CN102288395B - Precipitator inner wing valve fault detection method based on acoustic emission signal power spectrum calculation - Google Patents
Precipitator inner wing valve fault detection method based on acoustic emission signal power spectrum calculation Download PDFInfo
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- 238000001228 spectrum Methods 0.000 title claims abstract description 83
- 239000012716 precipitator Substances 0.000 title claims abstract description 27
- 238000004364 calculation method Methods 0.000 title claims abstract description 18
- 238000001514 detection method Methods 0.000 title claims abstract description 17
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- 238000012545 processing Methods 0.000 claims description 6
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- XOFYZVNMUHMLCC-ZPOLXVRWSA-N prednisone Chemical compound O=C1C=C[C@]2(C)[C@H]3C(=O)C[C@](C)([C@@](CC4)(O)C(=O)CO)[C@@H]4[C@@H]3CCC2=C1 XOFYZVNMUHMLCC-ZPOLXVRWSA-N 0.000 abstract 2
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- 238000004458 analytical method Methods 0.000 description 4
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- 238000004523 catalytic cracking Methods 0.000 description 3
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- 238000012544 monitoring process Methods 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
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- 230000003197 catalytic effect Effects 0.000 description 1
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Abstract
The invention discloses a precipitator inner wing valve fault detection method based on acoustic emission signal power spectrum calculation. The method comprises the following steps of: employing an acoustic emission technique, receiving an acoustic emission signal which is produced by the inner wing valve of a precipitator in a normal or abnormal working state at any moment i by means of an acoustic signal detector, obtaining an acoustic emission signal power spectrum by performing progressive average fast Fourier transform on the acoustic emission signal a plurality of times, and calculating the average energy Ei of the acoustic emission signal power spectrum, working out a relative offset delta E by comparing the average energy Ei with the average energy E0 of the acoustic emission signal power spectrum obtained through calculation in a reference state, and then determining whether a fault occurs to the inner wing valve of the precipitator by comparing delta E with a critical value to find out which one is bigger relatively. According to the technical scheme adopted by the invention, the working state of the inner wing valve of the precipitator can be detected conveniently and accurately in a real-time and on-line manner, and the method provided by the invention is applicable to industrial production.
Description
Technical field
The present invention relates to the acoustic emission detection field, relate in particular to a kind of precipitator inner wing valve fault detection method based on the acoustic emission signal spectra calculation.
Background technology
In catalytic cracking unit, cyclone separator is gas solid separation and the equipment that reclaims catalyzer, and the quality of its version, installation accuracy and operating conditions has directly affected internal circulating load and the separation efficiency of catalyzer.Wherein, flutter valve is an important component part of cyclone separator, and it is positioned at settler internal cyclone separators dipleg exit, is comprised of straight tube and inclined tube two parts with the dipleg equal diameters.The inclined tube port is smooth, smooth, seals with the flap plate, and the flap plate is hung on the round and smooth suspension ring of processing, and protective cover is equipped with in the outside, and its effect is the impact that protection flap plate is not subjected to bed.The effect of flutter valve is that the catalyzer in the dipleg can be flowed out smoothly, prevent that gas from altering, the joint that slows down dipleg gushes effect, stablize density and the reserve of catalyzer in the dipleg, thereby the organic efficiency of assurance cyclone separator (Liu Zongliang. [J] inquired in the design of fluidized catalytic cracker cyclone separation system. the petrochemical equipment technology, 1988,6:45-60).
Flutter valve has the characteristics of quantitative convey materials, and it is conducted oneself with dignity by the flap plate and closes.The static pressure that produces when the dipleg inner catalyst surpasses when opening the required pressure of flap plate, and the flap plate is opened catalyzer is flowed out.When the static pressure that produces when the dipleg inner catalyst was not enough to overcome this pressure, sealing is closed and formed to flutter valve, prevents that gas from altering.When catalyzer washes away flutter valve flap plate continuously, can cause the wearing and tearing of flap plate, when serious even can worn out flap plate, make flutter valve lose sealing function, thereby cause catalyzer to run in a large number damage, have a strong impact on the work efficiency of cyclone separator and the processing power of catalytic cracking unit, finally cause factory's parking maintenance.Therefore, to flutter valve carry out in real time, accurate fault detect for steady production, to improve the factory economy benefit significant.
