CN106438395A - Mining centrifugal pump on-line accelerated life test platform and test method thereof - Google Patents

Abstract

An online accelerated life test platform for mining centrifugal pumps and its test method. The test platform adopts a double-cycle measurement isolation pipeline structure, including a centrifugal pump accelerated life cycle pipeline and a centrifugal pump health performance measurement pipeline, and is monitored by the site The system structure is composed of the combination of the monitoring system and the remote monitoring system of the control computer; the test method automatically completes the accelerated life test of the centrifugal pump, draws the characteristic curve of the centrifugal pump remotely, and stores the healthy life information of the centrifugal pump. The invention has comprehensive monitoring parameters and a reasonable structure, effectively monitors the life cycle data of the centrifugal pump during the failure process, and protects other components such as sensors and pipelines from being eroded, laying a foundation for obtaining accelerated life data of the centrifugal pump.

Description

On-line accelerated life test platform and test method for mining centrifugal pump

technical field

The invention relates to an online centrifugal pump test platform and a test method thereof, in particular to a centrifugal pump accelerated life test platform for online measurement and a test method thereof.

Background technique

Centrifugal pump is a kind of rotating mechanical equipment widely used in industrial drainage, and it plays an important role in many industries such as electric power, mining, chemical industry, and agriculture. When the centrifugal pump transports the fluid medium, due to the erosion of the particles and impurities in the medium, the blades of the centrifugal pump will wear to a certain extent, which will eventually lead to the failure of the centrifugal pump. In order to reduce the economic losses and potential safety hazards caused by unexpected failure of centrifugal pumps, it is necessary to establish a condition-based maintenance system for centrifugal pumps. The basis for realizing condition-based maintenance of centrifugal pumps is to grasp its failure laws and understand its characteristic parameters at the time of failure, so as to predict its failure time and evaluate its effective remaining life. However, at present, the failure data of centrifugal pumps is not comprehensive. Most of the centrifugal pump failures develop rapidly, and the monitoring parameters of equipment on the job site are few and cannot fully reflect the failure characteristics; There is a certain difference with the failure process of the actual centrifugal pump, and the artificial fault points are relatively discrete and do not have continuous fault characteristics. At present, there is an urgent need to accelerate the life failure process of the centrifugal pump impeller wear fault, monitor its flow, pressure, vibration and current and other signals throughout the whole process, and obtain the fault information of its entire life, which will be used for the subsequent feature extraction and life management algorithm. Research lays the groundwork.

Contents of the invention

The purpose of the present invention is to provide a mining centrifugal pump online accelerated life test platform and its test method, which is used for the failure aging test of the centrifugal pump, obtains the failure sensor information of the centrifugal pump, and provides data for the fault diagnosis and life evaluation of the centrifugal pump support.

The technical scheme for realizing the object of the present invention is as follows.

An online accelerated life test platform for mining centrifugal pumps, characterized in that: the centrifugal pump accelerated life test platform is composed of a double-cycle measurement isolation pipeline structure and a monitoring and monitoring system;

The double-cycle measurement isolation pipeline structure includes a centrifugal pump, a sand tank, a clean water tank, a positive pressure gauge, a negative pressure gauge, a flow meter and a valve; wherein:

The centrifugal pump connects with the sand tank through valve Ⅲ to extract the sediment water in the sand tank, and sends the sediment water into the sand tank through valve V4 and valve V5 to form an accelerated life circulation pipeline;

The centrifugal pump is connected to the clean water tank through the valve V1 to extract the clean water in the clean water tank, and sends the clean water into the clean water tank through the valve V2, the flow meter and the valve V5 to form a measurement circulation pipeline;

The positive pressure gauge is installed at the outlet of the centrifugal pump, and the negative pressure gauge is installed at the water inlet of the centrifugal pump; the positive pressure gauge, negative pressure gauge and flowmeter are used to measure the pressure and flow hydraulic parameters of the centrifugal pump when circulating clean water on the accelerated life platform;

