基于振动检测的潜油电泵机组故障诊断的研究
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摘要
潜油电泵是目前国内外各大油田机械采油的主要设备之一,其可靠性和高效性是油田持续稳产高产的重要保证。潜油电泵机组的结构较为复杂,发生的许多故障都会引起机组的振动,因此可以通过对机组振动信号的分析,初步判断出相关故障。
对潜油电泵试验井井口的振动信号进行采集和分析,提取了潜油电泵机组故障的振动信号特征,完成了某些故障的诊断。论文完成的主要工作包括:
1.设计了一套基于数字信号处理器(DSP)和微机电系统(MEMS)加速度传感器的振动信号采集系统,以便对潜油电泵井井口的振动信号进行采集。并在采集系统中开发了通用串行总线(USB)主机功能,从而可以将采集到的数据直接以文本格式写入移动存储器中,实现了潜油电泵机组振动信号的便携式海量存储采集。
2.探讨了旋转机械故障诊断中传统的信号分析方法,如时域分析、幅值分析、频域分析等,阐述了这些方法的基本原理、优缺点及其应用场合。
3.研究了小波分析理论和小波变换在振动信号分析中的应用。小波分析属于时频分析的一种,具有多分辨分析的特点,克服了傅里叶变换的缺点。通过对潜油电泵机组的振动信号进行各种小波分析研究,可以实现对故障特征的提取。利用时域波形、功率谱、小波分解、小波包分解等多种方法对已测得的潜油电泵机组的多组振动信号数据进行了分析,经过分析对比和归纳总结,得到了潜油电泵机组轴窜动量过大和磨损这两种故障特征的提取方法,从而实现了这两种故障的诊断。
实验证明,对潜油电泵试验井井口的振动信号分析,并从中提取故障特征信息是可行和有效的。本文的工作为潜油电泵机组故障诊断技术的研究提供了有益的思路。
Electric submersible pump (ESP) unit is the main device to extract oil in the world .Its reliability and capability is important to assure the high yield of the oil field. The structure of ESP is relatively complex, and many faults of ESP will lead to vibration. Through analysis of the vibration signals of ESP, preliminary judgement of some faults can be concluded .
By acquiring and analyzing wellhead vibration signals of ESP test wells, the fault feature of ESP’s vibration can be extracted,and some faults of ESP can be found out. The discussion covers:
1. To detect the vibration of ESPs, a vibration signal acquisition system based on DSP (digital signal processor) and MEMS (Micro-electro-mechanical systems) acceleration sensor is designed to collect the ESP’s well-head vibration acceleration signals. The data acquisition system is developed to have the function of USB-Host, with which the vibration data can be written to files in mobile USB (universal serial bus) mass storage, thus achieving the portable and mass storage acquisition of ESP’s vibration signals.
2. The conventional technology of vibration signals is discussed in rotating machinery fault diagnosis, such as time-domain analysis, amplitude analysis, frequency-domain analysis. The base principle, advantage and disadvantage of these methods are expatiated.
3. Research on the wavelet analysis theory and wavelet transform in the vibration signal processing applications. Wavelet analysis is a kind of time-frequency analysis. Wavelet transform has the characteristic of multiresolution analysis and overcomes the limitations of Fourier transform. Wavelet analysis was applied to vibration signals of ESP in order to extract fault feature of ESP. A lot of methods, such as time-domain waveform, power spectrum, wavelet decomposition and wavelet packet decomposition and so on, were applied to analyze vibration data of ESP gathered in the experiment. After comparing, contrasting and summarizing, the extraction methods of shaft ran excessive and wear fault feature are obtained, and these faults are diagnosed.
In conclusion, it is feasible and effective to extract fault feature of ESP, by analyzing vibration acceleration signals of ESP’s wellhead. And the works of the paper provide useful ideas for fault diagnosis technology of ESP.
