CN117432645A - Safe shutdown method for series flow of centrifugal compressors - Google Patents
Safe shutdown method for series flow of centrifugal compressors Download PDFInfo
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- CN117432645A CN117432645A CN202311194221.2A CN202311194221A CN117432645A CN 117432645 A CN117432645 A CN 117432645A CN 202311194221 A CN202311194221 A CN 202311194221A CN 117432645 A CN117432645 A CN 117432645A
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- 230000002159 abnormal effect Effects 0.000 claims abstract description 7
- 230000007246 mechanism Effects 0.000 claims description 30
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- 230000009977 dual effect Effects 0.000 claims 1
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- 238000010586 diagram Methods 0.000 description 7
- 230000033228 biological regulation Effects 0.000 description 5
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D27/00—Control, e.g. regulation, of pumps, pumping installations or pumping systems specially adapted for elastic fluids
- F04D27/008—Stop safety or alarm devices, e.g. stop-and-go control; Disposition of check-valves
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Abstract
The invention relates to a safe shutdown method for a serial flow of centrifugal compressors, which is based on a serial flow formed by adjusting inlet guide vanes of the first two centrifugal compressors and adjusting variable rotation speed of the third centrifugal compressor, wherein the three compressors are respectively provided with an anti-surge control loop, and each anti-surge control loop is provided with an anti-surge controller for adjusting the inlet flow of the compressor; the shutdown operation steps are as follows: (1) primary load reduction stage: actively regulating the second compressor, and reducing the flow of gas in the process; (2) stage of step load reduction: simultaneously, three compressors are regulated, so that the flow and pressure of gas in the process are reduced; (3) unloading stage: closing the inlet guide vanes of the first compressor and the second compressor completely, and reducing the rotating speed of the variable frequency motor of the third compressor to the minimum allowable rotating speed; (4) and (3) a brake separating and stopping stage: the compressor motors are shut down. The invention can avoid the phenomenon of abnormal pressure in the shutdown process caused by interaction and mutual influence among a plurality of centrifugal compressors in the series flow, shortens the shutdown time consumption and has economical friendliness.
Description
Technical Field
The invention belongs to the technical field of new energy and energy conservation, and particularly relates to a safe shutdown method for a series flow of centrifugal compressors.
Background
Centrifugal compressors are gas pressurization devices commonly used in large chemical plants and energy plants. In order to increase pressure and reduce power consumption, industrial devices often employ a process in which multiple compressors are connected in series and coolers are provided between each compressor. When a plurality of compressors are operated in series, the compressors have the phenomena of mutual influence and interaction, and accidents such as abnormal pressure, surge, bearing damage and the like occur, so that the operation difficulty of the compressors connected in series is increased. In order to avoid the accidents, the application research is to carry out equipment transformation on the site of the existing accidents, and the transformation process delays the operation of equipment and increases the economic cost.
To avoid potential safety hazards, industrial process equipment needs to be overhauled regularly, and the equipment is stopped regularly. In the shutdown process, the equipment in the series flow is in a state that the operating point changes at any time, and belongs to an unstable operating state; compared with the normal running state, the interaction effect between the compressors in the unstable running state is stronger, and the potential safety hazard of running is more prominent. However, the current study on the shutdown process of the series flow of a plurality of centrifugal compressors is very limited. In the prior art, an operation method for realizing safe shutdown by only optimizing the shutdown process without equipment transformation is not needed.
Disclosure of Invention
The invention aims to provide a safe shutdown method for a series flow of a plurality of centrifugal compressors on the premise of not modifying a field device, so as to avoid the phenomenon of abnormal pressure in the shutdown process caused by interaction and mutual influence among the plurality of centrifugal compressors in the series flow.