The monitoring and monitoring system includes a tachometer, a current transformer, a voltage transformer, an acceleration sensor, a low-frequency data collector, a high-frequency data collector, a field controller, a display operation panel and a control computer; wherein:

The low-frequency data collector is connected with the positive pressure meter, negative pressure meter, flow meter and tachometer to collect low-frequency data signals during the accelerated life of the centrifugal pump; the high-frequency data collector is connected with the current transformer, voltage transformer and acceleration sensor, Collect the current, voltage and vibration signals during the operation of the centrifugal pump; the on-site controller is connected with the valves V1~V5 and the centrifugal pump to control the start and stop of the centrifugal pump and the valve switch; the display operation panel and the low-frequency data collector and high-frequency data collector It is connected to the acceleration sensor to display the collected data and the action of the centrifugal pump and valve; the control computer is connected to the low-frequency data collector, high-frequency data collector and acceleration sensor to remotely display the operating conditions of the centrifugal pump, realize remote monitoring, and store the collected data. data.

In the above technical solution, further technical features are as follows.

The flowmeter is arranged on the lowest level pipeline of the concave pipeline, and the concave pipeline is 5 times or 7 times larger than the straight pipeline.

The sand-water component of the sand water tank is quartz sand, the particle size of the quartz sand is 2-4 mesh, and the sand-water mixing ratio is 1:2.

The control computer is connected to the on-site controller and the data collector via Ethernet, displays the sensor data transmitted by the data acquisition unit in real time, and stores it in the hard disk of the computer, and at the same time remotely sends operation commands to the on-site controller to perform remote operations.

The field controller is a kind of PLC programmable device, which executes the commands issued by the buttons, and automatically switches the pipelines and switches the valves according to the pipeline conditions, and collects low-frequency sensor data at the same time, and uploads them to the control computer through Ethernet.

The core devices of the low-frequency data collector and the high-frequency data collector are acquisition cards or PLC devices capable of data collection, and the sampling frequency of the high-frequency data collector is at least 10 kHz.

The on-site controller includes a centrifugal pump start-stop button, a pipeline switching button, an adjustment knob for the opening of the total outlet regulating valve, a measurement button and an alarm buzzer; wherein, the measurement button is to automatically operate the opening of the total outlet regulating valve, and record The real-time flow and pressure are transmitted to the control computer to fit the real-time characteristic curve of the centrifugal pump; the on-site controller judges whether the current centrifugal pump is working normally according to the sensor information, and sends an alarm through the buzzer.

A test method for the online accelerated life test platform of a mining centrifugal pump provided above, the sand water tank in the accelerated life test circulation pipeline in the test method is a sand water mixed fluid, which is used to accelerate the centrifugal pump. Pump wear; the medium in the clean water tank in the measurement circulation pipeline is clean water, which is used to measure the hydraulic performance of the centrifugal pump. When the life of the centrifugal pump is accelerated, the medium is controlled by the valve to make the medium flow in the sand water tank; when measuring the centrifugal When the pump is performing, control the valve, switch the pipeline, and use the clean water in the clean water tank to realize the hydraulic performance test.

Wherein, in the test method, when measuring the characteristic curve of the centrifugal pump, the valve V1 and the valve V2 are opened, and the valve V3 and the valve V4 are closed; the accelerated life test platform runs on the "measurement circulation pipeline" and circulates the clean water in the clean water tank; By adjusting the opening of the valve V5, a series of P2, P1 and Q are measured, and the characteristic curve of the centrifugal pump is drawn according to the formula;

When the centrifugal pump is accelerated to failure, the valve V1 and valve V2 are closed, and the valve V3 and valve V4 are opened; the accelerated life test platform runs on the "accelerated life test circulation pipeline", and the sand-water mixed fluid in the sand water tank circulates through the The erosion of the centrifugal pump by the sandy water in the sand tank accelerates the failure process of the centrifugal pump.

Compared with the prior art, the above-mentioned technical solution of the present invention has the following advantages and positive effects.

