阅读说明：本技术 一种水厂泵房机组一键启动改造方法 (One-key starting transformation method for pump house unit of water plant ) 是由 王金恒 田友东 尹武杰 李傲楠 刘为伟 冯雪皓 于 2021-06-29 设计创作，主要内容包括：本发明涉及供水系统技术领域,具体为一种水厂泵房机组一键启动改造方法。包括以下步骤：步骤一、对泵房真空配电箱、液压油站配电箱、机旁箱柜进行梳理、对泵房总览操作界面增设上部超链接,重新布局分界面之间切换方式,加装了水泵上端真空管和电磁阀2个,配置水泵控制器进行设备控制编程；步骤二、设备自动化控制编程验证；步骤三、配置编程状态检查程序；步骤四、线路布局；步骤五、对水泵控制器进行合闸操作试验,对泵房排污系统进行检查,为对水泵抽真空实验做准备；步骤六、对所有水泵进行抽真空。可充分统一机组开停机步骤时间,最大程度降低人为误操作概率,增加工作效率,充分契合集团公司优质、稳定、高效主线要求。(The invention relates to the technical field of water supply systems, in particular to a one-key starting transformation method for a pump house unit of a water plant. The method comprises the following steps: step one, carding a pump house vacuum distribution box, a hydraulic oil station distribution box and a beside cabinet, adding upper hyperlinks to a pump house overview operation interface, rearranging a switching mode among the interfaces, additionally installing 2 vacuum tubes and electromagnetic valves at the upper end of a water pump, and configuring a water pump controller to perform equipment control programming; step two, the equipment automation control programming verification; step three, configuring a programming state checking program; step four, layout of the circuit; fifthly, a switching-on operation test is carried out on the water pump controller, a sewage system of the pump room is checked, and preparation is made for a water pump vacuumizing test; and step six, vacuumizing all the water pumps. The method can fully unify the starting and stopping steps of the unit, reduce the probability of artificial misoperation to the maximum extent, increase the working efficiency and fully meet the requirements of high-quality, stable and high-efficiency mainlines of group companies.)

1. A one-key starting transformation method for a water plant pump room unit is characterized by comprising the following steps: the method comprises the following steps:

step one, carding a pump house vacuum distribution box, a hydraulic oil station distribution box and a beside cabinet, adding upper hyperlinks to a pump house overview operation interface, rearranging a switching mode among the interfaces, additionally installing 2 vacuum tubes and electromagnetic valves at the upper end of a water pump, and configuring a water pump controller to perform equipment control programming;

step two, the equipment automation control programming verification;

step three, configuring a programming state checking program;

step four, layout of the circuit;

fifthly, a switching-on operation test is carried out on the water pump controller, a sewage system of the pump room is checked, and preparation is made for a water pump vacuumizing test;

and step six, vacuumizing all the water pumps.

2. The one-key starting transformation method for the water plant pump house unit as claimed in claim 1, wherein the method comprises the following steps: the automatic control programming verification in the second step comprises three stages;

stage one; checking the oil level and the oil pressure of the hydraulic station not to be lower than 8.5, starting a vacuum pump and a vacuum valve, and judging that the vacuum is met;

stage two; starting a motor of the unit, checking a closing signal and current, closing a vacuum pump and a vacuum electromagnetic valve, and entering the next stage after 5 seconds of delay;

stage three; adjusting the opening degree of the vacuum electromagnetic valve to 25 degrees at intervals of 30 seconds, adjusting the opening degree of the vacuum electromagnetic valve to 40 degrees at intervals of 3 minutes, adjusting the opening degree of the vacuum electromagnetic valve to 70 degrees at intervals of 3 minutes, and adjusting the opening degree of the vacuum electromagnetic valve to 99 degrees; the opening interval during shutdown is adjusted as follows: adjusting the opening degree of the vacuum electromagnetic valve to 70 degrees at intervals of 2 minutes, adjusting the opening degree of the vacuum electromagnetic valve to 40 degrees at intervals of 2 minutes, and adjusting the opening degree of the vacuum electromagnetic valve to 25 degrees at intervals of 30 seconds; adjusting the opening degree of the vacuum electromagnetic valve to 5 degrees, shutting down the vacuum electromagnetic valve, and adjusting the opening degree of the vacuum electromagnetic valve to 1 degree.