At present, judgement to the flutter valve working condition can be by carrying out sizing analysis to system's inner catalyst, perhaps the pressure drop according to cyclone separator reflect (red. the work condition abnormality analysis of causes of reactor internal cyclone separators and solution [J]. the petrochemical equipment technology, 2000,21(5): 12-14).Catalyzer is carried out sizing analysis, can the working condition of flutter valve and dipleg be judged to a certain extent, but accuracy is not high, for manometry, because the cyclone separator pressure tap is limited and the position is fixed, and organize cyclone separator more and usually only one group of cyclone separator is wherein arranged pressure tap, so other working conditions of respectively organizing cyclone separator often can't be judged.In addition, by the catalyst attrition numerical quantity is analyzed also can judge the precipitator inner wing valve working condition (Zhang Xinguo, Dan Lianzheng. the application [J] of flutter valve in catalytic cracking unit. the petrochemical equipment technology, 2000,21(4): 11-22).But generally, only have when cyclone separator and damage or dipleg flutter valve when not normal, just can cause the rapid increase of catalyst attrition, so the method has obvious hysteresis quality, can't before device fails, carry out in time early warning.
The present invention adopts acoustic emission that the working condition of flutter valve is diagnosed.Acoustic emission testing technology has flow field, the characteristics such as real-time, convenient of not invading, can comparatively accurately carry out detecting ﹠ monitoring to the flutter valve working condition, the flutter valve fault is in time carried out early warning, this to stability of improving cyclone separator work efficiency, ensuring equipment running, avoid stopping significant.
Summary of the invention
The objective of the invention is to overcome the deficiencies in the prior art, a kind of precipitator inner wing valve fault detection method based on the acoustic emission signal spectra calculation is provided.
Step based on the precipitator inner wing valve fault detection method of acoustic emission signal spectra calculation is as follows:
1) when flutter valve is in normal operating conditions, receive the acoustic emission signal that the flutter valve folding produces by the acoustic emission signal receiving trap that is installed on the settler outside wall surface, and as the acoustic emission signal with reference to state;
2) according to the acoustic emission signal that receives under the reference state, calculate the average energy of acoustic emission signal power spectrum under the power spectrum of acoustic emission signal and the reference state
E 0
3) at any time
i, the acoustic emission signal receiving trap that is in same position by being installed in settler wall and reference state receives the acoustic emission signal that the flutter valve folding produces;
4) according to step 3) in the acoustic emission signal that receives, calculate any time
iThe average energy of the power spectrum of acoustic emission signal and this moment acoustic emission signal power spectrum
E i
5) if at any time
iThe average energy of the acoustic emission signal power spectrum that calculates
E i Average energy with the acoustic emission signal power spectrum that calculates under the reference state
E 0 Relative deviation
△ EGreater than a certain critical value, judge that then fault has occured in precipitator inner wing valve work; Otherwise then flutter valve works well.
The average energy of described acoustic emission signal power spectrum
E 0 With
E i Calculation procedure comprise: at first acoustic emission signal is carried out normalized, then the acoustic emission signal power spectrum is carried out repeatedly the fast fourier transform of progressive mean, wherein repeatedly the number of times of progressive mean is sample frequency and chooses at every turn and carry out the ratio that the fast fourier transform processing is counted, obtain the acoustic emission signal power spectrum, calculate at last the mean value of having a few in the acoustic emission signal power spectrum.
The position that described acoustic emission signal receiving trap is located on the settler outer wall is the wall radial position that is in sustained height with flutter valve flap plate.
Described any time
iAcoustic emission signal refer to obtaining with same sample frequency with reference state under the normal or improper operating condition of flutter valve.