The invention is realized by adopting the following technical scheme:
a safe shutdown method for a series flow of centrifugal compressors is based on a series flow formed by adjusting inlet guide vanes of the first two centrifugal compressors and adjusting variable rotation speed of the third centrifugal compressor, wherein the three compressors are respectively provided with an anti-surge control loop, and each compressor is provided with an anti-surge controller for adjusting the inlet flow of the compressor;
the operation steps of the three-compressor series flow when the machine is stopped are as follows:
(1) Primary load reduction stage: in the stage, the second compressor is actively regulated, so that the aim of reducing load is fulfilled; setting an inlet guide vane adjusting mechanism of a first compressor to be passive response, and setting an inlet guide vane adjusting mechanism of a second compressor to be active adjustment, so as to maintain the rotating speed of a variable frequency motor of a third compressor to be unchanged when the variable frequency motor is in normal operation; gradually closing an inlet guide vane adjusting mechanism of the second compressor, and reducing the gas flow in the series flow path;
(2) Stage of step load reduction: in the stage, three compressors are regulated simultaneously, so that the aim of further reducing the process load is fulfilled; when the inlet guide vane adjusting mechanism of the second compressor is reduced to be 2% larger than that of the first compressor, the inlet guide vane adjusting mechanism of the first compressor is set to be actively adjusted, the inlet guide vane adjusting mechanism of the second compressor is set to be passively responded, and the inlet guide vane adjusting mechanism of the second compressor is set to be always 2% larger than that of the first compressor; thereafter, simultaneously reducing inlet guide vane adjustment mechanisms of both compressors; reducing the rotating speed of the variable frequency motor of the third compressor by 2%, and realizing double load reduction of flow and pressure in the series flow;
(3) Unloading stage: when all the anti-surge loops of the three compressors connected in series are established, the inlet guide vane regulating mechanisms of the first compressor are reduced to 30%, and the rotating speed of the third compressor is regulated to 90%, all the inlet guide vane regulating mechanisms of the first two compressors are closed, and the rotating speed of the variable frequency motor of the third compressor is reduced to the minimum allowable rotating speed;
(4) And (3) a brake separating and stopping stage: the compressor motors are shut down.
In the step (1), the second compressor inlet guide vane adjusting mechanism is turned down, so that the gas flow of the series flow can be reduced, and the load reduction is realized.
The invention further improves that in the step (1), the rotating speed of the variable frequency motor of the third compressor is maintained unchanged, which is helpful for balancing the flow load between the second compressor and the third compressor.
In the step (1), the anti-surge controllers of the three compressors are all automatically controlled to ensure the safe operation of the three compressors, and an anti-surge loop is opened in real time to protect the compressors.
In the step (2), when the inlet guide vane adjusting mechanism of the second compressor is reduced to be 2% larger than that of the first compressor, the operation modes of active adjustment and passive response of the first compressor and the second compressor are switched, so that the condition that the load distribution in each compressor is uneven due to the fact that a plurality of centrifugal compressors are simultaneously operated in a series flow is avoided.
In the step (2), the inlet guide vane mechanism of the second compressor is set to be always 2% larger than the inlet guide vane adjusting mechanism of the first compressor, so that the abnormal phenomenon that the inlet pressure of the second compressor is higher than the outlet pressure of the first compressor can be avoided.
In the step (2), the rotating speed of the variable frequency motor of the third compressor is reduced by 2%, so that the double load reduction of the flow and the pressure in the series flow is realized.
In the step (2), the anti-surge controllers of the three compressors are all automatically controlled to ensure the safe operation of the three compressors, and an anti-surge loop is opened in real time to protect the compressors.
In the step (3), the anti-surge controllers of the three compressors are actively controlled at the stage, and all anti-surge valves are set to be in a full-open state at the stage in view of safety.
In step (4), the invention further improves that in order to avoid dangerous operation in the shutdown process, active control of three anti-surge controllers is continuously kept, and the anti-surge valve is kept in a full-open state.
Compared with the prior art, the invention provides a safe shutdown method suitable for a series flow of a plurality of compressors, and has at least the following beneficial technical effects:
(1) The invention can effectively inhibit the pressure abnormality generated by the mutual influence between the devices in the shutdown process of the series flow of the plurality of compressors, thereby realizing the safe shutdown operation of the series flow.
(2) The invention can shorten the time consumption of the shutdown process and reduce the power consumption of the compression process.
(3) The invention can weaken the pressure fluctuation of the downstream compressor caused by transient operation in the unloading and brake-separating shutdown processes, and protect the safety of the series flow from another angle.
(4) The invention does not need to modify field equipment, thereby saving economic cost and not affecting the normal operation of the equipment.
In conclusion, the shutdown process disclosed by the invention achieves the safe, rapid and zero-cost load reduction target.
Drawings
FIG. 1 is a schematic diagram of a series flow of three centrifugal compressors.
The meaning of each reference numeral in the figures is: 1-a first centrifugal compressor, 2-a first cooler, 3-a first gas-liquid separator, 4-a second centrifugal compressor, 5-a second cooler, 6-a second gas-liquid separator, 7-a third centrifugal compressor, 8-a third cooler and 9-a third gas-liquid separator.
FIG. 2 is a schematic diagram of an operating instruction of a prior shutdown process.
The meaning of each symbol in the figure is: (1) -a load-shedding phase, (2) -an unloading phase, (3) -a brake-opening shutdown phase.
FIG. 3 is a graph of inlet pressure variation of a first compressor outlet pressure and a second compressor during an existing shutdown.
