摘要
随着流程工业快速发展及工艺过程复杂程度的不断增加,作为核心装备的热交换器存在有效故障早期预警难的问题。以管壳式热交换器为例,提出一种针对热交换器故障早期预警的新方法。该方法基于工艺流体温度、压力、流量等易测量参数构建、选取表征热交换器传热和流阻性能的监测指标,并引入指数移动平均(EMA)算法进行数据处理与指标动态特征提取;在多元状态估计理论(MSET)的基础上,构建表征热交换器健康运行状态的三维健康记忆矩阵,实现热交换器多变工况的融合,避免工况变化对监测指标的影响,然后针对设备当前运行观测值计算实时偏差,实现热交换器运行状态评估及故障预警;通过统计计算过程中各指标实时偏差贡献率锁定异常参数,实现故障精准定位。实验结果表明,该方法能够实现泄漏量占工艺流体流量1%以上泄漏故障预警及垢层厚度占管径2.2%以上结垢故障预警。
With the rapid development of process industry and the increasing complexity of process,heat exchangers which serve as the core equipment suffer from the difficulty of the fault early warning.This paper presents a novel method for the fault early warning of tubular heat exchangers.The monitoring indexes are constructed and selected considering the easily measured parameters including temperature,pressure and flow rate of the process fluid.The monitoring indexes are applied to represent the heat transfer and flow resistance performance of the heat exchangers.The EMA algorithm is introduced to process the data and extract the dynamic features of the indexes.A three-dimensional memory matrix is built to represent the working condition of the heat exchangers based on the theory of multiple state estimation(MSET),which avoids the influence of varying condition on the monitoring indexes.Then,the operating observation is applied to calculate the real-time deviation,which achieves the state assessment and fault early warning of the heat exchangers.The abnormal parameters are identified by calculating the real-time deviation contribution rate of each index to achieve accurate fault location.The experimental results show that the method can realize the early warning of leakage faults when the leakage volume accounts for more than 1%of the process fluid flow rate and the early warning of scaling faults when the thickness of the scale layer accounts for more than 2.2% of the pipe diameter.
作者
张凤丽
潘辉
王金江
ZHANG Fengli;PAN Hui;WANG Jinjiang(College of Mechanical and Transportation Engineering,China University of Petroleum Beijing,Beijing 102249,China)
出处
《化工学报》
EI
CAS
CSCD
北大核心
2022年第2期814-826,共13页
CIESC Journal
基金
国家自然科学基金项目(71871221)。
关键词
安全
热传导
结垢
热交换器
状态估计
故障预警
数据处理
safety
heat conduction
fouling
heat exchanger
state estimation
fault early warning
data treating