3. The one-key starting transformation method for the water plant pump house unit as claimed in claim 1, wherein the method comprises the following steps: and the third step comprises prompt type, pause type and accident type examination.

4. The one-key starting transformation method for the water plant pump house unit as claimed in claim 1, wherein the method comprises the following steps: and a PLC controller is also configured in the fourth step and is used for periodically acquiring the real-time operation parameters and states of the electrical quantity, the switching value and the analog quantity of the equipment, checking, calculating and processing the acquired data, and controlling and outputting the data.

5. The one-key starting transformation method for the water plant pump house unit as claimed in claim 1, wherein the method comprises the following steps: the water pump vacuum test in the sixth step comprises the following steps: and (4) carrying out vacuum-pumping experiments at different time periods and different water levels.

6. The one-key starting transformation method for the water plant pump house unit as claimed in claim 4, wherein the method comprises the following steps: the PLC controller comprises a CPU module and an AI module and is used for responding to an operation command of an upper computer and a touch screen, automatically starting the oil pump and the electromagnetic valve and realizing the adjustment of the opening degree of the valve.

Technical Field

The invention relates to the technical field of water supply systems, in particular to a one-key starting transformation method for a pump house unit of a water plant.

Background

The safety and reliability of the main water supply equipment are the precondition of ensuring the uninterrupted safe water supply of the water plant and improving the water supply efficiency.

The existing water supply pump room water machine set consists of a 575KW, 68A, 6KV Siemens motor, a 5000m3/h flow water pump, a DN1000 water inlet and outlet pipeline valve. The water supply of the unit is usually matched with a 45-degree communication valve for water taking and boiling (the clear water reservoir water level can be kept stable by matching the water taking and supplying flow rate), the starting operation process of the unit usually lasts for 5-10 minutes, and the main process is as follows: (1) receiving a water supply dispatching telephone, dispatching and issuing a unit starting instruction of a four-water plant, and recording the instruction receiving time; (2) when the crew member in the office manually opens 2 DN20 quick valves at the upper end of the unit water pump; (3) when the staff on duty goes to the pump room control cabinet, starting the vacuum pump; (4) the vacuum state in the water pump is judged to be formed by observing the water outlet state of the vacuum tube and listening the water flow sound in the vacuum tube when the user bends over; (5) going to a cabinet button beside the unit to start a unit motor; (6) manually closing 2 vacuum pipeline quick valves at the upper end of the water pump; (7) the user goes to a pump room control cabinet to stop the vacuum pump; (8) and the water outlet valve is opened sufficiently by going to a hydraulic station control cabinet beside the unit. The opening of the valve is controlled by a knob, the process is started in 4 stages, namely 15 degrees, 30 degrees, 60 degrees and 100 degrees, the operation interval is 3 times, and each time interval is 1 minute; (9) the machine set is moved to a duty room to observe flow display to confirm normal operation of the machine set and switch on the No. 1 capacitor; (10) and calling to inform the pressurizing station that the unit is started and informing of the starting time.

Because the water pump must pump out the air that is deposited in the pump body before beginning to operate, make the entrance form the vacuum, water gets into and fills up the pump body under the effect of atmospheric pressure, just can normally work like this after the water pump starts. The starting time of the water supply unit is usually in the morning, the stopping time is usually 23-24 o' clock in the evening, the water supply unit is manually operated by a duty worker in a pump room on duty in the middle and night shifts, the operators are proficient workers in water making shifts, the starting time period is before the middle and night shifts are shifted, the stopping time period is in a midnight physical state fatigue period, the starting time period is influenced by subjective factors such as different clear reservoir water levels, water suction well liquid levels, personal operation habits, different vacuum judging and vacuumizing judging methods, and the starting and stopping operation time is different. The manual operation steps are more, the manual operation steps are more complicated, objective factors such as personnel fatigue and temperature in summer and winter are combined, and various risk probabilities of misoperation, item leakage and deviation judgment are increased invisibly.