Described settler is that the catalyst solid particle is at the settler of interior motion.
Described relative deviation
△ EBe: any time
iThe average energy of acoustic emission signal power spectrum
E i Average energy with acoustic emission signal power spectrum under the reference state
E 0 Difference, with the average energy of acoustic emission signal power spectrum under the reference state
E 0 The ratio percent; The span of described critical value is 25%～35%.
The present invention compared with prior art has following advantage:
1) for any time the precipitator inner wing valve fault detection all have degree of precision, can reflect the working condition of precipitator inner wing valve in real-time online ground, and can carry out timely early warning to the flutter valve fault;
2) based on the calculation and comparision of acoustic emission power spectrum characteristic peak frequency, the flutter valve fault detection method that the present invention proposes has preferably adaptability, namely the operating mode for different internal circulating loads only need change with reference to acoustic emission power spectrum characteristic peak frequency, just can reach higher precision, have stronger adaptive faculty;
3) acoustic emission testing technology has the characteristics of real-time online, safety and environmental protection, convenient sensitivity, is a kind of Dynamic Non-Destruction Measurement of non-intrusion type, does not need emissive source;
4) the present invention can carry out on-line analysis exactly to precipitator inner wing valve working condition in fluid catalytic cracking (FCC) technique, variation for the flutter valve folding cycle can reflect delicately, and is significant for the long-term stability operation of keeping cyclone separator and package unit.
Description of drawings
Fig. 1 is the flutter valve structural representation;
Fig. 2 is flutter valve acoustic emission signal power spectrum chart under the reference state;
Acoustic emission signal power spectrum chart when Fig. 3 is the flutter valve normal operation;
Fig. 4 is flutter valve flap plate acoustic emission signal power spectrum chart can not seal the time;
Fig. 5 is that flutter valve is at any time in embodiment 1 cold model unit
iThe average energy of acoustic emission signal power spectrum
E i Average energy with acoustic emission signal power spectrum under the reference state
E 0 Relative deviation
△ E
Fig. 6 is that flutter valve is at any time in embodiment 2 certain factory's commercial plant
iThe average energy of acoustic emission signal power spectrum
E i Average energy with acoustic emission signal power spectrum under the reference state
E 0 Relative deviation
△ E
Embodiment
Step based on the precipitator inner wing valve fault detection method of acoustic emission signal spectra calculation is as follows:
1) when flutter valve is in normal operating conditions, receive the acoustic emission signal that the flutter valve folding produces by the acoustic emission signal receiving trap that is installed on the settler outside wall surface, and as the acoustic emission signal with reference to state;
2) according to the acoustic emission signal that receives under the reference state, calculate the average energy of acoustic emission signal power spectrum under the power spectrum of acoustic emission signal and the reference state
E 0
3) at any time
i, the acoustic emission signal receiving trap that is in same position by being installed in settler wall and reference state receives the acoustic emission signal that the flutter valve folding produces;
4) according to step 3) in the acoustic emission signal that receives, calculate any time
iThe average energy of the power spectrum of acoustic emission signal and this moment acoustic emission signal power spectrum
E i
5) if at any time
iThe average energy of the acoustic emission signal power spectrum that calculates
E i Average energy with the acoustic emission signal power spectrum that calculates under the reference state
E 0 Relative deviation
△ EGreater than a certain critical value, judge that then fault has occured in precipitator inner wing valve work; Otherwise then flutter valve works well.
The average energy of described acoustic emission signal power spectrum
E 0 With
E i Calculation procedure comprise: at first acoustic emission signal is carried out normalized, then the acoustic emission signal power spectrum is carried out repeatedly the fast fourier transform of progressive mean, wherein repeatedly the number of times of progressive mean is sample frequency and chooses at every turn and carry out the ratio that the fast fourier transform processing is counted, obtain the acoustic emission signal power spectrum, calculate at last the mean value of having a few in the acoustic emission signal power spectrum.