The main purpose of the present invention is to accelerate the failure process of the centrifugal pump, and simultaneously measure the characteristic curve and working condition information of the centrifugal pump in each stage of the failure process. The test platform or device in the prior art is mainly for the initial characteristic curve of the centrifugal pump Testing and recording, or mainly testing the hydraulic performance of centrifugal pumps, does not involve accelerated failure or accelerated life research of centrifugal pumps. The present invention can not only test the initial characteristic curve of centrifugal pumps, but also accelerate the failure process of centrifugal pumps. Its characteristic curves at different stages, so as to obtain the health data of the centrifugal pump failure process.

The invention adopts a double-cycle measurement isolation pipeline structure, the acceleration pipeline and the measurement pipeline are independent of each other, and are connected to the centrifugal pump at the same time, so that the characteristic curve and working condition information of the centrifugal pump can be measured online while accelerating the failure process of the centrifugal pump , prevent accelerated sand water from eroding the sensor, and also prevent sandy water from clogging the pipeline at the elbow section of the flowmeter.

The present invention collects comprehensive sensing data during the test process, including not only the necessary flow rate, positive pressure, negative pressure and rotational speed for measuring characteristic curves, but also vibration data, voltage and current data, in which voltage and current are not only effective for collecting Instead, use a high-speed acquisition card to collect the waveforms of three-phase voltage and three-phase current, analyze the power quality of the centrifugal pump, and store the change data of the power quality of the centrifugal pump during the failure process.

The present invention has on-site control, and controls the start-stop, pipeline switching and valve opening of the centrifugal pump on site through the manual control button. At the same time, the on-site controller has a man-machine interface, which can display the current working condition information of the centrifugal pump in real time. The on-site controller samples PLC as the main control unit, which can automatically switch pipelines, start and stop water pumps according to the sensor information, and can alarm through the buzzer when an unexpected situation occurs.

The data acquisition unit of the present invention adopts the scheme of combining PLC and acquisition card, divides sensor signals into low-frequency signals and high-frequency signals, uses different components to collect data, ensures the accuracy of data collection, and reduces the cost of the data acquisition unit.

The field controller of the present invention is connected to the control computer through the Ethernet, and the data collected by the data acquisition unit is uploaded to the control computer for display and storage. The control computer can display the working conditions of the centrifugal pump in real time through the Ethernet, and can remotely operate the test platform without testing. The personnel monitor the operation status of the centrifugal pump in real time on site, effectively improve the test management mode, reduce the work intensity of the test personnel, and improve the test work efficiency.

The control computer of the present invention draws the characteristic curve according to the sensor information collected by the data acquisition unit, and fits the characteristic curve equation of the centrifugal pump, and provides the confidence interval of the characteristic curve equation. Most of the prior art can draw the centrifugal pump The characteristic curve equation, but the confidence interval of the data cannot be given. The present invention can realize the display of the current characteristic curve and the corresponding confidence interval of the centrifugal pump, so that the test personnel can judge the reliability of the current working condition data of the centrifugal pump.

Description of drawings

Fig. 1 is a schematic diagram of the flat structure of the accelerated life test of the mine centrifugal pump of the present invention.

Fig. 2 is a flow chart of the accelerated life test of the centrifugal pump of the present invention.

In the figure: 1: Centrifugal pump; 2: Sand water tank; 3: Clean water tank; 4: Positive pressure gauge; 5: Negative pressure gauge; 6: Flowmeter; 7: Speedometer; 8: Current transformer; 10: acceleration sensor; 11: low frequency data collector; 12: high frequency data collector; 13: field controller; 14: display operation screen; 15: control computer.

Valve V1; valve V2; valve V3; valve V4; regulating valve V5.

detailed description

The specific embodiments of the present invention will be described in detail below in conjunction with the accompanying drawings. After reading this specific embodiment, those skilled in the art can realize the technical solutions described in the present invention, and can also embody the advantages and advantages of the present invention. positive effect.

As shown in accompanying drawing 1, implement a kind of on-line centrifugal pump accelerated life test platform provided by the present invention above, the test pipeline part of the system adopts the double cycle measurement isolation pipeline structure, including main pipeline, accelerated life management and measuring tube road.