Disclosure of Invention

Technical problem to be solved

In order to solve the problems in the prior art, the invention provides a one-key starting and transforming method for a water plant pump house unit, which can fully unify the starting and stopping steps of the unit, reduce the probability of artificial misoperation to the maximum extent, increase the working efficiency and fully meet the requirements of a high-quality, stable and efficient main line of a group company.

(II) technical scheme

In order to achieve the purpose, the invention adopts the main technical scheme that: the method comprises the following steps:

step one, carding a pump house vacuum distribution box, a hydraulic oil station distribution box and a beside cabinet, adding upper hyperlinks to a pump house overview operation interface, rearranging a switching mode among the interfaces, additionally installing 2 vacuum tubes and electromagnetic valves at the upper end of a water pump, and configuring a water pump controller to perform equipment control programming;

step two, the equipment automation control programming verification;

step three, configuring a programming state checking program;

step four, layout of the circuit;

fifthly, a switching-on operation test is carried out on the water pump controller, a sewage system of the pump room is checked, and preparation is made for a water pump vacuumizing test;

and step six, vacuumizing all the water pumps.

Preferably, the automatic control programming verification in the second step comprises three stages;

stage one; checking the oil level and the oil pressure of the hydraulic station not to be lower than 8.5, starting a vacuum pump and a vacuum valve, and judging that the vacuum is met;

stage two; starting a motor of the unit, checking a closing signal and current, closing a vacuum pump and a vacuum electromagnetic valve, and entering the next stage after 5 seconds of delay;

stage three; adjusting the opening degree of the vacuum electromagnetic valve to 25 degrees at intervals of 30 seconds, adjusting the opening degree of the vacuum electromagnetic valve to 40 degrees at intervals of 3 minutes, adjusting the opening degree of the vacuum electromagnetic valve to 70 degrees at intervals of 3 minutes, and adjusting the opening degree of the vacuum electromagnetic valve to 99 degrees; the opening interval during shutdown is adjusted as follows: adjusting the opening degree of the vacuum electromagnetic valve to 70 degrees at intervals of 2 minutes, adjusting the opening degree of the vacuum electromagnetic valve to 40 degrees at intervals of 2 minutes, and adjusting the opening degree of the vacuum electromagnetic valve to 25 degrees at intervals of 30 seconds; adjusting the opening degree of the vacuum electromagnetic valve to 5 degrees, shutting down the vacuum electromagnetic valve, and adjusting the opening degree of the vacuum electromagnetic valve to 1 degree.

Preferably, the third step includes a prompt type, a pause type and an accident type.

Preferably, a PLC controller is further configured in the fourth step, and the PLC controller is configured to periodically acquire real-time operation parameters and states of an electrical quantity, a switching quantity, and an analog quantity of the device, check, calculate, and process the acquired data, and control output.

Preferably, the water pump vacuum test in the sixth step includes: and (4) carrying out vacuum-pumping experiments at different time periods and different water levels.

Preferably, the PLC controller comprises a CPU module and an AI module, and is used for responding to an operation command of the upper computer and the touch screen, automatically starting the oil pump and the electromagnetic valve, and realizing the adjustment of the valve opening.

(III) advantageous effects

The invention provides a one-key starting transformation method for a pump house unit of a water plant. The method has the following beneficial effects:

(1) the improved system works stably and reliably. The machine set realizes automatic startup and shutdown, the steps from vacuumizing to complete opening of the hydraulic valve can be executed by one key of a computer in the pump room, and all the sub-steps in execution and the state data and the process of each current node are clearly displayed in a current interface on a computer screen; each sub-step in execution can be manually suspended or terminated, and does not conflict with manual operation at any time, namely, the sub-steps can be manually operated at any time after being suspended or terminated, and the steps can be automatically executed by the computer after the manual operation is suspended and then the computer is resumed; key parameters such as valve opening degree, valve opening interval and the like which are automatically executed can be modified and changed by technicians, and interface entrance setting passwords are modified; a key button in the main interface is provided with a step of clicking confirmation again after clicking, so that the mistaken clicking of a mouse is prevented; all the steps are executed before the system is set with an automatic checking necessary condition checking program, when the system is found to have faults and the necessary conditions do not have the execution of the next step, the current flow is prompted and automatically terminated.

