US20220356873A1 - Method for identifying damage on a compressor - Google Patents

Method for identifying damage on a compressor Download PDF

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US20220356873A1
US20220356873A1 US17/618,545 US202017618545A US2022356873A1 US 20220356873 A1 US20220356873 A1 US 20220356873A1 US 202017618545 A US202017618545 A US 202017618545A US 2022356873 A1 US2022356873 A1 US 2022356873A1
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intake
temperature
pressure
compressor
determined
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Lorenz Kunz
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BASF SE
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B51/00—Testing machines, pumps, or pumping installations
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
    • F04B49/06—Control using electricity
    • F04B49/065—Control using electricity and making use of computers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
    • F04B49/10—Other safety measures
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B2205/00—Fluid parameters
    • F04B2205/02—Pressure in the inlet chamber
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B2205/00—Fluid parameters
    • F04B2205/04—Pressure in the outlet chamber
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B2205/00—Fluid parameters
    • F04B2205/10—Inlet temperature
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B2205/00—Fluid parameters
    • F04B2205/11—Outlet temperature
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B2207/00—External parameters
    • F04B2207/70—Warnings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B39/00—Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00
    • F04B39/10—Adaptations or arrangements of distribution members

Definitions

  • the invention relates to a method for identifying damage on a compressor having an intake side and a discharge side, in which, starting from measurement data of intake pressure, intake temperature, end pressure and end temperature, a comparison variable is calculated as a measure of damage.
  • Compressors belong to the fluid energy machines which, as work machines, convert supplied energy into different energy states. Compressors are used in various forms, for example in the form of reciprocating compressors for compressing gases.
  • Compressors are usually operated continuously for several months or years and are stopped only for maintenance purposes. During this continuous operation, the functionality of components of the compressor may become impaired, for example by wear, deposits or component failure. This can lead to a drop in the efficiency of the compressor up to the complete functional incapability thereof.
  • various monitoring and diagnosis methods are known in the prior art. In reciprocating compressors, monitoring of the valves on the intake side and on the discharge side is highly relevant in this respect.
  • document EP 1 184 570 A2 describes a system for monitoring the valves of a reciprocating compressor, in which piezoelectric vibration sensors are mounted on each cylinder of the compressor. The sensors detect, via vibrations, the noise generated by the valves as they open and close. By means of downstream signal processing, conclusions can be drawn about the current state of the compressor.
  • sensors are mounted on all the valves to be monitored.
  • sensors are mostly temperature sensors or vibration sensors from which alone or from a combination with further sensors on the compressor, information about the state of the machine is obtained.
  • US patent application US 2017/0030349 A1 describes such a method.
  • Document JP 2002 147905 A discloses a method for monitoring a compressor in a refrigerating apparatus, in which, via pressure and temperature sensors at the inlet and at the outlet of the compressor, a criterion for the state of the compressor is determined from measured values of the intake temperature, the intake pressure, the outlet temperature and the outlet pressure, for example by calculation of a polytropic exponent.
  • a disadvantage of the methods and systems known from the prior art is that they require complicated instrumentation, for example in the form of vibration sensors on all the components to be measured, and/or a complicated evaluation logic for supplying the desired information from the measured signals.
  • the object was to provide a method for monitoring compressors which is able to reliably provide information about possible damage within the compressor and is thereby simple and inexpensive to install and maintain.
