such as resonance and timely
Alarm and the handling suggestion for proposing directiveness improve production efficiency to avoid non-programmed halt.
(4) intelligent diagnosis system of this output pump unit on-line monitoring failure provided by the invention and method are by adopting
It is provided with explosion-proof tank on storage, improves the security reliability of system, collector of the present invention is distributed vibration number
According to intelligent collector, vibrating data collection system is a operating condition for being adapted to Oil Field, powerful data acquisition
The experience for for many years manufacturing Diagnosing System for Oil Pump vibration protecting device is utilized in device, from design, buying, the too many levels such as production
The reliability and stability of product quality are ensured.
The present invention is described in further details below with reference to attached drawing.
Detailed description of the invention
Fig. 1 is the structural schematic diagram of the intelligent diagnosis system of output pump unit on-line monitoring failure of the present invention；
Description of symbols: 1, Web server；2, remote diagnostic center；3, Central Control Room computer；4, more mouthfuls of transponders；
5, engineer station's host computer；6, collector；7, motor；8, output pump；9, detection vibration compound sensor.
Specific embodiment
Embodiment 1:
In order to overcome defeated main pump unit outside oil field there is no single-minded on-line monitoring Fault Intelligent Diagnosis System, Long-term Vibration super
It marks, there are dangerous and waste electric energy, easily cause the problems such as stopping transportation causes damages, present embodiments provides one kind such as Fig. 1 institute
Show output pump unit on-line monitoring failure intelligent diagnosis system, including output pump unit, collector 6, more mouthfuls of transponders 4,
Monitoring unit and remote monitoring unit on the spot.The output pump unit includes the motor 7 and output pump 8 being connected, on output pump 8
Compound sensor 9 is vibrated equipped with detection, the detection is vibrated compound sensor 9 and is electrically connected with collector 6, the collector 6, just
Ground monitoring unit and remote monitoring unit are both electrically connected in more mouthfuls of transponders 4.
The intelligent diagnosing method of this output pump unit on-line monitoring failure of the invention, comprising the following steps:
Step 1) loads onto detection vibration compound sensor 9 on the output pump 8 of defeated pump assembly outside, will test the compound biography of vibration
Sensor 9 is electrically connected to collector 6, and collector 6, on the spot monitoring unit and remote monitoring unit are both electrically connected with and forwarded in more mouthfuls
Device 4；
Step 2 collector 6 collects the signal of detection vibration compound sensor 9 and is translated into data, is transmitted to
More mouthfuls of transponders 4, the collected data of collector 6 include the data of the real-time running state of 8 front-end and back-end of output pump, including
Vibration amplitude data, acceleration information, rotary speed data, pressure data and temperature data；
More mouthfuls of transponders 4 of step 3) send data to monitoring unit on the spot, and monitoring unit includes that Central Control Room calculates on the spot
Machine 3 and engineer station's host computer 5, the Central Control Room computer 3 and engineer station's host computer 5 are all stored and are monitored for data,
Central Control Room computer 3 can also be diagnosed to be the various failures of output pump unit on the spot, and data are uploaded in digitalized network, together
When local operation personnel according to the fail result being diagnosed to be and carry out guiding maintenance；
Data are also uploaded to remote monitoring unit by oil field private network optical fiber simultaneously by more mouthfuls of transponders 4 of step 4), described
Remote monitoring unit includes Web server 1 and remote diagnostic center 2, and the Web server 1 is for remotely monitoring output pump machine
Group operating condition and storing data carry out Web publication, and remote diagnostic center 2 is used for remote data storage and monitoring, realize outer defeated
Pump assembly status monitoring, data analysis and Remote Fault Diagnosis result.