(2) The method can fully unify the starting and stopping steps of the unit, reduce the probability of artificial misoperation to the maximum extent, increase the working efficiency and fully meet the requirements of high-quality, stable and high-efficiency mainlines of group companies.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

The one-key starting transformation method for the water plant pump house unit comprises the following steps:

step one, carding a pump house vacuum distribution box, a hydraulic oil station distribution box and a beside cabinet, adding upper hyperlinks to a pump house overview operation interface, rearranging a switching mode among the interfaces, additionally installing 2 vacuum tubes and electromagnetic valves at the upper end of a water pump, and configuring a water pump controller to perform equipment control programming;

step two, the equipment automation control programming verification;

step three, configuring a programming state checking program;

step four, layout of the circuit;

fifthly, a switching-on operation test is carried out on the water pump controller, a sewage system of the pump room is checked, and preparation is made for a water pump vacuumizing test;

and step six, vacuumizing all the water pumps.

As a specific embodiment of the present invention, the automatic control programming verification in step two includes three phases;

stage one; checking the oil level and the oil pressure of the hydraulic station not to be lower than 8.5, starting a vacuum pump and a vacuum valve, and judging that the vacuum is met;

stage two; starting a motor of the unit, checking a closing signal and current, closing a vacuum pump and a vacuum electromagnetic valve, and entering the next stage after 5 seconds of delay;

stage three; adjusting the opening degree of the vacuum electromagnetic valve to 25 degrees at intervals of 30 seconds, adjusting the opening degree of the vacuum electromagnetic valve to 40 degrees at intervals of 3 minutes, adjusting the opening degree of the vacuum electromagnetic valve to 70 degrees at intervals of 3 minutes, and adjusting the opening degree of the vacuum electromagnetic valve to 99 degrees; the opening interval during shutdown is adjusted as follows: adjusting the opening degree of the vacuum electromagnetic valve to 70 degrees at intervals of 2 minutes, adjusting the opening degree of the vacuum electromagnetic valve to 40 degrees at intervals of 2 minutes, and adjusting the opening degree of the vacuum electromagnetic valve to 25 degrees at intervals of 30 seconds; adjusting the opening degree of the vacuum electromagnetic valve to 5 degrees, shutting down the vacuum electromagnetic valve, and adjusting the opening degree of the vacuum electromagnetic valve to 1 degree.

As a specific implementation mode of the invention, the third step comprises the detection of a prompt class, a pause class and an accident class.

In the fourth step, a PLC controller is further configured, and the PLC controller is configured to periodically collect real-time operating parameters and states of the electrical quantity, the switching quantity, and the analog quantity of the device, check, calculate, and process the collected data, and control the output.

As a specific embodiment of the present invention, the water pump vacuum test in step six includes: and (4) carrying out vacuum-pumping experiments at different time periods and different water levels.

As a specific implementation mode of the invention, the PLC comprises a CPU module and an AI module, and the AI module is used for responding to the operation commands of the upper computer and the touch screen, automatically starting the oil pump and the electromagnetic valve and realizing the adjustment of the valve opening.

The working principle is as follows: day one of the first week: the pump room vacuum distribution box, the hydraulic oil station distribution box and the beside cabinet are inspected, the pump room on duty personnel (two people in the morning duty and the night duty) are inquired in detail about the specific operation flow of starting and stopping the pump room, and records are made. And in the afternoon of the day, an upper hyperlink is additionally arranged on the production overview operation interface of the pump room, and the switching mode between the interfaces is rearranged, so that the operation is more convenient and visual.

The trend, the original component model and the line diameter of each related distribution line of the unit are combed the next day of the first week. The vacuum tubes at the upper end of the machine water pump and 2 electromagnetic valves are additionally arranged, and the electromagnetic valves are 2W and 10kg/cm2.

And in the third to fifth days of the first week, the drawing of the operation interface of the unit computer is finished, and key data such as water outlet flow, oil station pressure, water levels, water outlet pressure and the like in the operation interface are on-line. The new setting comprises the completion of the vacuum pressure, the manual operation interface entrance, the display of the state of each process and the like.

