WO2012076427A1 - Procédé et dispositif pour la surveillance d'une turbomachine, basée sur un modèle - Google Patents

Procédé et dispositif pour la surveillance d'une turbomachine, basée sur un modèle Download PDF

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Publication number
WO2012076427A1
WO2012076427A1 PCT/EP2011/071682 EP2011071682W WO2012076427A1 WO 2012076427 A1 WO2012076427 A1 WO 2012076427A1 EP 2011071682 W EP2011071682 W EP 2011071682W WO 2012076427 A1 WO2012076427 A1 WO 2012076427A1
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Prior art keywords
turbomachine
oil
process parameters
model
monitoring unit
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PCT/EP2011/071682
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German (de)
English (en)
Inventor
Uwe Eike KRÜGER
Bernd Flick
Hans-Josef Roth
Ping Zhang
Olaf Kahrs
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Basf Se
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Publication of WO2012076427A1 publication Critical patent/WO2012076427A1/fr

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    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B23/00—Testing or monitoring of control systems or parts thereof
    • G05B23/02—Electric testing or monitoring
    • G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
    • G05B23/0218—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
    • G05B23/0243—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults model based detection method, e.g. first-principles knowledge model

Definitions

  • the present invention relates to a method for model-based monitoring of a turbomachine by means of a monitoring unit that receives relevant process parameters of the turbomachinery, performs calculations on the basis of these parameters and, as a result, determines one or more state values by means of which the state of the turbomachine can be evaluated the state value calculations are performed based on one or more physical models of at least one subsystem of the turbomachine. Furthermore, the invention relates to a device for model-based monitoring of a turbomachine.
  • Turbomachines are among the fluid energy machines that convert as engines different types of energy, such as thermal energy, into mechanical energy or converted as working machines energy into other energy states. Turbomachines are used in a variety of ways, for example in the form of steam turbines, gas turbines, water turbines or turbocompressors.
  • turbo machines are operated continuously for several years and parked only for maintenance purposes. During this continuous operation, the functioning of components of the machine may be impaired, for example due to wear, deposits or component failure. This can lead to the reduction of the efficiency of the machine up to its complete inoperability.
  • different monitoring and diagnostic methods are known in the prior art. For safety reasons, limit values for individual important measured variables are usually monitored, for example for bearing temperatures, oil pressures or axial distances of the rotor relative to the housing. With the help of an oil analysis, information about wear particles in the lubricating oil and barrier oil as well as about the change of the oil quality can be obtained. An efficiency monitoring allows conclusions on effects such as fouling or Friedan- currents. Vibration diagnostics are used to detect imbalances and other causes of periodic mechanical vibrations.
  • Neural networks are a representative of empirical black-box models whose expressiveness depends crucially on the data on which they were generated.
  • historical data from selected measures of both input and interest outputs are used to create links in the network. These links form the model on the basis of which, after the training phase, current output values are calculated from current input variables.
  • a neural network is a so-called black box model, which in this case means that the model does not allow any conclusions to be drawn about the internal relationships of the underlying real system, but only makes statements about the input and output variables considered. This lack of transparency represents a further disadvantage, since requirements for diagnostic functions can thus only be met to a limited extent.
  • a monitoring unit receives relevant process parameters of the turbomachine.
  • process parameters all data can be taken into account which can be metrologically recorded on or in parts of the turbomachine or its auxiliary systems, for example the oil system.
  • process parameters of the turbomachine may be data that can be metrologically recorded on or in other technical systems that are in communication with the turbomachine or its auxiliary systems.
  • process parameters are the properties such as pressure, temperature, composition, volume or volume flow of the gas stream in a process gas supply line to a turbomachine or the Power and speed of an electric motor or a steam turbine that drives a turbocompressor.
  • the relevance of the process parameters depends on the subsystem considered and must be determined on a case-by-case basis. As an example, subsystems with their associated relevant process parameters are specified below.
  • the detection of the process parameters and their transmission to the monitoring unit can take place in different ways, for example by electrical signals of a suitable transducer to the monitoring unit. Corresponding metrological and information technology methods and means are known in the art.
  • the monitoring unit On the basis of the received process parameters, the monitoring unit carries out calculations and determines as a result one or more state values by means of which the state of the turbomachine can be evaluated. According to the invention, the calculations are performed on the basis of one or more physical models of at least one subsystem of the turbomachine.
  • a physical model is to be understood as meaning that in reality existing interactions between process parameters and state values are mapped in the model.
