CN105114334A - Method for monitoring abrasion loss of impeller wear ring of multi-stage centrifugal pump based on computational fluid dynamics theory - Google Patents
Method for monitoring abrasion loss of impeller wear ring of multi-stage centrifugal pump based on computational fluid dynamics theory Download PDFInfo
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Abstract
The invention discloses a method for monitoring abrasion loss of an impeller wear ring of a multi-stage centrifugal pump based on the computational fluid dynamics theory. The method comprises the following steps: 1) modeling a flow field of the complete set of the multi-stage centrifugal pump on the basis of the complete flow field modeling analyzing part of the computational fluid dynamics theory, and calculating the efficiency of the multi-stage centrifugal pump under different wear ring gap size, so as to obtain a curve that the efficiency varies based on the abrasion loss of the wear ring; 2) monitoring the efficiency of the multi-stage centrifugal pump in real time, correspondingly reading pressure and flow data from inlet and outlet pressure transmitters and flow transmitter of the multi-stage centrifugal pump, and reading the motor efficiency and power factors, so as to achieve real-time monitoring of the efficiency of the multi-stage centrifugal pump; 3) acquiring axial and radial vibrating signals, and measuring the radial vibration number of a rotor; 4) determining whether the efficiency is reduced due to the abrasion loss of the wear ring according to the acquired axial and radial vibration signals, and presuming the abrasion loss of the wear ring according to the calculated real-time efficiency and efficiency relationship curve of the multi-stage centrifugal pump.
Description
Technical field
The invention belongs to equipment intelligent diagnosis technical field.
Background technique
Choma is as the significant components of multistage centrifugal pump seal, and in running, wearing and tearing are inevitable.In engineer applied; maintenance for centrifugal pump mouth ring sealing adopts the pattern of periodic replacement; because different centrifugal pump mouth ring deterioration rate is different, adopt the way of periodic replacement can cause keeping in repair reduction that is superfluous or manufacturing efficiency, so the wear condition of Real-Time Monitoring choma is even more important.
At present the research of centrifugal pump mouth ring to be focused mostly in the optimization on sealing configuration and performance, choma gap on the impact of rotor and choma dynamics, choma gap in the impact of centrifugal pump complete machine Flow Field Performance etc. three.The people such as old fish utilize the method for experiment and calculating to record the impact of size for centrifugal pump performance in choma gap, show that preoral loop is larger than rear choma on the impact of pump performance, and change choma gap to all influential conclusion of the indices of centrifugal pump optimum operating condition.The people such as J.Denecke analyze the impact of seal groove on gap sealed sealability, and proposing seal groove can increase orifice size, improves sealing effect.The people such as the Lomakin theoretical and experimental analysis excitation force at clearance seal place, the excitation force proposing clearance seal place can affect critical turn of rotor-fast and stability.The people such as KurokawaJ analyze centrifugal pump preoral loop gap to the impact of impeller disc friction, and proposing to increase leakage rate can reduce disc friction losses, optimizes choma gap and can optimize performance of centrifugal pump.The people such as AlexandrinaUntaroiu, by carrying out Accurate Model to seal clearance flow field, demonstrate that to carry out structure optimization by numerical simulation and experiment be feasible.Research about centrifugal pump monitoring analysis focuses mostly in the fault such as rolling bearing, cavitation.As the people such as ZekiKiral analyze defective rolling bearing, simulate the oscillating signal that defect produces.The people such as Zhang Zhigang propose a kind of based on the Rolling Bearing Fault Character extracting method of EMD with spectrum kurtosis method.When the people such as Wang Yang utilize cavitation model to analyze centrifugal pump generation cavitation fault, the generation of bubble is vanished process.The people such as RichardB.Medvitz adopt Two-phase flow's separation to analyze the performance parameter variations of centrifugal pump under cavitation operating mode.The people such as Duan Xiangyang explore the noise of centrifugal pump under cavitation operating mode and oscillating signal by experiment, and the high frequency proposing more than 5kHz can as the detection foundation of Cavitation Occurred in Centrifugal Pumps.The people such as Dou Wei, according to pump pressure fluctuation situation, propose impeller excitation force relevant with spiral case cut water, and excited frequency is the frequency of impeller by cut water.As can be seen here, the current research for centrifugal pump fault concentrates on the research of the faults such as Cavitation Occurred in Centrifugal Pumps, excitation force, bearing, research for choma concentrates on aspects such as optimizing choma structure raising choma efficiency, not to the research of choma wear extent Real-Time Monitoring aspect.