Fig. 4 is a state diagram of an operating point of the first compressor during a conventional shutdown.
FIG. 5 is a state diagram of the operating point of the second compressor during a prior shutdown.
FIG. 6 is an operational instruction of the proposed shutdown procedure of the present invention.
The meaning of each symbol in the figure is: (1) -a primary load-shedding phase, (2) -a step-shedding phase, (3) -an unloading phase, (4) -a brake-opening shutdown phase.
FIG. 7 is a graph of inlet pressure variation of the first compressor and the second compressor during shutdown of the present invention.
FIG. 8 is a state diagram of the operating point of the first compressor during shutdown of the present invention.
FIG. 9 is a state diagram of the operating point of the second compressor during shutdown of the present invention.
Detailed Description
The following specific embodiments of the present invention are provided, and it should be noted that the present invention is not limited to the following specific embodiments, and all equivalent changes made on the basis of the technical solutions of the present application fall within the protection scope of the present invention.
Take the three centrifugal compressor series flow shown in fig. 1 as an example. To achieve flow and pressure regulation in a series flow path, the flow path uses both inlet guide vane regulation and variable rotation regulation. The first compressor and the second compressor are inlet guide vane adjustment (IGV) and the third compressor is driven by a variable frequency motor. The three compressors are respectively provided with an anti-surge control loop, and each anti-surge control loop is provided with an anti-surge controller for adjusting the inlet flow of the compressor, so that the three compressors can be ensured to operate in a safe area.
The shutdown process of the existing series flow is as follows:
(1) Load reduction stage: the IGVs of the first compressor and the second compressor are reduced, and the variable frequency motor speed of the third compressor is reduced. At this time, the anti-surge controllers of the three compressors are provided to be automatically controlled in view of safety.
(2) Unloading stage: the IGVs of the first compressor and the second compressor are closed completely, and the rotating speed of the variable frequency motor of the third compressor is reduced to the minimum allowable rotating speed; in order to avoid danger during the shut down, all anti-surge valves are set to a fully open state.
(3) And (3) a brake separating and stopping stage: shutting down all compressor motors; the fully open state of all anti-surge valves is maintained.
The operating instructions of the three compressors and the operating process of the three anti-surge valves are shown in fig. 2.
During the shutdown of the industrial site described above, the first compressor outlet gas pressure gradually decreases, but the second compressor inlet gas pressure gradually increases, even above the first compressor outlet gas pressure, as IGV of the first and second compressors decreases (fig. 3), which is an abnormal phenomenon. Since the second compressor is downstream of the first compressor, the outlet gas of the first compressor is the inlet gas source of the second compressor, and the trend of the inlet gas pressure of the second compressor should be consistent with the trend of the outlet gas pressure of the first compressor.
This pressure anomaly was analyzed to be due to interactions, interactions between multiple compressors in a series flow path. The first compressor is upstream, the IGV of the first compressor gradually decreases as the shutdown process progresses, the inlet flow of the first compressor decreases, and when the flow decreases to a point near the anti-surge control line, the anti-surge system of the first compressor automatically starts, and the anti-surge control valve opens, so that the gas flow flowing into equipment downstream of the system is smaller than the inlet flow of the first compressor. I.e., after the anti-surge control valve of the first compressor is opened, the inlet flow of the second compressor is less than the inlet flow of the first compressor.
During shutdown, the IGVs of the second compressor are progressively reduced and the inlet flow to the second compressor is reduced, and the anti-surge system is automatically activated when the inlet flow to the second compressor is reduced to near the anti-surge control line. At this time, the inlet gas of the second compressor is partially derived from the outlet of the first compressor and partially derived from the anti-surge control circuit of the second compressor, which is another reason for the mismatch of the flow rates of the first and second compressors.
Meanwhile, the variable frequency motor of the third compressor is in rotation speed reduction operation, the inlet flow rate of the third compressor is reduced along with the rotation speed reduction of the variable frequency motor, so that the gas at the outlet of the second compressor cannot flow into the third compressor completely, and flows back to the inlet of the second compressor from the anti-surge control loop of the second compressor, and the flow mismatch degree of the first compressor and the second compressor is increased.
The flow mismatch between the first compressor and the second compressor caused by the above reasons gradually develops a load mismatch between the two compressors, and thus an inlet pressure abnormality phenomenon of the second compressor occurs. The phenomenon that the inlet pressure of the compressor is abnormally increased easily causes accidents such as shaft vibration increase, bearing burning loss, even initiation of interlocking shutdown and the like when the compressor unit is operated, and the safe operation of the compressor unit is influenced.