  • the level of detail depends, among other things, on the state values of interest and the available computing time. Examples of models and their calculated state values are given below in connection with the corresponding subsystems.
  • Turbomachinery especially in the chemical industry, are often designed and instrumented for the specific application.
  • the respective process gas properties such as pressure, temperature range or chemical composition as well as operational requirements such as mileage, redundant design, startup and shutdown processes and safety must be taken into account.
  • different requirements for monitoring can be met by means of the physical models according to the invention.
  • the calculations of the state values are carried out on the basis of a plurality of physical models, each of which represents a subsystem of the turbomachine.
  • the models of the subsystems are preferably created as modules, so that an overall model can be selected from the individual modules and assembled as needed.
  • calculated state values can be linked to other state values or measured values by means of equations, inequalities or characteristic maps.
  • the respective models of the subsystems themselves can be modular, so that can be used for the overall model creation on a kind of modular modules and submodules.
  • This embodiment has the advantage that a monitoring unit according to the invention can be flexibly and efficiently adapted to the most varied designs, process conditions and instrumentation of a turbomachine.
  • state values are calculated on the basis of the relevant process parameters which are not detected by measurement or can not be detected, but contain important information about the state of the turbomachine.
  • state values are mechanical forces, bearing load or heat generation in a subsystem of the turbomachine.
  • monitoring of the turbomachine can be carried out by comparing calculated state values with their respective limit values, for example the bearing load calculated from relevant process parameters with the limit value of the maximum permissible bearing load given by the bearing material properties.
  • state values are calculated on the basis of the relevant process parameters, which are detected by measurement in or on the turbomachine or its auxiliary systems.
  • the monitoring of the turbomachine may mean that calculated state values are compared with the respective measured values. This type of monitoring is also referred to as "software redundancy.”
  • the magnitude of the difference between the calculated and measured values can give an indication of the condition and quality of the meter, and the size of the difference can also indicate an untypical or faulty condition of the meter
  • the physical models used in the monitoring unit are based on conservation equations for energy, mass, momentum and / or forces. Such models are valid over a wide range of values of the process parameters used, such as pressures or temperatures, thus providing information about in the past not occurred effects are possible. This represents a significant advantage over empirical black box models. Another advantage is that such physical models can be transferred to other turbomachinery with little effort.
  • a turbomachine is usually constructed of several physically delimitable parts. Examples of such separable parts are thrust bearings, radial bearings, clutch, rotor, shaft, housing, slip ring, floating ring, lubricating oil tank, lubricating oil pump and lubricating oil filter.
  • a subsystem in the sense of this invention may represent a model of an apparatus-technical part of the turbomachine, but it may also comprise a number of apparatus-related parts, for example, axial and radial bearings, barrier oil system or lubricating oil system.
  • the method according to the invention is carried out online during operation of the turbomachine.
  • Relevant process parameters are determined continuously or discontinuously. Depending on the model used, As well as the relevant process parameters required for this purpose, some parameters can also be determined continuously while other parameters are determined discontinuously.
  • the method is applied to a turbo-compressing in a preferred embodiment, it is a multi-stage turbocompressor.
  • a turbocompressor several subsystems can be identified, for which the invention can be used advantageously.
  • the at least one subsystem is selected from barrier oil seal, oil filter and / or bearings, in particular thrust bearing.
  • barrier oil seal, oil filter and / or bearings in particular thrust bearing.
  • the one or more state values preferably contain characteristic information about
  • the axial shaft stand in a warehouse and / or
  • the method according to the invention can furthermore be advantageously applied to the checking of protective devices of a turbomachine.
  • critical values of a turbomachine are usually monitored, for example the axial shaft level, also referred to as the axial distance.
  • the position of the rotor is monitored relative to the compressor housing by distance sensors in order to reliably prevent the rotor from rubbing against the housing.
  • the measuring signals of the redundantly designed sensors must be within a range defined by limits during normal operation of the machine. If the limit of one of the signals is exceeded, the machine is usually automatically moved to a safe state.
  • An advantage of the method according to the invention is that the expected axial distance can be calculated from process parameters such as pressures, temperatures, flow rates and coupling forces in the turbomachine and compared with the metrologically recorded values for the axial distance.
  • process parameters such as pressures, temperatures, flow rates and coupling forces in the turbomachine and compared with the metrologically recorded values for the axial distance.