The basis forming computation fluid dynamics theory is the large law of physics three, the motion of this three large law fluid system describes from art of mathematics and just constitutes fluid dynamic Basic equation group---and Navier-Stokes set of equation, this set of equation includes the three prescription journeys such as equation of continuity, momentum equation and energy equation.
Along with numerical computation method reaches its maturity and the appearance of business software based on computation fluid dynamics (CFD:ComputationalFluidDynamics), CFD is utilized to simulate centrifugal pump and research has feasibility.The people such as Zhu Lei as blade tip clearance, sidewall spacers calculate, analyze its impact etc. for performance of centrifugal pump to centrifugal pump key structure.These research in due to choma gap smaller and flowing more complicated, CFD simulation in usually ignore choma gap, cause research in cannot consider the impact of choma on centrifugal pump.Along with the development of computer hardware technology, computing capability promotes greatly, starts to consider that choma gap exists in the research for centrifugal pump overall performance, makes the impact analysis of analytical port czermak space to centrifugal pump complete machine flow field become possibility.As the people such as Zhao Weiguo utilize CFD to simulate different choma gap to the impact of centrifugal pump Flow Field Distribution, analytical port czermak space is for the impact of each performance parameter of centrifugal pump.
The present invention utilizes CFD to carry out flow field modeling to centrifugal pump, research and analyse the Parameter Variation such as efficiency, axial force under different choma gap, set up the change curve that multistage centrifugal pump efficiency and axial force are worn and torn along with choma, a kind of choma wear extent Real-Time Monitoring evaluating method based on multi-parameter fusion is proposed, analyse in depth the impact of choma wear extent being monitored by force unbalance, impeller channel burn into plugging fault etc., make the monitoring for choma wear extent more accurate.
Summary of the invention
The object of the invention is to overcome prior art to wear and tear the shortcoming assessed to choma, a set of method can carrying out assessing to choma wear extent diagnosis is newly provided.The method can get rid of the interference of other fault in diagnostic procedure, improves the accuracy of choma wear extent assessment.
The invention discloses a kind of multistage centrifugal pump impeller port ring wear extent monitoring method based on computation fluid dynamics theory, comprise the steps:
1) set up runner model, set up choma gap flow field, impeller channel model and spiral casing flow passage model based on computation fluid dynamics theory, three is carried out assemble the complete machine runner model that can obtain centrifugal pump.
2) change choma gap size, obtain the complete machine runner model in the situation of different choma gaps, calculate the efficiency value of multistage centrifugal pump under different choma gap, obtain efficiency and to blurt out czermak space change curve.
3) the efficiency Real-Time Monitoring of multistage centrifugal pump, pressure versus flow data are read respectively from multistage centrifugal pump entrance and exit pressure transmitter and flow transmitter, electric moter voltage, current data is read from motor inverter, reading electric efficiency and power factor import and export flow, inlet and outlet pressure, electric current, voltage, electric efficiency and power factor calculating multistage centrifugal pump Real time Efficiency to utilize, and realize multistage centrifugal pump efficiency Real-Time Monitoring.
4) gather axial vibration and radial vibration signal, the bearing housing of drive end with anti-drive end is installed level, vertical and axial acceleration sensor, gather the vibration values at multistage centrifugal pump drive end bearing and non-driven-end bearing place.The bearing (ball) cover of each bearing housing installs current vortex sensor, measures rotor radial vibration values.
6) according to axial vibration and radial vibration value, the monitoring part of choma wearing and tearing, determines whether that choma weares and teares the decrease in efficiency caused, according to the multistage centrifugal pump Real time Efficiency calculated and relationship between efficiency history estimating outlet ring wear extent.
Wherein step 1) set up the model that complete machine runner model needs to comprise three parts, due to the difference of different piece structure, its model modelling approach is not identical.Impeller channel is more complicated, cannot direct Modling model, is subtracted each other set up impeller channel model by vane profile model and impeller solid domain model.The part that in spiral casing flow passage, pumping chamber is connected with suction chamber adopts space curve to scan suction chamber tangent direction as scanning track by pumping chamber tangent direction.Each Assembly of the parts is obtained multistage centrifugal pump complete machine flow field model.Multistage centrifugal pump flow field model is complicated, and the distortion of the runner such as impeller, pumping chamber is comparatively large, so adopt tetrahedral grid to carry out stress and strain model to it.