  • a subject of the invention is a method for identifying damage on a compressor having an intake side and a discharge side, wherein the method comprises the following steps: (i) acquiring measurement data of the measurement variables intake pressure (p1) and intake temperature (T1) on the intake side and end pressure (p2) and end temperature (T2) on the discharge side;
  • the target variable determined in step (ii) is determined according to an isentropic compression model including the isentropic exponent ( ⁇ K) of the gas to be compressed and a correction factor ( ⁇ ), and the correction factor ( ⁇ ) is adjusted on the basis of measurement data.
  • the isentropic exponent ( ⁇ ) of the gas to be compressed required for the calculation is known to the person skilled in the art and can be found, for example, in publicly accessible or commercially available databases or tables.
  • the correction factor ( ⁇ ) can in this case be omitted or be set at a neutral value.
  • the correction factor ( ⁇ ) is to be included in the calculation of the target variables, the correction factor taking account of effects of the actual compression, for example owing to heating of the gas during the intake stroke by thermal conduction at inner walls of the compressor, in the intake valve or by mixing of the gas drawn in with hot residual gas in the compression chamber.
  • This correction factor ( ⁇ ) is adjusted on the basis of measurement data.
  • steps (i) to (iv) can be carried out in the indicated order. However, different orders of the method steps are also covered by the invention. In particular, steps (ii) and (iii) can also be carried out in the reverse order or also simultaneously.
  • a calculated end temperature (T2b) is determined as the target variable as a function of the measurement data of the end pressure (p2), the intake pressure (p1) and the intake temperature (T1), and in step (iii) the measured end temperature (T2) is determined as the comparison variable.
  • the method accordingly comprises the steps:
  • a calculated intake temperature (T1b) is determined as the target variable as a function of the measurement data of the intake pressure (p1), the end pressure (p2) and the end temperature (T2), and in step (iii) the measured intake temperature (T1) is determined as the comparison variable.
  • the method accordingly comprises the steps:
  • the intake temperature (T1b) calculated in step (ii) is determined according to an isentropic compression model including the isentropic exponent ( ⁇ ) of the gas to be compressed and a correction factor ( ⁇ ), and the correction factor ( ⁇ ) is adjusted on the basis of measurement data.
  • a calculated end pressure (p2b) is determined as the target variable as a function of the measurement data of the end temperature (T2), the intake pressure (p1) and the intake temperature (T1), and in step (iii) the measured end pressure (p2) is determined as the comparison variable.
  • the method accordingly comprises the steps:
  • step (ii) wherein the end pressure (p2b) calculated in step (ii) is determined according to an isentropic compression model including the isentropic exponent ( ⁇ ) of the gas to be compressed and a correction factor ( ⁇ ), and the correction factor ( ⁇ ) is adjusted on the basis of measurement data.
  • a calculated intake pressure (p1b) is determined as the target variable as a function of the measurement data of the intake temperature (T1), the end pressure (p2) and the end temperature (T2), and in step (iii) the measured intake pressure (p1) is determined as the comparison variable.
  • the method accordingly comprises the steps:
  • the intake pressure (p1b) calculated in step (ii) is determined according to an isentropic compression model including the isentropic exponent ( ⁇ ) of the gas to be compressed and a correction factor ( ⁇ ), and the correction factor ( ⁇ ) is adjusted on the basis of measurement data.
  • the measurement variables intake pressure, intake temperature, end pressure and end temperature are acquired as separate measurement variables. It is possible in accordance with the invention, in dependence on the specific embodiment, also to acquire combined or derived measurement variables. For example, in an embodiment in which the determination of the target variable in step (ii) is dependent on a ratio of the end pressure (p2) to the intake pressure (p1), it is possible, instead of acquiring the measurement variables intake pressure (p1) and end pressure (p2), also to acquire the ratio (p2/p1 or p1/p2) thereof directly as the measurement variable.
  • T 2 b T 1/ ⁇ ( p 2/ p 1) ⁇ circumflex over ( ) ⁇ (1 ⁇ 1/ ⁇ ),
  • ⁇ is the isentropic exponent of the gas to be compressed.
  • the correction factor ⁇ can be constant or can be adjusted in dependence on the measurement variables.
  • the correction factor ⁇ is determined as a function of the intake temperature (T1), the intake pressure (p1) and the end pressure (p2).