The accelerated life pipeline is composed of sand water tank 2, sand water tank inlet valve V4, and sand water tank outlet valve V3; the measurement pipeline is composed of clean water tank 3, clean water tank inlet valve V2, clean water tank outlet valve V1 and flowmeter; the main pipe is composed of a centrifugal pump, positive It consists of a pressure gauge, a negative pressure gauge and a total outlet regulating valve. The accelerated life pipeline is connected with the uniform main pipeline of the measuring pipeline, and different circulation pipelines are switched through valves. The sand water tank is equipped with a 1:2 mixed medium of quartz sand and water, and the accelerated life pipeline has no concave and bent pipelines in its pipeline, so as to avoid the deposition of sand-water mixed medium to block the pipeline. The flowmeter in the measurement pipeline is located in the concave section of the pipeline, and there are straight pipes 7 times and 5 times the diameter of the pipeline at the front and rear respectively to ensure the accuracy of the flowmeter measurement. In order to prevent the flowmeter from being abraded by sandy water, a non-contact electromagnetic flowmeter is used to measure the pipeline flow.

When measuring the characteristic curve of the centrifugal pump, the valves V1 and V2 are opened, and the valves V3 and V4 are closed. The accelerated life test platform runs on the "measurement circulation pipeline" to circulate the clean water in the clean water tank T1. By adjusting the opening of V5, a series of P2, P1 and Q are measured, and the characteristic curve of the centrifugal pump is drawn according to the following formula;

In the formula, ρ is the fluid density, kg/m ³ ; h ₀ is the height difference between the pressure gauge and the negative pressure gauge, m; P ₂ and P ₁ are the pressures at the inlet and outlet of the pump, Pa; u ₂ and u ₁ are respectively The flow velocity of the pump inlet and outlet, m/s; because the two-section pipeline of the centrifugal pump is very short, the square difference of the flow velocity is very small, so it can be ignored.

When the centrifugal pump is accelerated to failure, the valves V1 and V2 are closed, and V3 and V4 are opened. The accelerated life test platform runs on the "accelerated life test circulation pipeline", and the sand-water mixed fluid in the circulating sand water tank (2) passes through The erosion of the centrifugal pump by the sandy water in the sand tank accelerates the failure process of the centrifugal pump.

Through the method of double-cycle measurement isolation, the conditions of the pipeline and sensor for each measurement remain unchanged, and only the centrifugal pump and the accelerated wear pipeline are worn, thereby ensuring accuracy and preventing the existence of the elbow section of the pipeline, causing pipeline damage The road is blocked.

As shown in Figure 1, this centrifugal pump life acceleration platform adopts a two-level network structure, with PLC and high-speed acquisition card as the core. connection, the PLC mainly realizes the control of the on-site controller and the collection of information from the low-frequency sensor, and the acquisition card is connected with the acceleration sensor, the three-phase Hall voltage sensor and the three-phase Hall current sensor. In this embodiment, the PLC adopts Siemens S7-200 Type PLC, the acquisition card is NI 9234 high-speed acquisition card of NI Company, the PLC and the acquisition card are connected to the control computer through Ethernet, the control computer can store the real-time centrifugal pump health data uploaded by it, and can remotely issue the operation command of the test platform. In the present embodiment, the control computer software is developed on the platform of LabVIEW of NI Company, the man-machine interface and the PLC are connected by the RS-485 serial port, and the current health condition of the centrifugal pump is displayed on the spot in real time. The monitoring and monitoring system of the test platform of the present invention mainly Complete the following functions:

1) It can reliably collect low-frequency and large-lag signals such as pressure and flow, and realize the mapping of centrifugal pump characteristic curves;

2) It can regularly collect high-frequency signals such as vibration, current and voltage to meet the sampling frequency requirements;

3) It can realize the automatic control of the automatic start and stop of the water pump, the valve opening control, the pipeline switching and other operations, and automatically and regularly control the relevant valves to complete the point-by-point measurement of the characteristic curve;