By changing choma gap size, the multistage centrifugal pump flow field of different choma wear extent being simulated, the multistage centrifugal pump efficiency under utilizing multistage centrifugal pump simulation precision formula to calculate different choma gap size, obtaining efficiency and wearing and tearing change curve with choma.The efficiency calculation formula of multistage centrifugal pump is:
N
e＝MHg
V
o: inlet velocity m/s;
V
i: outlet velocity m/s;
P
o: inlet pressure Pa;
P
i: outlet pressure Pa;
H: lift m;
N: centrifugal pump shaft power w;
N: rotating speed r/min;
T
y: act on the moment of torsion Nm around y-axis on impeller;
N
e: centrifugal pump useful horsepower w;
M: mass flow rate kg/s;
η: efficiency of centrifugal pump.
Access inlet and outlet pressure respectively from multistage centrifugal pump entrance and exit pressure transmitter and flow transmitter and import and export data on flows, electric moter voltage, current data is read from motor inverter, read electric efficiency and power factor, utilize the Real time Efficiency formula of pump to calculate the real-time useful horsepower of multistage centrifugal pump, realize multistage centrifugal pump efficiency Real-Time Monitoring.More complicated owing to directly measuring multistage centrifugal pump impeller moment of torsion, this patent is by introducing current of electric and voltage data calculating air horsepower.The efficiency calculation formula of real-time multi-stage pump is:
N
e＝MHg
V
o: inlet velocity m/s;
V
i: outlet velocity m/s;
P
o: inlet pressure Pa;
P
i: outlet pressure Pa;
H: lift m;
N: centrifugal pump shaft power w;
U: line voltage V;
I: line current A;
Cos α: power factor;
Δ---electric efficiency
N
e: centrifugal pump useful horsepower w;
M: mass flow rate kg/s;
η: efficiency of centrifugal pump.
Gather axial vibration and radial vibration signal, the bearing housing of drive end with anti-drive end is installed level, vertical and axial acceleration sensor, gather the vibration values of multistage centrifugal pump drive end bearing and non-driven-end bearing.The bearing (ball) cover of each bearing housing installs current vortex sensor, measures rotor radial vibration values.Data capture is completed by data acquistion system, data acquistion system involving vibrations sensor, guard grating, data acquisition unit, data application management device.
Determine whether that choma weares and teares the decrease in efficiency caused, according to the multistage centrifugal pump Real time Efficiency calculated and relationship between efficiency history estimating outlet ring wear extent according to axial vibration and radial vibration value.
Accompanying drawing explanation
Fig. 1 modeling procedure
Fig. 2 choma monitoring method schematic diagram
Fig. 3 efficiency is with choma wearing and tearing change modeling curve
Axial vibration and nominal situation comparison diagram when Fig. 4 wear extent is 0.3mm and 0.7mm
Embodiment
Below in conjunction with accompanying drawing, the present invention is described further the diagnostic method of choma wear extent.
As shown in Figure 1 and Figure 2, flow process of the present invention comprises:
1) set up runner model, set up choma gap flow field, impeller channel model and spiral casing flow passage model based on computation fluid dynamics theory, three is carried out assemble the complete machine runner model that can obtain centrifugal pump.
2) change choma gap size, and then complete machine runner there occurs change, obtains the complete machine runner model in the situation of different choma gaps.
3) carry out computational analysis to model, under different choma gap size, the pressure reduction between the inlet and outlet pressure of multistage centrifugal pump changes, and can draw the relation between multistage centrifugal pump efficiency and choma gap length by numerical calculation.
4) calculate the efficiency of multistage centrifugal pump, from multistage centrifugal pump entrance and exit pressure transmitter and flow transmitter cut-in pressure and data on flows respectively, utilize the efficiency calculation formula of pump can calculate the real-time useful horsepower of multistage centrifugal pump.
5) gather axial vibration and radial vibration signal, the bearing housing of drive end with anti-drive end is installed level, vertical and axial acceleration sensor, gather the vibration values of the crucial measuring point of multistage centrifugal pump.The bearing (ball) cover of each bearing housing installs current vortex sensor, measures rotor displacement vibration values.
6) the monitoring part of choma wearing and tearing, judges whether it is choma wearing and tearing according to axis and radial vibration, according to efficiency and relationship between efficiency history estimating outlet ring abrasion condition.
Below various piece is specifically described.