In order to avoid the pressure anomaly, the invention provides a series compressor unit shutdown method, which comprises the following operation steps:
(1) Primary load reduction stage: the IGV of the first compressor is set to be passive response, the IGV of the second compressor is set to be active regulation, and the rotating speed of the variable frequency motor of the third compressor is maintained unchanged. The IGVs of the second compressor are gradually turned off to achieve the purpose of reducing the gas flow in the series flow. The anti-surge controllers of the three compressors are all automatically controlled.
The gas flow in the series flow can be reduced by reducing the IGV of the second compressor, so that the load reduction purpose is realized; the rotation speed of the variable frequency motor of the third compressor is maintained unchanged, so that flow balance between the second compressor and the third compressor is facilitated, and load balance between the two compressors is ensured.
(2) Stage of step load reduction: when the IGV of the second compressor is 2% greater than the IGV of the first compressor, the IGV of the first compressor is set to actively modulated, the IGV of the second compressor is set to passively responsive, and the IGV of the second compressor is set to always be 2% greater than the IGV of the first compressor. Thereafter, simultaneously reducing the IGV of both compressors; the rotation speed of the variable frequency motor of the third compressor is reduced by 2 percent. The anti-surge controllers of the three compressors are all automatically controlled.
The operation modes of active regulation and passive response of the first compressor and the second compressor are switched, so that the condition of uneven load distribution among the compressors caused by simultaneously operating a plurality of centrifugal compressors can be avoided. The inlet guide vane mechanism of the second compressor is set to be 2% larger than the inlet guide vane adjusting mechanism of the first compressor all the time, and the abnormal phenomenon that the inlet pressure of the second compressor is higher than the outlet pressure of the first compressor can be effectively avoided.
(3) Unloading stage: and (3) closing the IGVs of the first compressor and the second compressor completely, and reducing the rotating speed of the variable frequency motor of the third compressor to the minimum allowable rotating speed. For safety reasons, the anti-surge controllers actively control three compressors and set all anti-surge valves to be in a full-open state.
(4) And (3) a brake separating and stopping stage: shutting down all compressor motors; at the moment, in order to avoid dangerous operation in the shutdown process, active control of three anti-surge controllers is continuously kept, and the anti-surge valve is kept in a full-open state.
The operational instructions of the proposed shutdown procedure are shown in fig. 6.
Industrial field shutdown operations were performed as described above, and the pressure changes of the first and second compressors during shutdown are shown in fig. 7. In the primary load reduction stage and the step load reduction stage, the inlet pressure of the second compressor is always lower than the outlet pressure of the first compressor, so that the shutdown method can effectively inhibit pressure abnormality generated by the mutual influence between devices in the shutdown process of the series flow of a plurality of compressors, and realize the safe shutdown process of the series flow of the compressors.
The operating point state diagrams of the first compressor and the second compressor are shown in fig. 8 and 9, respectively, and in order to keep business data secret, the performance curves are shown in a dimensionless manner, the maximum IGV of the first compressor and the second compressor is taken as 100%, the dimensionless flow of the performance curves of the compressors takes the maximum blocking flow of the compressors as a dimensionless reference, and the normalized pressure ratio of the compressors takes the maximum pressure ratio as a reference. Compared with the existing shutdown process (fig. 4 and 5), the shutdown method proposed by the invention has smooth and smooth track of the running points of the first compressor and the second compressor, and the shutdown process is smooth, and the phenomenon that more working points repeatedly fluctuate does not occur.
In comparison with fig. 2 and 6, the load reduction process is shortened by about 1300s after the shutdown method proposed by the present invention is adopted. The stopping method provided by the invention can be used for rapidly completing the load reduction process, shortening the stopping time and being beneficial to reducing the equipment power consumption in the stopping process.
In summary, the method for stopping the series flow of the plurality of centrifugal compressors, which is proposed by the invention, can inhibit the pressure abnormality of the downstream compressors, weaken the pressure fluctuation of the downstream compressors caused by transient operation, and take account of time and power consumption in the stopping process, thereby realizing the safe stopping of the series flow from multiple dimensions. Meanwhile, the shutdown method proposed by the invention does not generate economic cost, and has the safety and economic friendliness in the shutdown process.
While the invention has been described in detail in the foregoing general description and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that modifications and improvements can be made thereto. Accordingly, such modifications or improvements may be made without departing from the spirit of the invention and are intended to be within the scope of the invention as claimed.