  • T 1 b T 2 ⁇ ( p 1/ p 2) ⁇ circumflex over ( ) ⁇ (1 ⁇ 1/ ⁇ ),
  • ⁇ is the isentropic exponent of the gas to be compressed.
  • the correction factor ⁇ can be constant or can be adjusted in dependence on the measured variables.
  • the correction factor ⁇ is determined as a function of the end temperature (T2), the intake pressure (p1) and the end pressure (p2).
  • ⁇ is the isentropic exponent of the gas to be compressed.
  • the correction factor ⁇ can be constant or can be adjusted in dependence on the measurement variables.
  • the correction factor ⁇ is determined as a function of the intake temperature (T1), the intake pressure (p1) and the end temperature (T2).
  • p 1 b p 2 ⁇ ( T 1/ T 2/ ⁇ ) ⁇ circumflex over ( ) ⁇ ( ⁇ /( ⁇ 1)),
  • ⁇ is the isentropic exponent of the gas to be compressed.
  • the correction factor ⁇ can be constant or can be adjusted in dependence on the measurement variables.
  • the correction factor ⁇ is determined as a function of the intake temperature (T1), the end temperature (T2) and the end pressure (p2).
  • the adjustment of the correction factor ⁇ can be carried out in different ways.
  • the correction factor ⁇ is determined by regression from historical measurement data.
  • the adjustment of the correction factor ( ⁇ ) is carried out on the basis of measurement data in that, following an overhaul of a compressor, the measurement values acquired after restarting are defined as good and used for adjusting the correction factor.
  • the compressor can thereby purposively be operated by predefined operating states in order to define the good state.
  • T1 intake temperature
  • p1 intake pressure
  • T2 end temperature
  • measurable variables can also be used, for example a speed of the compressor (N), control signals of the intake valve lifter (s), a clearance volume (k) or the gas composition (w 1 , w 2 , w 3 , etc.).
  • the correction factor ⁇ can be calculated, for example, in accordance with the equation
  • ⁇ a ⁇ T 1+ b ⁇ p 2/ p 1+ c+d ⁇ N+e ⁇ s+f ⁇ k+g 1 ⁇ w 1 +g 2 ⁇ w 2 + . . .
  • the factors (a, b, c, d, e, f, g 1 , g 2 , . . . ) can be determined by regression from the corresponding measurement data.
  • the correction factor ⁇ can be calculated, for example, in accordance with the equation
  • ⁇ a ⁇ T 2+ b ⁇ p 1/ p 2+ c+d ⁇ N+e ⁇ s+f ⁇ k+g 1 ⁇ w 1 +g 2 ⁇ w 2 + . . .
  • the correction factor ⁇ can be calculated, for example, in accordance with the equation
  • ⁇ a ⁇ p 1+ b ⁇ T 2/ T 1+ c+d ⁇ N+e ⁇ s+f ⁇ k+g 1 ⁇ w 1 +g 2 ⁇ w 2 + . . .
  • the factors (a, b, c, d, e, f, g 1 , g 2 , . . . ) can be determined by regression from the corresponding measurement data.
  • the correction factor ⁇ can be calculated, for example, in accordance with the equation
  • ⁇ a ⁇ p 2+ b ⁇ T 1/ T 2+ c+d ⁇ N+e ⁇ s+f ⁇ k+g 1 ⁇ w 1 +g 2 ⁇ w 2 + . . .
  • the method in accordance with the invention can be used both in compressors with only one compressor stage and in compressors with a plurality of compressor stages.
  • method steps (i) to (iv) are preferably carried out for at least two compressor stages, particularly preferably for all the compressor stages. It is thereby possible to localize damage in the sense that it can be associated with the respective compressor stage.
  • a further subject of the invention is an apparatus for identifying damage on a compressor having an intake side and a discharge side, wherein the apparatus comprises the following:
  • the apparatus in accordance with the invention can be used both in compressors with only one compressor stage and in compressors with a plurality of compressor stages.
  • the apparatus in accordance with the invention preferably comprises sensors for acquiring measurement data on at least two compressor stages, particularly preferably on all the compressor stages, and the calculation unit is preferably adapted to carry out the calculation steps (a), (b) and (c) for at least two compressor stages, particularly preferably for all the compressor stages.
  • the computer program in accordance with the invention contains program code which, when the computer program is executed on a suitable computer system, is suitable for carrying out the method in accordance with the invention.
  • the computer program product in accordance with the invention comprises a computer-readable medium and a computer program, stored on the computer-readable medium, with program code means which are suitable, when the computer program is run on a suitable computer system, for carrying out the method in accordance with the invention.
  • the subjects in accordance with the invention are suitable for detecting many kinds of damage on different machine elements of compressors. Examples are damage on valves, piston rings, packing glands, defective control devices, for example on intake valve lifters. The only requirement is that the damage manifests itself in the thermodynamic behavior of the compressor stage under consideration.