One, the foundation of runner model
The main flow passage components of multistage centrifugal pump comprise entrance, suction chamber, impeller, pumping chamber, outlet, choma gap.Formed by the model of multiple parts and obtain setting up complete machine runner model, due to the difference of different piece structure, its model modelling approach is not identical.Impeller channel is more complicated, cannot direct Modling model, subtracted each other by vane profile model and impeller solid domain model and set up impeller channel model, the part that in spiral casing flow passage, pumping chamber is connected with suction chamber adopts space curve to scan suction chamber tangent direction as scanning track by pumping chamber tangent direction.Each part is assembled in a certain order and obtains multistage centrifugal pump complete machine flow field model.Multistage centrifugal pump flow field model is complicated, and the distortion of the runner such as impeller, pumping chamber is comparatively large, so adopt tetrahedral grid to carry out stress and strain model to it.In order to improve analysis precision, different size of mesh opening is adopted to obtain higher mesh quality to different parts.And by changing choma gap size, change the complete machine flow field of centrifugal pump, and form the simulation to different choma wear extent situation.
Two, model analysis calculates
Computational analysis is carried out to multistage centrifugal pump runner model, obtains the relation between multistage centrifugal pump efficiency and choma gap length.Computational analysis is carried out to multistage centrifugal pump runner model, obtains the relation between multistage centrifugal pump efficiency and choma gap length.Asynchronous for choma gap situation is defined as the different faults stage of choma, be normal phase, mild wear stage and heavy wear stage, by the calculating to model, the efficiency of the multistage centrifugal pump when choma wearing and tearing are in different phase can be obtained, to data analysis, along with choma gap length changes, there is change in the pressure reduction between the inlet and outlet pressure of multistage centrifugal pump, use multistage pump efficiency calculation formula, can be calculated the relation between multistage centrifugal pump efficiency and choma gap length, along with choma serious wear, its gap increases, the decrease in efficiency of multistage centrifugal pump.
Three, multistage centrifugal pump parameter acquisition
Multistage pump efficiency and inlet and outlet pressure, import and export speed and motor performance relevant, be calculate the real-time useful horsepower of multistage centrifugal pump, from multistage centrifugal pump entrance and exit pressure transmitter and flow transmitter cut-in pressure and data on flows respectively.Gather axial vibration and radial vibration signal, the bearing housing of drive end with anti-drive end is installed level, vertical and axial acceleration sensor, gather the vibration values of the crucial measuring point of multistage centrifugal pump.The bearing (ball) cover of each bearing housing installs current vortex sensor, measures rotor displacement vibration values.
Four, choma wear monitoring
In choma wear monitoring evaluation process, the assessment of choma abrasion condition is carried out by the relation curve of the efficiency that obtained and wear extent, efficiency, axial vibration and radial vibration four indexs, in practical engineering application, the factor affecting multistage centrifugal pump efficiency also comprises impeller burn into impeller blocking etc. except choma wearing and tearing.Introduce radial displacement vibration index and get rid of impeller corrosion and the impact of impeller plugging fault, make the accuracy of choma wear fault diagnosis and Real-Time Monitoring choma wear extent higher.Determine whether choma wear-out failure according to axis and radial vibration, then according to efficiency and relationship between efficiency history estimating outlet ring abrasion condition, choma fault degree is assessed.
Five, experimental verification
Build multistage centrifugal Test-bed for pump, bearing housing is installed equally level, vertical, axial acceleration sensor.From multistage centrifugal pump entrance and exit pressure transmitter and flow transmitter cut-in pressure and data on flows respectively, calculate the real-time useful horsepower of multistage centrifugal pump, introducing current of electric and voltage data calculate air horsepower to calculate multistage centrifugal pump Real time Efficiency.
To blurt out czermak space change curve based on computation fluid dynamics theoretical modeling analysis mode efficiency as shown in Figure 3, the choma that wear extent is 0.3mm and 0.7mm has been manufactured in advance with changing, its axial vibration declines to some extent than under nominal situation as shown in Figure 4, calculating its Real time Efficiency is 65.13%, 62.41%, 3 wear extenies that can check in when Real time Efficiency is 65.13% are 0.33mm with reference to the accompanying drawings, when Real time Efficiency is 62.41%, wear extent is 0.74mm, and experimental result is close with the wear extent manufactured in advance.