The position that described acoustic emission signal receiving trap is located on the settler outer wall is the wall radial position that is in sustained height with flutter valve flap plate.
Described any time
iAcoustic emission signal refer to obtaining with same sample frequency with reference state under the normal or improper operating condition of flutter valve.
Described settler is that the catalyst solid particle is at the settler of interior motion.
Described relative deviation
△ EBe: any time
iThe average energy of acoustic emission signal power spectrum
E i Average energy with acoustic emission signal power spectrum under the reference state
E 0 Difference, with the average energy of acoustic emission signal power spectrum under the reference state
E 0 The ratio percent; The span of described critical value is 25%～35%.
Employing has the FCC catalyzer of certain coke content, operates according to the method described above, and flutter valve can not seal flutter valve by fixing its flap plate after normal operation a period of time.Fig. 1 is the structural representation of flutter valve that device is installed.Fig. 2 is the acoustic emission signal power spectrum that the acoustic emission signal of the normal folding generation of flutter valve under the reference state calculates.As shown in Figure 2, when flutter valve was in normal operating conditions, the acoustic emission signal that the flutter valve folding produces belonged to low frequency signal, and its frequency should be positioned at the scope of 0～50 kHz.Fig. 3 and Fig. 4 are reaching the acoustic emission signal power spectrum chart that receives under the not complete hermetic abnormal operating state of flap plate under the flutter valve normal operating conditions.As shown in Figure 4, when flutter valve breaks down owing to the flap plate can't normally seal, catalyzer can run in a large number and decrease, receive the acoustic emission signal obtain this moment and be mainly and run the high-frequency signal that the catalyst granules bump wall that decreases produces, the frequency of its characteristic peak is by character decisions such as the particle diameter of settler wall characteristic and catalyst granules itself, density, elastic modulus.When flutter valve worked, the acoustic emission signal that the folding of flutter valve own produces concentrated on the low frequency frequency range of power spectrum, and signal is relatively stable, the acoustic emission signal power spectrum that obtains during from the flutter valve fault compare on the frequency range of signal and intensity, all have different.Hence one can see that, the different operating state of the inner flutter valve of settler with the different motion Determines of catalyst granules the characteristic peak of acoustic emission signal power spectrum distribute, can judge tentatively according to different characteristic peak positions and energy intensity whether settler inside flutter valve works well.
The average energy of flutter valve acoustical signal power spectrum under the computing reference state
E 0 , it as with reference to value, is calculated arbitrarily again
iThe average energy of moment flutter valve acoustical signal power spectrum
E i , calculate any time at last
iThe average energy of flutter valve work acoustical signal power spectrum
E i Average energy with acoustical signal power spectrum under the reference state
E 0 Relative deviation
△ E, as shown in Figure 5.As shown in Figure 5, reached the later on average energy of flutter valve acoustical signal power spectrum on the 8th minute
E i Average energy with acoustical signal power spectrum under the reference state
E 0 Relative deviation
△ EAll greater than 30%, and moment of being fixed of corresponding flutter valve flap plate just in time this moment.By experimental result as can be known, when detecting
△ EDuring greater than critical value 30%, illustrate that flutter valve work breaks down, otherwise illustrate that then flutter valve is working properly.
In sum, acoustic emission can be carried out fault diagnosis to flutter valve, and its working condition is carried out real time and on line monitoring, to avoid decreasing the parking loss that causes owing to the wearing and tearing of flutter valve flap valve plate, catalyzer run in a large number.In addition, can also further extrapolate the efficient of cyclone separator and the internal circulating load of catalyzer according to the flutter valve folding cycle that detection obtains, this control for technological parameter also has certain directive significance with adjustment.