And on the sixth day of the first week, replacing the new power distribution cabinet by the vacuum pump of the pump room, and dismantling the original power distribution cabinet. The new vacuum power distribution cabinet is connected with the PLC, and a white line is a 24V signal feedback line. The yellow line is the 220V control line. The existing breaker, fuse, contactor, thermal relay and wiring terminal in the cabinet are new accessories, and the main functions are unchanged. And (4) testing the vacuum pump after replacing the new cabinet, wherein the main parameters of the vacuum pump are 4KV, 380V, 8.8A and delta connection. The actual operating current of the vacuum pump is 12A after the test of a pincerlike ammeter, and then the thermal relay is replaced by JR36-20, so that the tripping level is higher and is matched with the thermal relay.

On day seven of the first week, the programming of the automated one-touch start-up procedure was already rudimentary and further verified.

The automatic process is mainly divided into three stages:

whether various power supply conditions such as integrated protection are met or not is checked by using the power supply in the first stage

The capsule wall is used to inspect hydraulic stations. (oil level and oil pressure should not be lower than 8.5)

⒊ starting vacuum pump and vacuum valve

⒋ determining vacuum satisfaction

Please choose whether to proceed to the next step automatically

Second stage ⒌ starting group five motor

⒍ checking the closing signal and current (judged from the signal of indicator light) and executing the shutdown operation if the signal and current meet the conflict

⒎ turning off vacuum pump and vacuum solenoid valve

After a 5 second delay

The third stage ⒏ adjusts the opening degree to 25 degrees

At intervals of 30 seconds

Adjusting the opening to 40 DEG

At an interval of 3 minutes

⒑ regulating the opening degree to 70 degrees

At an interval of 3 minutes

Adjusting opening degree to 99 degree

The opening interval during shutdown is adjusted as follows:

adjusting the opening degree to 70 degrees

At intervals of 2 minutes

Adjusting the opening degree to 40 degrees

At intervals of 2 minutes

Adjusting the opening degree to 25 degrees

At intervals of 30 seconds

Adjusting the opening degree to 5 degrees

Shutdown

Adjusting the opening degree to 1 degree

The status check program was programmed on the first day and night of the second week. The method mainly comprises three types of self-checking, namely a prompt type, a pause type and an accident type. The pause, terminate, resume functions are programmed.

And (3) laying out the circuit from the second to the fourth day of the second week, and connecting the PLC signal circuit:

i1.1 vacuum Pump 1 run white 2

I1.2 vacuum pump 1 Fault white 3

I1.3 running of vacuum pump 2 white 5

I1.4 vacuum pump 2 Fault blank 6

I1.5 Unit operation

Q12.0 vacuum pump 1 turn on yellow 1, 2

Q12.1 vacuum pump 1 yellow 5, 6 are turned off

Q12.2 vacuum pump 2 on yellow 3, 4

Q12.3 vacuum pump 2 off yellow 7, 8

Q12.4 unit start-up

Q12.5 train shutdown

Q12.6 solenoid 1 open

Q12.7 solenoid 2 open

And (4) carrying out statistical combing on the mounted components on the fifth day of the second week: the field control unit is configured as a set of Siemens Smart series PLC, and can automatically and periodically acquire real-time running parameters and states of various electrical quantities, switching values, analog quantities and the like of equipment, check, calculate and process acquired data, and control and output the data.

Collecting switching value: collecting the state positions of a breaker, a switch, a valve and the like;

analog quantity acquisition: mainly collecting the opening degree, oil pressure and vacuum degree of a valve;

and carrying out A/D conversion on the acquired analog quantity, and carrying out analysis, processing and operation to form data required by various monitoring and management functions of the main control layer. The analog quantity is checked for limit value, when it exceeds the specified value, it can give an alarm and produce correspondent control according to the requirements. The main treatment conditions are:

opening degree value: filtering and averaging; and comparing with a set value.

Electrical quantity: overrun judgment, three-phase unbalance comparison and the like.

During operation of the valves and the unit, the following events occur as a normal shutdown:

the opening value is close to the set value;

when the valve is closed, the opening degree is close to 0 opening degree, and the machine is stopped in a delayed mode;

and responding to the shutdown command of the upper computer.