Claims (6)
1., based on a multistage centrifugal pump impeller port ring wear extent monitoring method for computation fluid dynamics theory, its feature comprises the steps:
1) set up runner model, set up choma gap flow field, impeller channel model and spiral casing flow passage model based on computation fluid dynamics theory, three is carried out assemble the complete machine runner model that can obtain centrifugal pump;
2) change choma gap size, obtain the complete machine runner model in the situation of different choma gaps, calculate the efficiency value of multistage centrifugal pump under different choma gap, obtain efficiency and to blurt out czermak space change curve;
3) the efficiency Real-Time Monitoring of multistage centrifugal pump, pressure versus flow data are read respectively from multistage centrifugal pump entrance and exit pressure transmitter and flow transmitter, electric moter voltage, current data is read from motor inverter, reading electric efficiency and power factor import and export flow, inlet and outlet pressure, electric current, voltage, electric efficiency and power factor calculating multistage centrifugal pump Real time Efficiency to utilize, and realize multistage centrifugal pump efficiency Real-Time Monitoring;
4) gather axial vibration and radial vibration signal, the bearing housing of drive end with anti-drive end is installed level, vertical and axial acceleration sensor, gather the vibration values at multistage centrifugal pump drive end bearing and non-driven-end bearing place; The bearing (ball) cover of each bearing housing installs current vortex sensor, measures rotor radial vibration values;
6) according to axial vibration and radial vibration value, the monitoring part of choma wearing and tearing, determines whether that choma weares and teares the decrease in efficiency caused, according to the multistage centrifugal pump Real time Efficiency calculated and relationship between efficiency history estimating outlet ring wear extent.
2. method according to claim 1, it is characterized in that: step 1) set up the model that complete machine runner model needs to comprise three parts, subtracted each other by vane profile model and impeller solid domain model and set up impeller channel model, the part that in spiral casing flow passage, pumping chamber is connected with suction chamber adopts space curve to scan suction chamber tangent direction as scanning track by pumping chamber tangent direction; Each part is joined and obtains multistage centrifugal pump complete machine flow field model; Impeller, pumping chamber, suction chamber, choma gap adopt tetrahedral grid to carry out stress and strain model to it.
3. method according to claim 1 and 2, it is characterized in that: step 2) by changing choma gap size, the multistage centrifugal pump flow field of different choma wear extent is simulated, multistage centrifugal pump efficiency under utilizing multistage centrifugal pump simulation precision formula to calculate different choma gap size, obtains efficiency and to wear and tear change curve with choma; The efficiency calculation formula of multistage centrifugal pump is:
N
e＝MHg
V
o: inlet velocity m/s;
V
i: outlet velocity m/s;
P
o: inlet pressure Pa;
P
i: outlet pressure Pa;
H: lift m;
N: centrifugal pump shaft power w;
N: rotating speed r/min;
T
y: act on the moment of torsion Nm around y-axis on impeller;
N
e: centrifugal pump useful horsepower w;
M: mass flow rate kg/s;
η: efficiency of centrifugal pump.
4. method according to claim 1-3 any one, it is characterized in that: access inlet and outlet pressure respectively from multistage centrifugal pump entrance and exit pressure transmitter and flow transmitter and import and export data on flows, electric moter voltage, current data is read from motor inverter, read electric efficiency and power factor, utilize the Real time Efficiency formula of pump to calculate the real-time useful horsepower of multistage centrifugal pump, the efficiency calculation formula of real-time multi-stage pump is:
N
e＝MHg
V
o: inlet velocity m/s;
V
i: outlet velocity m/s;
P
o: inlet pressure Pa;
P
i: outlet pressure Pa;
H: lift m;
N ': the real-time air horsepower w of centrifugal pump;
U: line voltage V;
I: line current A;
Cos α: power factor;
Δ---electric efficiency
N
e: centrifugal pump useful horsepower w;
M: mass flow rate kg/s;
η: efficiency of centrifugal pump.
5. method according to claim 1-4 any one, it is characterized in that: gather axial vibration and radial vibration signal, the bearing housing of drive end with anti-drive end is installed level, vertical and axial acceleration sensor, gathers the vibration values of multistage centrifugal pump drive end bearing and non-driven-end bearing; The bearing (ball) cover of each bearing housing installs current vortex sensor, measures rotor radial vibration values.
6. method according to claim 1-5 any one, it is characterized in that: not rising according to radial vibration, judging efficiency decline is not damage in impeller, the blocking of leaf destruction, impeller causes, decline to judge it is to be worn and torn the decrease in efficiency caused by choma according to axial vibration, according to simulation gained efficiency with multistage centrifugal pump choma wearing and tearing change curve, the multistage centrifugal pump Real time Efficiency that utilization monitors finds out the choma wear extent corresponding to this efficiency, anti-release choma grinding away over time amount.
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| CN112594064A (en) * | 2020-11-25 | 2021-04-02 | 北京航空航天大学 | S2 flow field diagnosis method based on interstage measurement parameters of axial flow compressor |
| WO2023030486A1 (en) * | 2021-09-03 | 2023-03-09 | 中国核电工程有限公司 | Online monitoring method for wall surface abrasion of concrete volute pump |
| CN114790991A (en) * | 2022-04-14 | 2022-07-26 | 国家电投集团电站运营技术（北京）有限公司 | Cavitation detection system and method for water feed pump |
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