对潜油电泵试验井井口的振动信号进行采集和分析,提取了潜油电泵机组故障的振动信号特征,完成了某些故障的诊断。论文完成的主要工作包括:
1.设计了一套基于数字信号处理器(DSP)和微机电系统(MEMS)加速度传感器的振动信号采集系统,以便对潜油电泵井井口的振动信号进行采集。并在采集系统中开发了通用串行总线(USB)主机功能,从而可以将采集到的数据直接以文本格式写入移动存储器中,实现了潜油电泵机组振动信号的便携式海量存储采集。
2.探讨了旋转机械故障诊断中传统的信号分析方法,如时域分析、幅值分析、频域分析等,阐述了这些方法的基本原理、优缺点及其应用场合。
3.研究了小波分析理论和小波变换在振动信号分析中的应用。小波分析属于时频分析的一种,具有多分辨分析的特点,克服了傅里叶变换的缺点。通过对潜油电泵机组的振动信号进行各种小波分析研究,可以实现对故障特征的提取。利用时域波形、功率谱、小波分解、小波包分解等多种方法对已测得的潜油电泵机组的多组振动信号数据进行了分析,经过分析对比和归纳总结,得到了潜油电泵机组轴窜动量过大和磨损这两种故障特征的提取方法,从而实现了这两种故障的诊断。
实验证明,对潜油电泵试验井井口的振动信号分析,并从中提取故障特征信息是可行和有效的。本文的工作为潜油电泵机组故障诊断技术的研究提供了有益的思路。
Electric submersible pump (ESP) unit is the main device to extract oil in the world .Its reliability and capability is important to assure the high yield of the oil field. The structure of ESP is relatively complex, and many faults of ESP will lead to vibration. Through analysis of the vibration signals of ESP, preliminary judgement of some faults can be concluded .
By acquiring and analyzing wellhead vibration signals of ESP test wells, the fault feature of ESP’s vibration can be extracted,and some faults of ESP can be found out. The discussion covers:
1. To detect the vibration of ESPs, a vibration signal acquisition system based on DSP (digital signal processor) and MEMS (Micro-electro-mechanical systems) acceleration sensor is designed to collect the ESP’s well-head vibration acceleration signals. The data acquisition system is developed to have the function of USB-Host, with which the vibration data can be written to files in mobile USB (universal serial bus) mass storage, thus achieving the portable and mass storage acquisition of ESP’s vibration signals.
2. The conventional technology of vibration signals is discussed in rotating machinery fault diagnosis, such as time-domain analysis, amplitude analysis, frequency-domain analysis. The base principle, advantage and disadvantage of these methods are expatiated.
3. Research on the wavelet analysis theory and wavelet transform in the vibration signal processing applications. Wavelet analysis is a kind of time-frequency analysis. Wavelet transform has the characteristic of multiresolution analysis and overcomes the limitations of Fourier transform. Wavelet analysis was applied to vibration signals of ESP in order to extract fault feature of ESP. A lot of methods, such as time-domain waveform, power spectrum, wavelet decomposition and wavelet packet decomposition and so on, were applied to analyze vibration data of ESP gathered in the experiment. After comparing, contrasting and summarizing, the extraction methods of shaft ran excessive and wear fault feature are obtained, and these faults are diagnosed.
In conclusion, it is feasible and effective to extract fault feature of ESP, by analyzing vibration acceleration signals of ESP’s wellhead. And the works of the paper provide useful ideas for fault diagnosis technology of ESP.
引文
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[2] Milne,William.Electric Submersible Pumping Innovations for the Oil Industry[J].Word pumps, 1994,334(7):43-44
[3]徐长航,杨其俊,陈国明等.潜油电泵机组振动检测与故障诊断系统[J].石油矿场机械,2003,32(1):14-16
[4]樊灵,李炳辉.振动分析技术在电潜泵井工况诊断中的应用[J].石油大学学报(自然科学版),1994,7:43-47.
[5]李洪周,朱法银,邹积举.潜油电泵振动故障分析及振动模型[J].石油机械,1997, 25(12):24-26.