Embodiment 1
Utilize acoustic emission on the cold model unit of laboratory, the flutter valve working condition to be detected.Settler is made by transparent organic glass, high 1500 mm, internal diameter 450 mm, the flutter valve structure as shown in Figure 1, acoustic emission signal adopts the acoustic measurement instrument to gather.Wherein the acoustic measurement instrument comprises sound wave receiving trap, multiplying arrangement, signal pickup assembly and signal processing apparatus.Calibrate AE sensor places on the settler wall, is in sustained height with flutter valve flap plate, sample frequency 300 kHz, and enlargement factor is 10, sampling interval time 1 min, each sampling times 10 s.The FCC catalyzer that the experiment catalyst system therefor provides for certain factory, mean grain size is 102.3 μ m.
At first receive the acoustic emission signal under the reference state, the signal that reception is obtained carries out repeatedly the Fast Fourier Transform (FFT) of progressive mean, obtains acoustic emission signal power spectrum chart (Fig. 2), the acoustical signal power spectrum average energy under the computing reference state
E 0 Then receive respectively constantly different
iCorresponding acoustic emission signal is carried out repeatedly respectively the Fast Fourier Transform (FFT) of progressive mean, obtains different acoustic emission signal power spectrum charts constantly, and calculates respectively acoustical signal power spectrum average energy
E i Wherein, front 7 minutes is the flutter valve normal operating conditions, and the fixing flutter valve flap plate since the 8th minute can not seal it.Calculate at last any time i acoustical signal power spectrum average energy
E i With acoustical signal power spectrum average energy under the reference state
E 0 Relative deviation
△ E(Fig. 5), judge whether flutter valve is in normal operating conditions.Find relative deviation under the normal condition by calculating
△ EAll in 30%, determine that thus the critical value of experimental system acoustical signal energy relative deviation is 30%.As shown in Figure 5, the measurement point relative deviation in front 7 minutes is less,
△ E＜30%, this moment, flutter valve was in normal operating conditions; Measurement point relative deviation in the 8th～15 minute is larger,
△ E30%, illustrate that precipitator inner wing valve work breaks down, cause acoustic emission signal to change.
Embodiment 2
Utilize acoustic emission on certain factory's industry FCC apparatus, the precipitator inner wing valve working condition to be detected.Settler has the cyclone separator of three groups of same model and size, and along circumferentially evenly distributing, the sustained height of cyclone separator bottom is equipped with flutter valve, three in normal operation in turn foldings of flutter valve.Acoustic emission signal adopts the acoustic measurement instrument to measure, wherein the acoustic measurement instrument comprises acoustic emission signal receiving trap, multiplying arrangement, signal pickup assembly and treating apparatus, sample frequency 300 kHz, and enlargement factor is 1, sampling interval is 15 min, and each sampling time is 10 s.
Size composition according to cyclone separator outlet catalyzer judges whether settler is in normal operating conditions, receive simultaneously the acoustic emission signal in this moment, the acoustic emission signal that reception obtains is passed through first normalized, carry out repeatedly again the Fast Fourier Transform (FFT) of progressive mean, obtain the acoustical signal power spectrum in this moment, calculate acoustical signal power spectrum average energy, and with reference state under the average energy of acoustical signal power spectrum
E 0 Relatively, obtain relative deviation
△ EIf
△ E＜30%, then precipitator inner wing valve is in normal operating conditions; If
△ E30%, the precipitator inner wing valve running is broken down.
As shown in Figure 6, from 2009-12-20 15:39, relative deviation
△ EBegin to increase and surpass 30%, illustrate that flutter valve running is arranged in the settler is undesired, and the size composition result of cyclone separator outlet catalyzer shows that settler inner catalyst particle diameter becomes large, i.e. flutter valve work is broken down, and proves that thus acoustic emission can detect the flutter valve working condition comparatively exactly.