  • the method in accordance with the invention and the apparatus in accordance with the invention acquire and process only pressure and temperature data.
  • the sensors required in accordance with the invention are inexpensive and in most cases are already provided as standard equipment of the compressors. Cost-intensive retrofitting with vibration sensors, for example, is not necessary.
  • the determination of the target variable and comparison variable and the comparison thereof in steps (ii) to (iv) of the method in accordance with the invention require only the evaluation of a small number of mathematical equations and can be implemented at low expense.
  • the method in accordance with the invention and the apparatus in accordance with the invention allow possible damage such as wear, erosion or deposits to be identified early during operation of the compressor, so that measures which prevent component failure and unplanned machine downtime can be taken in good time.
  • the method in accordance with the invention was applied to the third stage of a compressor in order to identify possible damage occurring there.
  • the compressor was a six-stage, two-crank reciprocating compressor which compresses carbon monoxide from 100 mbarg at about 5° C. to 35° C. to about 325 barg.
  • the first stage of the compressor is equipped with backflow control, with which the delivery rate of the compressor can be set between about 70% and 100% of the maximum delivery rate.
  • the third compressor stage comprises a double-acting piston inside a cylinder.
  • the cylinder of the third stage is so constructed that the two compression chambers on the cover side and on the crank side draw in their gas from a common intake chamber and deliver into a common discharge chamber.
  • the machine is equipped in each compression chamber with two plate valves on each of the intake side and the discharge side.
  • Each stage of the machine is equipped with temperature sensors and pressure sensors on the piping on the intake side and on the discharge side.
  • FIG. 1 shows a extract from the operating data information system of the compressor for the third compressor stage in the period from September 2015 to October 2016.
  • the following variables are shown in the diagram, wherein the left-hand scale indicates temperatures in degrees Celsius and the right-hand scale indicates pressures in barg:
  • a calculated end temperature (T2b) of the third stage was determined as a function of the measurement data of the end pressure (p2), the intake pressure (p1) and the intake temperature (T1).
  • the calculated end temperature (T2b) was determined according to an isentropic compression model including the isentropic exponent ( ⁇ ) of the gas to be compressed and a correction factor ( ⁇ ).
  • the isentropic exponent for carbon monoxide was set in the relevant pressure and temperature range at 1.4.
  • the correction factor ( ⁇ ) was determined from historical data at the value 0.972.
  • the measured end temperature (T2) was used as the comparison variable.
  • the method in accordance with the invention on the basis of the apparatus in accordance with the invention, thus identified damage reliably and early during operation of the compressor. Comparing the comparison variable and the target variable not only provided information on whether damage was present, but also gave a measure of the severity of the damage. On the basis thereof, it was possible to make decisions about measures for preventing a potential component failure and unplanned machine downtime.
  • the method in accordance with the invention was applied to the first stage of a compressor in order to identify possible damage occurring there.
  • the compressor was a seven-stage, two-crank reciprocating compressor which compresses carbon monoxide from 100 mbarg at about 5° C. to 35° C. to about 325 barg.
  • the first stage of the compressor is equipped with backflow control, with which the delivery rate of the compressor can be set between about 70% and 100% of the maximum delivery rate.
  • the first compressor stage comprises a double-acting piston inside a cylinder.
  • the cylinder is so constructed that the two compression chambers on the cover side and on the crank side draw in their gas from a common intake chamber and deliver into a common discharge chamber.
  • the machine is equipped in each compression chamber with three plate valves on each of the intake side and the discharge side.
  • Each stage of the machine is equipped with temperature sensors and pressure sensors on the piping on the intake side and on the discharge side.