And when the following conditions occur, the system is regarded as fault shutdown, and fault shutdown information is reported:

the action of a thermal relay;

the opening of the valve is changed too small within 5 seconds;

loss of signal in remote control mode;

the oil pressure is overrun.

The PLC includes a CPU module, an AI module, etc. Actual monitoring points DI:13, DO:4, AI: and (5) point 2. The functions of the unit system include:

collecting encoder data (rotary encoder BTS58, 3000r/min rotating speed, 4-20MA output) in real time, and calculating the opening degree of a water outlet;

and responding to the operation commands of the upper computer and the touch screen, and automatically starting the oil pump and the electromagnetic valve to realize the adjustment of the opening of the valve. The opening value can be set by an operator according to the electric value, and the valve can be automatically adjusted to the position.

The device has the functions of overpressure protection, no-voltage alarm, abnormal opening change, over-limit alarm, timely switching of control loops and fault information reporting.

And after the pump house stops production on the first day in the third week, all the automatic processes in the sub-steps are tested one by one, and the 47/48 terminals of the unit 6KV power distribution cabinet are subjected to short circuit to perform a test position closing operation test, so that the process is smoothly developed. The value of the vacuum pump pressure for judging whether the vacuum is provided needs to be continuously verified, and the rule is searched

And checking the pump room sewage system in the third week, the third day and the fourth day to prepare for frequently testing the vacuum pump.

And carrying out automatic vacuum-pumping test on the machine set which is not used in daytime. And (5) carrying out vacuum-pumping test on the unit after night stopping.

And (3) test results: the vacuum degree of all units shows that two peak values exist, the peak value coming later is the highest peak, and the pressure stationary period after the highest pressure peak value is the vacuum possessing period. The test vacuum pump pressure was slightly higher than the south vacuum pump pressure. Influenced by the liquid level of the suction well, the water stored in the pipeline and the length of the pipeline, the peak value of each vacuumizing is different, but the general trend is similar.

And performing experiments with longer discontinuous time on the vacuum pump in the fourth and fifth days in the third week, wherein the experiments aim to verify whether the pressure sensor additionally arranged on the vacuum tube can provide analog quantity data for judging whether the vacuum is pumped up for the PLC. The experiment is respectively carried out on the units under different clear water reservoir water levels, real-time data of full pipe water reaching the pressure sensor in the vacuumizing process is intercepted and compared, and regularity numerical values are searched. Experiments show that although the general trends are similar, the pressure sensor has large degree difference when vacuum comes each time, and the data is not stable enough, so that the pressure sensor is not reliable, and a new method needs to be found.

A DN40 electromagnetic flowmeter is additionally arranged on the vacuum tube on the sixth day of the third week and used for replacing the function of the pressure sensor in the system, outlet pipes DN63 of the two vacuum pumps are changed into DN40 inlet flowmeters, the flowmeters get electricity from a sewage pump power cabinet and are independently opened, a flowmeter control box is arranged on the right wall of the sewage pump cabinet, and after the flowmeter control box is installed in place, the display unit of the flowmeter is changed from L/m to m3/h so that the flowmeter can be conveniently debugged.

And performing the vacuum pumping test of the unit at different time intervals and different water levels in the fourth day. The 19-day test determines that the flowmeter is more reliable than a pressure sensor, data can be used for judging vacuum, but the pump is slightly larger than a south pump due to different vacuum pump flows, and then the original planned intercepting stable full-pipe water flow judging method is changed into an accumulated flow judging method; the cumulative flow was evaluated and programmed through multiple trials over 20 days.

And performing a general coordination test on all the automatic flows of the unit after the unit is shut down at night in the next day, wherein individual programming self-checking conflict situations occur in the test period, the general flows are completed at one time at 3 am after the programming modification is solved, and the automatic function is realized.

And (4) establishing a simple operation rule for the staff on duty to look up at any time by operating and training the staff on duty in the pump room from the fourth week to the fifth week. And carrying out an actual operation test, and carrying out individual modification on part of the operation interface links to facilitate operation.