Output pump unit may be implemented in the intelligent diagnosis system of this output pump unit on-line monitoring failure of the invention
The timely discovery and the analysis of causes and the guidance of precognition equipment maintenance of monitoring, the equipment fault of operating status, thoroughly solve
Output pump unit existing failure problems.The zero failure rate in output pump unit future is realized simultaneously, realizes the vibration of output pump unit
Dynamic value drops to international vibration severity standard (ISO2372) below.It preferably grasps the state change of feeding oil pump and development becomes
Gesture, accident prevention eliminate accident in rudiment, to avoid the generation of major accident, reduce the harmfulness of accident in possible trouble.And
This intelligent diagnosing method is easy to operate, improves the efficiency of management, greatly prolongs the service life of outer defeated unit, extends maintenance week
Phase reduces the hang-up accident of output pump group equipment, carries out the preparation of output pump group plant maintenance in advance, tie up equipment
The efficiency that nurse makees is greatly improved, and has good promotional value.
Embodiment 2:
A kind of intelligent diagnosis system of output pump unit on-line monitoring failure is present embodiments provided, it is further, described
Central Control Room computer 3 and remote diagnostic center 2 are both provided with Database Unit, data acquisition unit, Condition Monitoring Unit, move and put down
Weigh computing unit and analyzing and diagnosing unit, and these units are special cell, belong to the prior art.
Wherein, Database Unit is used for the storage of data, it is by lifting speed database, historical data base and event database
Deng composition, it is stored to related data in different databases according to the different conditions of unit, in order to subsequent analysis.Data are adopted
Collection unit further includes setting unit, and data acquisition unit is acquired for data, and the operating status of its energy automatic identification unit is such as opened
Shutdown, lifting speed and normal or abnormal state, and data acquisition device is passed through according to the state of unit and carries out data acquisition.In stabilization
Under operating status, data acquisition device is acquired with timing mode, and is then carried out according to the variation of revolving speed under lifting speed state
Acquisition；The equipment such as gear-box, rolling bearing are acquired using high-speed encryption.Collected data by Condition Monitoring Unit and
Dynamic balance calculation unit obtains data, is classified according to the database of Database Unit, and ultimate analysis diagnosis unit is divided
Analysis diagnosis.Condition Monitoring Unit has more picture monitoring functions, using tree-shaped equipment navigational structure, can according to process flow into
The editor of row monitoring picture and setting.System, which has, emulates main watch circle, rod figure, data and list of thing, and the forms such as curve are aobvious
Show the state of measuring point, the icon for abnormal corresponding alarm occur carries out color exception automatically and shows.Analyzing and diagnosing unit contains powerful
Bearing database analysis system and expert's Analysis on Fault Diagnosis system database, full and accurate foundation can be provided for analyzing and diagnosing,
Analyzing and diagnosing unit mainly carries out online or off-line analysis to various data, to judge the operating status of unit and can provide automatically
Unit failure cause and handling suggestion.
Remote diagnostic center 2 have a variety of data storage methods: constant duration samples storage, etc. revolving speeds interval sampling deposit
Storage, etc. load spacers samples storage, alarm storage and manual type storing data.
Constant duration sampling refers to unit (revolving speed is between revolving speed upper limit and lower rotation speed limit of setting) in steady-state operation,
Per after a period of time, storing one group of data in historical data base；
Equal revolving speeds interval sampling refers to unit, and in the operation of transient state startup-shutdown, (revolving speed is on the revolving speed upper limit of setting or revolving speed
Under lower limit), the every variation △ RPM of revolving speed stores one group of data in startup-shutdown database；
Alarm storage is the storing data automatically when equipment is alarmed, and forms black box data library；
Artificial storage is storing data as needed, can using unit first time log-on data as original relatively data into
Row storage.Time, the variable quantity of revolving speed and load and alarming value, the revolving speed upper limit, lower rotation speed limit, △ RPM can be existed by user
It is configured in system.
The operating status different for unit of remote diagnostic center 2, is automatically stored related data, forms various databases.
The finger of discovery and the analysis of causes and precognition equipment maintenance in time of monitoring, the equipment fault of equipment running status may be implemented
It leads.