[6] Samanta B., Al-Balushi K.R., Siddiqui R.A.,et al. Failure Analysis of Seal Lock Plates in Electric Submersible Pumps[J]. Middle East Oil Show,2003,6:1-8
[7] Brinner, T.R., Traylor, F.T., Stewart, R.E.. Causes and Prevention of Vibration Induced Failure in Submersible oilwell Pumping Equipment [C]. SPE Annual Technical Conference and Exhibition,1982,26-29(9)
[8]李哲,杨艳芬,代忠良等.基于质量分析的潜油离心泵叶轮和导轮修复工艺技术[J].石油工业技术监督,2007,(12):26-28
[9]尹承罡,刘炜光.潜油多级离心泵的振动分析[J].中国设备管理,1999,5:25-27
[10] Durham, M.O., Williams, J. H., Goldman, D. J. Vibration Failure Analysis of Electric Submersible Pumps[J]. Society of Petroleum Engineers of AIME,1987,Pi:449-455
[11]冯定,李成见,朱宏武等.潜油电泵的振动失效分析研究[J].石油天然气学报(江汉石油学院学报),2005,27(4):519-521
[12] Coltharp, Eustace D., Conoco Inc. Subsurface Electrical Centrifugal Pumps[J]. Journal of Petroleum Technology,1984,36(4):645-652
[13]白晶.潜油电泵变频调速技术的研究[D].大庆:大庆石油学院,2003
[14] Durham M.O., Williams J. H., Goldman D. J. Effect of Vibration on Electric Submersible Pump Failures[J]. Journal of Petroleum Technology,1992,42(2): 186-190
[15] Thorsen O. V. Dalva M.. Survey of Faults on Induction Motors in Offshore Oil Industry, Petrochemical Industry, Gas Terminals, and Oil Refineries[J].IEEE Transactions on Industy Apllications,1995,31(5):1186-1196
[16]张玉斌,于海春.潜油电泵机组可靠性研究[J].石油学报,2003,24(4):103-107
[17]梅思杰,邵永实,刘军等.潜油电泵技术(下册)[M].北京:石油工业出版社,2004.7: 171-218
[18]徐秀玉,原培新,杨文平.复杂机械故障诊断的分析与小波方法[M].北京:机械出版社,2003,3:1-10
[19] Behzad M., Bastami A,R., Maassoumian M.. Fault Diagnosis of Centrifugal Pump by Vibration Analysis[C].Proceedings of 7th Biennial Conference on Engineering System Design an analysis.2004,3:221-226
[20]李志敏.基于振动分析的内燃机主轴承状态监测与故障诊断方法研究[D].大连:大连理工大学,2001
[21]刘军.潜油电泵井下多元测试系统研究[D].哈尔滨:哈尔滨工程大学,2005
[22] Texas Instruments Incorporated著. TMS320C28X系列DSP的CPU与外设(上)[M].北京:清华大学出版社,2004
[23]苏奎峰,吕强,耿庆峰等.TMS320F2812原理与开发[M].北京:电子工业出版社,2005:1-19
[24] MMA7260Q Datasheet.Rev.2.0 [DB/OL].http://www.freescale.com
[25] AD7865 Datasheet. Rev B[DB/OL] .http://www.analog.com
[26]张隽,丁仁杰.一种基于DSP和AD7865数据采集卡的设计与实现[J].电测与仪表,2004, 41(6):37-40
[27]张念淮,江浩. USB总线接口开发指南[M] .北京:国防工业出版社,2001,3 :1-3
[28]许永和. EZ-USB FX系列单片机USB外围设备设计与应用[M].北京:北京航空航天大学出版社,2002,11:3-4
[29] SL811HS Datasheet[DB/OL].http://www.cypress.com.2002.3
[30] Universal Serial Bus Mass Storage Class UFI Command Specification EB/OL]. http://www.usb.org/developers/devclass_docs/usbmass-ufi10.pdf. 1998.12
[31] Microsoft Extensible Firmware Initiative FAT32 File System Specification [EB/OL]. http://download.microsoft.com/download/1/6/1/161ba512-40e2-4cc9-843a-923143f3456c/fatgen103.doc. 2000.1
[32]韩捷,张瑞林等.旋转机械故障机理及诊断技术[M].北京:机械出版社,1997,8: 35-75
[33]应怀樵.波形和频谱分析与随机数据处理[M].北京:中国铁道出版社,1983:78-84.
[34]李香莲.机械振动信号的时频分析[J].山东工程学院学报,1999,3(13):42-47.
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