面向系统层级的复杂工业过程全息故障诊断

doi:10.11949/j.issn.0438-1157.20181349

摘要/Abstract

摘要：

复杂工业过程具有长流程、系统层级多、故障潜在分布空间范围较广的特点，是当前故障诊断领域的热门研究方向。首先，对主流故障诊断技术进行了分类和概述；其次，采用定量与定性相结合思路，提出了面向系统层级的复杂工业过程全息故障诊断框架，为复杂工业全流程的过程监测提供一整套技术和解决方案。相比于目前的故障诊断方法，该框架不仅包括故障检测和故障辨识，还包括故障根源诊断、故障传播路径识别、故障的定量诊断与评估，可有效解决复杂工业过程系统的综合故障诊断问题，实用性强，能够有效地减少或避免故障发生、保证产品的质量、提高企业的生产效率与生产安全；最后对故障诊断技术的发展趋势和亟待解决的问题进行了展望。

关键词: 过程系统, 全流程, 故障诊断, 故障传播, 故障评估, 生产, 安全

Abstract:

Complex industrial process has long processes, many system levels and a wide range of potential fault distribution space, which is a hotspot in the current fault diagnosis field. Firstly, the current mainstream fault diagnosis methods in process monitoring are classified and summarized. Secondly, this study adopts the combination of quantitative and qualitative, which is based on data and knowledge. A system-level holographic fault diagnosis framework for complex industrial process is proposed, which provides a complete set of techniques and solutions for process monitoring in complex industrial plant-wide process. Compared with current fault diagnosis methods, the framework not only includes fault detection and fault identification, but also includes root cause diagnosis, fault propagation path identification, quantitative fault diagnosis and evaluation. It is quite a practical method for process systems, which can effectively reduce or avoid the fault occurrence, guarantee the quality of the product, and improve the production efficiency and safety of enterprises. Finally, the development trend of fault diagnosis technology and problems to be solved are prospected.

Key words: process systems, plant-wide process, fault diagnosis, fault propagation, fault assessment, production, safety

中图分类号:

TP 273

彭开香, 张传放, 马亮, 董洁, 焦瑞华, 唐鹏. 面向系统层级的复杂工业过程全息故障诊断[J]. 化工学报, 2019, 70(2): 590-598.

Kaixiang PENG, Chuanfang ZHANG, Liang MA, Jie DONG, Ruihua JIAO, Peng TANG. System-levels-based holographic fault diagnosis for complex industrial processes[J]. CIESC Journal, 2019, 70(2): 590-598.

图/表 9

图1 复杂工业过程监测流程

Fig.1 Schematic diagram for complex industrial process monitoring

图2 带钢热连轧综合自动化系统

Fig.2 Integrated automation system for strip hot rolling

图3 面向系统层级的复杂工业过程全息故障诊断框架

Fig.3 System-levels-based holographic fault diagnosis framework for complex industrial processes

表1 精轧机过程变量与质量变量分配

Table 1 Description of process and quality variables in hot strip mill process

变量	类型	描述	单位
G₁～G₇	过程变量	第i机架的平均辊缝(i=1,…,7)	mm
F₁～F₇	过程变量	第i机架的轧制力(i=1,…,7)	MN
B₂～B₇	过程变量	第i机架的弯辊力(i=2,…,7)	MN
S	质量变量	平直度	I

图4 精轧机组故障检测结果

Fig.4 Fault detection result of finishing mill

图5 精轧机组故障变量相对重构贡献

Fig.5 rRBC plot of fault variables of finishing mill

图6 精轧机组冷却水阀故障传播路径

Fig.6 Fault propagation path of cooling water valves in finishing mill

图7 基于偏离度大小的故障程度划分

Fig.7 Fault level classification based on deviation degree

图8 全息故障诊断流程

Fig.8 Flow chart of holographic fault diagnosis

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