Embodiment 3:
Present embodiments provide a kind of intelligent diagnosis system of output pump unit on-line monitoring failure, the output pump unit
It can be single group or multiple groups.The intelligent diagnosis system of this output pump unit on-line monitoring failure of the invention can supervise simultaneously
Survey single group or multiple groups output pump unit.
Further, 8 front and back end of output pump horizontally and vertically on be equipped with detection and vibrate compound biography
Sensor 9, the detection vibration compound sensor 9 includes vibration acceleration sensor, temperature sensor, speed probe and pressure
The extraordinary compound sensor of sensor integration, by ATEX certification of explosion protection.
Sensor used in the present invention, be a kind of built-in IEPE circuit, advanced structure electromechanical integration piezoelectricity vibration
Dynamic measurement sensor, temperature sensing sensor, Hall sensor and press sensor.Sensitivity principle system is utilizing passive piezo-electric crystal just
Piezoelectric effect, sensitive structure use advanced shear structure, the output charge of piezo-electric crystal are converted to and are vibrated by IEPE
Measure directly proportional low-resistance voltage signal.Instrument display reading, record, data collector can directly be matched and be acquired analysis, passed through
The suitable parameters such as instrument or software expandable measuring speed, displacement.Since the sensing element in sensor is made pottery using P5 piezoelectricity
Porcelain crystal, the crystal are function ceramics crystal, belong to brittle non-metallic material, are become without apparent mechanical yield limit and plasticity
Shape, allow using the range of stress in, belong to without tired material, base metal material --- stainless steel is also with higher
Mechanical strength, piezoelectric structure itself no-movable part in addition, therefore service life is extremely long.Single sensitive measurement centered on the sensor
Acceleration transducer can measure the vibration of vertical direction, the vibration in detection level direction can also be horizontally mounted, if need to detect
The vibration of angle then should can measure sensor by tooling along direction of vibration impression.Since the small product size is small, rigidity
Greatly, frequency response is wide, and voltage sensibility is high, the service life is long, Low ESR (100 Ω of <=signal transmission, good airproof performance, installs reliable, wiring
It is easy to use, the sensitive series of advantages such as passive.Temperature detection is completed using temperature sensing sensor, and pressure detecting uses silicon crystal
Piezoresistive effect pressure sensor complete, Rotating speed measring completed using Hall switch sensor.Scene is using in the world
First is supported being digitally transmitted for " one-wire bus " interface, substantially increases the anti-interference of system.Cable is using screen
4 core twisted pairs are covered, one pair of them line ground line and signal wire, another pair line meet VCC and ground wire, and shielded layer connects in source single-point
Ground.
It, can by being equipped with detection vibration compound sensor 9 in horizontal direction in 8 front and back end of output pump and disposition direction
To find and diagnose mass unbalance existing for output pump unit in time, initial bending, thermal flexure, leaf abscission, misalign, oil
Film oscillation, steam flow excitation, electromagnetic exciting, friction, bearing shell loosen and resonance etc. fault conditions and and alarm and propose directiveness
Handling suggestion improve production efficiency to avoid non-programmed halt.
Embodiment 4:
A kind of intelligent diagnosis system of output pump unit on-line monitoring failure is present embodiments provided, in order to improve the system
Security reliability, be provided with explosion-proof tank on the collector 6.
Collector of the present invention is distributed vibration data intelligent collector, and vibrating data collection system is one
Money is adapted to the operating condition of Oil Field, powerful data collector.For many years manufacture Diagnosing System for Oil Pump vibration is utilized
The experience of dynamic protective device, from design, buying, the too many levels such as production have ensured the reliability and stability of product quality.
Vibration data intelligent collector has the advantage that
1, high hardware reliability: producing data acquisition equipment with the technique of manufacture Large-scale machine set protection system,
Possess the stability and reliability of superelevation.
2, stringent EMC design: design source has just fully considered EMC index, and has passed through recognizing for national authority department
Card.
3, " seamless " data acquisition technology: intelligent collector has seamless data acquisition technology, it can to all channels
Carry out continual data acquisition and transmission.The maximum data length of endless.