  • FIG. 2 shows a extract from the operating data information system of the compressor for the first compressor stage in the period from December 2017 to May 2018.
  • the following variables are shown in the diagram, wherein the left-hand scale indicates temperatures in degrees Celsius and the right-hand scale indicates pressures in barg:
  • a calculated end temperature (T2b) of the first stage was determined as a function of the measurement data of the end pressure (p2), the intake pressure (p1) and the intake temperature (T1).
  • the calculated end temperature (T2b) was determined according to an isentropic compression model including the isentropic exponent ( ⁇ ) of the gas to be compressed and a correction factor ( ⁇ ).
  • the isentropic exponent for carbon monoxide was set in the relevant pressure and temperature range at 1.4.
  • the measured end temperature (T2) was used as the comparison variable.
  • the method in accordance with the invention on the basis of the apparatus in accordance with the invention, is capable of identifying damage reliably and early during operation of the compressor.
  • the method in accordance with the invention was applied to a one-stage, double-acting, two-crank reciprocating compressor which compresses hydrogen from 25 barg at about 5° C. to 35° C. to about 40 barg.
  • Both cylinders are each equipped with an intake line and a discharge line.
  • the compression chambers on the cover side and on the crank side obtain their gas from a common intake chamber and deliver into a common discharge chamber.
  • the machine is equipped in each compression chamber with an annular valve on each of the intake side and the discharge side.
  • the valves on the intake side are each equipped with hydraulic backflow control for regulating the delivery rate.
  • the machine is equipped with temperature sensors and pressure sensors on the piping on the intake side and on the discharge side.
  • the machine was further equipped with a monitoring device as is known from the prior art.
  • This monitoring device comprises temperature sensors on the valve covers of the intake side and the discharge side, which sensors detect the outside temperature of the valve covers. As soon as the measured temperature is above a limit value of 50° C., an alarm is triggered, which indicates defective valves.
  • FIG. 3 shows a extract from the operating data information system of the compressor in the period from September 2017 to March 2018.
  • the following variables are shown in the diagram, wherein the left-hand scale indicates temperatures in degrees Celsius and the right-hand scale indicates the pressure ratio (p2/p1) as a dimensionless number:
  • top curve (solid) end temperature (T2) second curve from the top (solid) calculated end temperature (T2b) third curve from the top (dotted) pressure ratio (p2/p1) second curve from the bottom (dashed) valve cover temperatures 1 and 2 bottom curve (dot-dashed) intake temperature (T1)
  • a calculated end temperature (T2b) was determined as a function of the measurement data of the end pressure (p2), the intake pressure (p1) and the intake temperature (T1).
  • the calculated end temperature (T2b) was determined according to an isentropic compression model including the isentropic exponent ( ⁇ ) of the gas to be compressed and a correction factor ( ⁇ ).
  • the isentropic exponent for hydrogen was set in the relevant pressure and temperature range at 1.4.
  • the correction factor ( ⁇ ) was adjusted on the basis of historical data to the value 0.975.
  • the measured end temperature (T2) was used as the comparison variable.
  • the method in accordance with the invention based on the apparatus in accordance with the invention, thus detected damage reliably and early during operation of the compressor, whereas conventional monitoring by means of temperature measurement at valve covers gave no indication of possible damage.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Computer Hardware Design (AREA)
  • Control Of Positive-Displacement Pumps (AREA)
US17/618,545 2019-06-14 2020-06-04 Method for identifying damage on a compressor Pending US20220356873A1 (en)

Applications Claiming Priority (3)

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EP19180261.0 2019-06-14
EP19180261 2019-06-14
PCT/EP2020/065490 WO2020249461A1 (de) 2019-06-14 2020-06-04 Verfahren zur erkennung von schäden an einem verdichter

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CN114876781A (zh) * 2022-05-13 2022-08-09 液空厚普氢能源装备有限公司 一种加氢站氢气压缩机性能检测方法及系统
CN116104789B (zh) * 2023-02-08 2024-06-11 新疆敦华绿碳技术股份有限公司 一种二氧化碳压缩储能作业中压缩机的运行维护方法

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EP3983681A1 (de) 2022-04-20
WO2020249461A1 (de) 2020-12-17

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