Claims (10)
1. A safe shutdown method for a series flow of centrifugal compressors is characterized in that the method is based on a series flow formed by adjusting inlet guide vanes of the first two centrifugal compressors and adjusting variable rotation speed of the third centrifugal compressor, wherein the three compressors are respectively provided with an anti-surge control loop, and each anti-surge control loop is provided with an anti-surge controller for adjusting the inlet flow of the compressor;
the operation steps of the three-compressor series flow when the machine is stopped are as follows:
(1) Primary load reduction stage: in the stage, the second compressor is actively regulated, so that the aim of reducing load is fulfilled; setting an inlet guide vane adjusting mechanism of a first compressor to be passive response, and setting an inlet guide vane adjusting mechanism of a second compressor to be active adjustment, so as to maintain the rotating speed of a variable frequency motor of a third compressor to be unchanged when the variable frequency motor is in normal operation; gradually closing an inlet guide vane adjusting mechanism of the second compressor, and reducing the gas flow in the series flow path;
(2) Stage of step load reduction: in the stage, three compressors are regulated simultaneously, so that the aim of further reducing the process load is fulfilled; when the inlet guide vane adjusting mechanism of the second compressor is reduced to be 2% larger than that of the first compressor, the inlet guide vane adjusting mechanism of the first compressor is set to be actively adjusted, the inlet guide vane adjusting mechanism of the second compressor is set to be passively responded, and the inlet guide vane adjusting mechanism of the second compressor is set to be always 2% larger than that of the first compressor; thereafter, simultaneously reducing inlet guide vane adjustment mechanisms of both compressors; reducing the rotating speed of the variable frequency motor of the third compressor by 2%, and realizing double load reduction of flow and pressure in the series flow;
(3) Unloading stage: when all the anti-surge loops of the three compressors connected in series are established, the inlet guide vane regulating mechanisms of the first compressor are reduced to 30%, and the rotating speed of the third compressor is regulated to 90%, all the inlet guide vane regulating mechanisms of the first two compressors are closed, and the rotating speed of the variable frequency motor of the third compressor is reduced to the minimum allowable rotating speed;
(4) And (3) a brake separating and stopping stage: the compressor motors are shut down.
2. The method for safely stopping a serial flow of centrifugal compressors according to claim 1, wherein in the step (1), the second compressor inlet guide vane adjusting mechanism is turned down to reduce the gas flow rate of the serial flow, thereby realizing load reduction.
3. The method of claim 1, wherein in step (1), maintaining the speed of the variable frequency motor of the third compressor constant helps balance the flow load between the second compressor and the third compressor.
4. The method for safely stopping a serial flow of centrifugal compressors according to claim 1, wherein in the step (1), in order to ensure safe operation of three compressors, anti-surge controllers of the three compressors are all automatically controlled, and an anti-surge loop is opened in real time to protect the compressors.
5. The method according to claim 1, wherein in the step (2), when the inlet guide vane adjusting mechanism of the second compressor is reduced to 2% greater than that of the first compressor, the operation modes of active adjustment and passive response of the first compressor and the second compressor are switched, so as to avoid uneven load distribution in each compressor caused by simultaneous operation of a plurality of centrifugal compressors in the serial flow.
6. The method according to claim 1, wherein in the step (2), the inlet guide vane mechanism of the second compressor is set to be always 2% larger than the inlet guide vane adjusting mechanism of the first compressor, so that an abnormal phenomenon that the inlet pressure of the second compressor is higher than the outlet pressure of the first compressor can be avoided.
7. The safe shutdown method of a serial flow of centrifugal compressors according to claim 1, wherein in the step (2), the rotation speed of a variable frequency motor of the third compressor is reduced by 2%, so as to realize dual load reduction of flow and pressure in the serial flow.
8. The method for safely stopping a serial flow of centrifugal compressors according to claim 1, wherein in the step (2), in order to ensure safe operation of three compressors, anti-surge controllers of the three compressors are all automatically controlled, and an anti-surge loop is opened in real time to protect the compressors.
9. The method according to claim 1, wherein in step (3), the anti-surge controllers of three compressors are actively controlled in this stage, and all anti-surge valves are set to be in a fully open state in view of safety.
10. The method of claim 1, wherein in step (4), in order to avoid dangerous operation during shutdown, active control of three anti-surge controllers is continuously maintained, and the anti-surge valve is kept in a fully open state.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202311194221.2A CN117432645A (en) | 2023-09-15 | 2023-09-15 | Safe shutdown method for series flow of centrifugal compressors |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202311194221.2A CN117432645A (en) | 2023-09-15 | 2023-09-15 | Safe shutdown method for series flow of centrifugal compressors |
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| CN202311194221.2A Pending CN117432645A (en) | 2023-09-15 | 2023-09-15 | Safe shutdown method for series flow of centrifugal compressors |
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