4, full technical grade chip, ultra-wide Acclimation temperature range, has ensured the stability of system.
5, ultra-high-speed data acquisition rate: the up to data acquisition rate of 400K, it being capable of point of the safeguards system with superelevation
Analyse frequency capabilities.
The foregoing examples are only illustrative of the present invention, does not constitute the limitation to protection scope of the present invention, all
It is within being all belonged to the scope of protection of the present invention with the same or similar design of the present invention.
Claims (1)
1. a kind of intelligent diagnosis system of output pump unit on-line monitoring failure, it is characterised in that: including output pump unit, acquisition
Device (6), more mouthfuls of transponders (4), on the spot monitoring unit and remote monitoring unit；The output pump unit includes the motor being connected
(7) and output pump (8), output pump (8) are equipped with detection vibration compound sensor (9), and compound sensor (9) are vibrated in the detection
It is electrically connected with collector (6), the collector (6), on the spot monitoring unit and remote monitoring unit are both electrically connected with to be forwarded in more mouthfuls
Device (4)；Cable for connection is using 4 core twisted pairs of shielding；
The monitoring unit on the spot includes Central Control Room computer (3) and engineer station's host computer (5), the Central Control Room computer
(3) it all stores and monitors for data with engineer station's host computer (5), Central Control Room computer (3) can also be diagnosed to be outer defeated on the spot
Pump assembly failure, and data are uploaded in digitalized network；
The remote monitoring unit includes Web server (1) and remote diagnostic center (2), and the Web server (1) is for remote
Journey monitors output pump unit operating condition and storing data, carries out Web publication, the remote diagnostic center (2) is for remotely number
According to storage and monitoring, and output pump unit fail result is diagnosed in time；
The Central Control Room computer (3) and remote diagnostic center (2) are both provided with Database Unit, data acquisition unit, state
Monitoring unit, dynamic balance calculation unit and analyzing and diagnosing unit；
The output pump unit is single group or multiple groups；
Output pump (8) front and back end horizontally and vertically on be equipped with detection vibration compound sensor (9), it is described
Detection vibration compound sensor (9) includes vibration acceleration sensor, temperature sensor, speed probe and pressure sensor,
It is a kind of while can detects amplitude, acceleration, temperature, revolving speed and pressure integrated special type compound sensor, it is anti-by ATEX
Quick-fried certification；Sensing element in compound sensor uses P5 piezoceramics crystal；The compound sensor can find and diagnose in time
Mass unbalance existing for output pump unit, initial bending, thermal flexure, leaf abscission, misalign, oil whip, steam flow excitation,
Electromagnetic exciting, friction, bearing shell loosens and resonance various faults situation；
Explosion-proof tank is provided on the collector (6).
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| CN108105081B (en) * | 2018-02-05 | 2023-10-27 | 中国石油化工股份有限公司 | Water injection pump unit fault diagnosis method and device |
| CN109538459B (en) * | 2018-10-17 | 2021-04-30 | 重庆川仪自动化股份有限公司 | Machine pump equipment fault monitoring operation and maintenance system and method based on networking |
| CN114353881B (en) * | 2022-03-18 | 2022-06-24 | 广东银纳增材制造技术有限公司 | Equipment abnormity monitoring method and system based on composite sensor |
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Effective date of registration: 20201118 Address after: 100007 Dongcheng District, Dongzhimen, China, North Street, No. 9 Oil Mansion, No. Patentee after: CHINA NATIONAL PETROLEUM Corp. Patentee after: CNPC CHUANQING DRILLING ENGINEERING Co.,Ltd. Address before: 710018 Shaanxi city of Xi'an province Changqing Changqing Park District Science and technology building is booming Patentee before: CNPC CHUANQING DRILLING ENGINEERING COMPANY LIMITED ENGINEERING TECHNOLOGY Research Institute Patentee before: XI'AN CHUANQIN PETROLEUM TECHNOLOGY Co.,Ltd. |
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