4) It has the functions of liquid leakage alarm, emergency stop of water pump, etc., realizes local sound and light alarm, and can remotely alarm through the control computer;

5) It can automatically fit the curve of the collected data and display the characteristic curve of the centrifugal pump in real time;

6) Friendly human-computer interaction interface, convenient test operation, and equipped with a powerful database function, which can store all working condition data during the failure process of the centrifugal pump;

As shown in accompanying drawing 2, a kind of centrifugal pump accelerated life test platform test method provided above-mentioned of the present invention is as follows:

1) To determine the initial parameters of the life index of the centrifugal pump, before the accelerated life test of the centrifugal pump, the life index of the centrifugal pump in a healthy state should be measured, including: the characteristic curve of the centrifugal pump, the operating speed, the initial vibration spectrum and the power quality of the power supply .

2) Set the initial wear time interval t. The present invention is an online centrifugal pump accelerated life test platform. During the accelerated life test, the sensor needs to be isolated, and the characteristic curve and life related data of the centrifugal pump will be tested again after a certain time of acceleration. Therefore, The accelerated life time and the test interval t should be set.

3) According to the initial setting, the accelerated life test of the centrifugal pump is carried out, and the accelerated life time is determined according to the initial interval t.

4) Measure the mass of the impeller. It is difficult to measure the wear of the impeller by volume and shape, so the present invention provides the use of the measured mass to judge the wear degree of the impeller.

5) After the current impeller wear degree is completed, the health performance test of the centrifugal pump should be carried out to form the corresponding relationship between the current health data and the impeller wear.

6) According to the measured health data, judge whether the current centrifugal pump has reached the failure index. If the centrifugal pump has reached the failure index, stop the test and analyze the failure process of the centrifugal pump; According to the difference, the acceleration time interval t of the next acceleration life is determined according to the difference, and then the acceleration fails again until the centrifugal pump fails.

Claims (9)

1. a kind of online accelerated life test platform of mining centrifugal pump it is characterised in that：Described centrifugal pump accelerated life test is put down Platform is to be equipped with monitoring and controlling system by Two-way Cycle measurement isolation pipeline structure to constitute；

Described Two-way Cycle measurement isolation pipeline structure, including centrifugal pump（1）, sand water tank（2）, filtered water tank（3）, malleation meter（4）, negative Pressure meter（5）, effusion meter（6）With valve V1 ~ V5；Wherein：

Centrifugal pump（1）It is by valve III（V3）With sand water tank（2）Sand water tank is extracted in connection（2）In silt water, and through valve Silt water is sent into sand water tank by door V4 and valve V5（2）Constitute accelerated aging circulation line；

Centrifugal pump（1）It is by valve V1 and filtered water tank（3）Filtered water tank is extracted in connection（3）In clear water, and through valve V2, stream Gauge（6）With valve V5, clear water is sent into filtered water tank（3）Constitute measurement circulation line；

Malleation meter（4）It is installed on centrifugal pump（1）Outlet, depressimeter（5）It is installed on centrifugal pump（1）Water inlet；Malleation meter （4）, depressimeter（5）And effusion meter（6）During for accelerated aging platform loop clear water, measurement centrifugation pump pressure and flow waterpower are joined Number；

Described monitoring and controlling system, including tachoscope（7）, current transformer（8）, voltage transformer（9）, acceleration transducer （10）, low-frequency data harvester（11）, high-frequency data harvester（12）, field controller（13）, display operator control panel（14）And control Computer processed（15）；Wherein：

Low-frequency data harvester（11）With malleation meter（4）, depressimeter（5）, effusion meter（6）And tachoscope（7）Connect, collection centrifugation Pump（1）Low-frequency data signal during accelerated aging；High-frequency data harvester（12）With current transformer（8）, mutual induction of voltage Device（9）And acceleration transducer（10）Connect, gather centrifugal pump（1）Electric current in running, voltage and vibration signal；Scene Controller（13）With valve V1 ~ V5 and centrifugal pump（1）Connect the start and stop controlling centrifugal pump and valve switch；Display operator control panel（14） With low-frequency data harvester（11）, high-frequency data harvester（12）And acceleration transducer（10）Connect display gathered data and from Heart pump and valve event situation；Control computer（15）With low-frequency data harvester（11）, high-frequency data harvester（12）With plus Velocity sensor（10）Connect, remotely show Working Conditions of Centrifugal Injection Pumps, realize remote monitoring, and store gathered data.