Claims (6)
1. precipitator inner wing valve fault detection method based on the acoustic emission signal spectra calculation is characterized in that its step is as follows:
1) when flutter valve is in normal operating conditions, receive the acoustic emission signal that the flutter valve folding produces by the acoustic emission signal receiving trap that is installed on the settler outside wall surface, and as the acoustic emission signal with reference to state;
2) according to the acoustic emission signal that receives under the reference state, calculate the average energy of acoustic emission signal power spectrum under the power spectrum of acoustic emission signal and the reference state
E 0
3) at any time
i, the acoustic emission signal receiving trap that is in same position by being installed in settler wall and reference state receives the acoustic emission signal that the flutter valve folding produces;
4) according to step 3) in the acoustic emission signal that receives, calculate any time
iThe average energy of the power spectrum of acoustic emission signal and this moment acoustic emission signal power spectrum
E i
5) if at any time
iThe average energy of the acoustic emission signal power spectrum that calculates
E i Average energy with the acoustic emission signal power spectrum that calculates under the reference state
E 0 Relative deviation
△ EGreater than a certain critical value, judge that then fault has occured in precipitator inner wing valve work; Otherwise then flutter valve works well.
2. a kind of precipitator inner wing valve fault detection method based on the acoustic emission signal spectra calculation according to claim 1 is characterized in that: the average energy of described acoustic emission signal power spectrum
E 0 With
E i Calculation procedure comprise: at first acoustic emission signal is carried out normalized, then acoustic emission signal is carried out repeatedly the fast fourier transform of progressive mean, wherein repeatedly the number of times of progressive mean is sample frequency and chooses at every turn and carry out the ratio that the fast fourier transform processing is counted, obtain the acoustic emission signal power spectrum, calculate at last the mean value of having a few in the acoustic emission signal power spectrum.
3. a kind of precipitator inner wing valve fault detection method based on the acoustic emission signal spectra calculation according to claim 1, it is characterized in that: the position that described acoustic emission signal receiving trap is located on the settler outer wall is the wall radial position that is in sustained height with flutter valve flap plate.
4. a kind of precipitator inner wing valve fault detection method based on the acoustic emission signal spectra calculation according to claim 1 is characterized in that: described any time
iAcoustic emission signal refer to obtaining with same sample frequency with reference state under the normal or improper operating condition of flutter valve.
5. a kind of precipitator inner wing valve fault detection method based on the acoustic emission signal spectra calculation according to claim 1, it is characterized in that: described settler is that the catalyst solid particle is at the settler of interior motion.
6. a kind of precipitator inner wing valve fault detection method based on the acoustic emission signal spectra calculation according to claim 1 is characterized in that: described relative deviation
△ EBe: any time
iThe average energy of acoustic emission signal power spectrum
E i Average energy with acoustic emission signal power spectrum under the reference state
E 0 Difference, with the average energy of acoustic emission signal power spectrum under the reference state
E 0 The ratio percent; The span of described critical value is 25%～35%.
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| CN106814136A (en) * | 2015-11-27 | 2017-06-09 | 北京声华兴业科技有限公司 | A kind of on-line fault monitoring method for high pressure apparatus top hammer |
| CN109297864B (en) * | 2018-10-08 | 2020-10-27 | 浙江大学 | Detection method of sticky particle fluidized bed |
| CN111855491B (en) * | 2019-04-28 | 2023-08-22 | 中国石油化工股份有限公司 | Method and device for detecting flow state of polymer melt |
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| CN1253620A (en) * | 1994-04-26 | 2000-05-17 | Cytec技术有限公司 | Settling process analysis device and method |
| DE19924377B4 (en) * | 1999-05-27 | 2004-12-02 | Siemens Ag | Diagnostic system for a valve actuated by a positioner via a drive |
| DE19947129A1 (en) * | 1999-09-30 | 2001-04-05 | Siemens Ag | Diagnosis system, especially for control |
| DE10218830C1 (en) * | 2002-04-26 | 2003-12-18 | Siemens Ag | Diagnostic system and method for a valve |
| US7387018B2 (en) * | 2006-11-17 | 2008-06-17 | Gm Global Technology Operations, Inc. | Discrete variable valve lift diagnostic systems and methods |
| CN201740632U (en) * | 2010-08-11 | 2011-02-09 | 长沙理工大学 | Leakage fault diagnosing apparatus for high temperature and high pressure valves by using acoustic emission signals |
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