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石化旋转机械故障诊断及维修管理优化研究
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摘要
旋转机械是石化企业生产中的核心设备,任何设备不可避免会出现故障,维修是保障其正常运行的重要手段。但石化旋转机械故障原因具有复杂性、多样性和不确性的特点,而且影响维修决策的因素很多,所以其维修决策管理过程非常复杂。为此,本文对石化旋转机械的故障诊断和维修管理优化进行了研究。
     建立了基于贝叶斯网络的故障诊断模型。为防止或避免同类故障的再次发生,首先将故障原因进行分类分析,提出了相应的维修措施;然后将故障模式与影响分析与贝叶斯网络方法相结合,从而可定量地分析出影响设备运行的薄弱环节。以一台石化企业生产中的离心泵为应用实例,分析结果表明,该方法可为石化旋转机械的故障诊断提供一定的依据。
     开发了计算机辅助设备维修管理系统。该系统使用VB语言编写,采用模块化设计框架。它能够对设备的基本信息进行管理,并且建立了故障模式数据库,同时实现了贝叶斯网络的自动化分析。该系统可提高设备信息管理和故障诊断的效率。
     以单位时间内设备寿命管理费用最低为目标,建立了适用于各种寿命分布的基于几何过程维修优化模型,并引入了蒙特卡罗方法,运用Matlab编制了相应的仿真程序,对机械设备的最佳寿命周期进行预测。以服从二参数威布尔分布的离心泵作为分析实例。结果表明,所建立的模型具有一定的合理性,能够对机械设备的维修决策提供一定的指导。
Rotary machinery is the core equipment in the petrochemical production. The failurefor any equipment will occur inevitably and maintenance is an essential means forensuring the normal operation of rotary machinery. But the fault reason of petrochemicalrotating machinery has the complexity, diversity and uncertainty characteristics, andmaintenance decision-making is influenced by many factors, so the process ofmaintenance decision-making management is very complex. For this reason, themaking-decision management on the petrochemical rotary machine was investigated inthis paper.
     The fault diagnosis model, which is based on Bayesian network, was established. Toprevent or avoid the recurrence of the similar fault again, first of all, the fault reasons areclassified and analyzed and the corresponding maintenance measures was put forward;Then the failure modes and effects analysis was combined with Bayesian networkmethods, so the weak link can be analyzed for the influence of the equipment operation. Apetrochemical enterprise of centrifugal pump was taken as an application example. Theresults show that the method can provide certain basis for fault diagnosis of thepetrochemical rotary machine fault diagnosis.
     The computer of equipment maintenance management system was developed. VBlanguage was used and modular design framework was designed in this system. It canmanagement the basic information of the equipment can be managed through it, and afault model database was built. Meanwhile the automation analyze for the Bayesiannetworks analyze was realized. The system can improve the efficiency of equipmentinformation management and the fault diagnosis.
     Taking the least equipment management cost within unit time as the target, amaintenance optimization model based on monotonous geometric process wasestablished,which can be applied to many types of life distribution. And Monte Carlosimulation method was introduced into this mode. The simulation program by Matlab wasobtained and can predict the optimum life cycle of the mechanical equipment of. The centrifugal pump for Weibull distribution of two parameters was analyzed as a study case.Results show that the model is reasonable, which can supply a scientific guideline formaintenance making-decision.
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