2. the online accelerated life test platform of mining centrifugal pump according to claim 1 it is characterised in that：Described effusion meter （6）It is disposed on the floor level pipeline of matrix pipeline, and matrix pipeline is 5 times or 7 times of direct pipings.

3. the online accelerated life test platform of mining centrifugal pump according to claim 1 it is characterised in that：Described sand water tank （2）Sand water constituent be quartz sand, quartz sand particle size be 2 ~ 4 mesh, sand water mixing ratio be 1：2.

4. the online accelerated life test platform of mining centrifugal pump according to claim 1 it is characterised in that：Described control is counted Calculation machine（15）It is that Ethernet is connected with field controller data harvester, the sensor of displaying data in real-time collecting unit transmission Data, and be stored in computer hard disc, remotely send operational order to field controller simultaneously, execute remote operation.

5. the online accelerated life test platform of mining centrifugal pump according to claim 1 it is characterised in that：The control of described scene Device processed（13）It is one kind of PLC programming device, the instruction that executive button sends, and according to pipeline situation, automatic switching-over pipeline, Controlled valve, gathers low-frequency sensor data simultaneously, is uploaded to control computer by Ethernet.

6. the online accelerated life test platform of mining centrifugal pump according to claim 1 it is characterised in that：Described low frequency number According to harvester（11）With high-frequency data harvester（12）Core devices be the device that capture card or PLC have data acquisition ability Part, the sample frequency of high-frequency data harvester is at least 10kHz.

7. according to claim 1 or 5 the online accelerated life test platform of mining centrifugal pump it is characterised in that：Described existing Field controller（13）Including centrifugal pump start-stop button, pipeline switching push button, general export's control valve opening adjusting knob, measurement button And alarm buzzer；Wherein, measurement button is to be automatically brought into operation general export's control valve opening, and records real-time traffic and pressure, and It is transferred to control computer and simulate centrifugal pump（1）Real-time characteristic curve；Field controller（13）Sentenced according to sensor information Read current centrifugal pump（1）Whether normal work, by buzzer warning.

8. a kind of test method for the online accelerated life test platform of mining centrifugal pump as claimed in claim 1, described It is sand water fluid-mixing in the sand water tank in accelerated life test circulation line in test method, for accelerating centrifugal pump to grind Damage；The medium in filtered water tank in measurement circulation line is clear water, for measuring the hydraulic performance of centrifugal pump, when acceleration centrifugal pump During the life-span, by Valve controlling, it flows in sand water tank self-loopa to make medium；When measuring performance of centrifugal pump, control valve, cut Change pipeline, realize hydraulic performance test using the clear water in filtered water tank.

9. the test method of the online accelerated life test platform of mining centrifugal pump according to claim 8, described test side In method when measuring characteristic curve of centrifugal pump, valve V1 and valve V2 opens, and valve V3 and valve V4 closes；Accelerated life test Platform operates on " measurement circulation line ", circulates filtered water tank（3）Interior clear water；By the aperture of control valve V5, measure one Series P 2, P1 and Q, draw out centrifugal pump according to formula（1）Characteristic curve；

When to centrifugal pump（1）When carrying out accelerating to lose efficacy, valve V1 and valve V2 closes, and valve V3 and valve V4 opens；Accelerate the longevity Life test platform operates on " accelerated life test circulation line ", recirculation system sand water tank（2）Interior sand water fluid-mixing, by sand Water tank（2）In the erosion to centrifugal pump for the water containing sand, accelerate centrifugal pump failure procedure.