  • those temporal variations of the measurement signal which are generated by variations in the process parameters, differ from those caused by damage, wear, deposits, errors in the sensor and evaluation electronics or by other errors.
  • the axial distance monitoring is merely an example of a check of a safety device of a turbomachine on the basis of a calculated state value. Further state values suitable for checking are e.g. the barrier oil outlet temperature and the calculated power dissipation in the barrier oil seal, as described below.
  • monitoring of one or more protective devices is based not only on current data but also on historical data.
  • Historical data refers to relevant process parameters whose values have been recorded in the past and stored in a data storage system. It is preferably in the Data storage system to a storage system that is integrated in a process control system, or a so-called operating data information system.
  • An operating data information system is advantageously installed on a separate computer and has data interfaces to the sensors of the turbomachine or to a process control system, which in turn is connected to the information technology of the turbomachinery.
  • sensor technology is understood to mean the entirety of all measuring devices on the turbomachine and their auxiliary systems, for example for detecting temperature, pressure, mass flow, volume flow, distances, current or speed.
  • the historical data contains the information about the behavior of the turbomachine under normal operating conditions and possibly in a defective state. Combined with machine and process knowledge, the historical data allow modeling of normal machine behavior and validation of models. If the turbomachinery had already suffered damage prior to model creation, the historical data can be used to analyze the temporal evolution of the damage and to validate and, if necessary, refine the diagnostic algorithm.
  • the inclusion of historical data is particularly advantageous when measuring devices are to be monitored with regard to their temporal behavior, for example, phenomena such as the drift of measured values.
  • the inventive method is implemented in the form of a program code for a computer program which is suitable for carrying out the method when the computer program is executed on a suitable computer system.
  • the invention further comprises a computer program product with a computer-readable medium and a computer program stored on the computer-readable medium with program code means which are suitable for carrying out the method according to the invention on the execution of the computer program on a suitable computer system.
  • the computer program is preferably created in a familiar programming language and adapted to the respective hardware and software technical requirements of the computer system used.
  • the computer program has a modular structure. This enables efficient implementation of monitoring algorithms for the diverse monitoring requirements, machine designs and equipment variants of the measurement technology.
  • the device comprises a monitoring unit having a calculation unit and a valuation unit, wherein the monitoring unit is prepared for receiving relevant process parameters from the turbomachine, calculations are carried out in the calculation unit on the basis of these parameters and one or more state values can be determined as a result, and the evaluation unit based on the state values of the state of the turbomachine can be evaluated, and wherein the monitoring unit such is arranged such that the calculations on the basis of one or more physical models of at least one subsystem of the turbomachine are feasible.
  • calculation unit preferably all calculation rules such as equations, inequalities and / or characteristic maps of the at least one physical model are stored, which are necessary in order to be able to calculate state values based on the relevant process parameters.
  • the calculated state values are used to evaluate the state of the turbomachine.
  • a report may be prepared for the maintenance personnel, e.g. at fixed times or triggered by valuation unit results such as a limit violation.
  • Such a report can contain information about the current time as well as information about the past or the future.
  • An example of past data is the textual and / or graphical representation of the evolution of calculated state values over a period of time in the past.
  • An example of forward-looking data is predictive values for state values over a given period of time in the future that have been calculated based on the one or more physical models.
  • the monitoring unit is fully or partially implemented on a computer system, and the apparatus further comprises means for transmitting the relevant process parameters from the turbomachine to the monitoring unit.
  • Suitable computer systems are, for example, personal computers (PCs), industrial PCs, process control systems (PCS), programmable logic controllers (PLCs), safety-related PLCs (SSPS), microprocessors embedded in the turbomachine or even central data processing platforms such as manufacturing execution systems.
  • Suitable means for transmitting the relevant process parameters are, for example, wired signal transmission systems such as the 4-20 mA signal or fieldbus systems customary in the process industry, but also wireless systems such as radio links.
  • the means for transmitting relevant process parameters can be implemented as individual connections or in the form of networks, for example as local area networks (LANs), wireless LANs, Internet or intranet connections.
  • the means comprise a system for storing and processing relevant process parameters.
  • this system is an operating data information system.
  • the monitoring unit is completely or partially implemented in the form of function blocks in a process control system.
  • a warning message or alarm message can be sent or an automatic intervention in the process control can be made.
  • the monitoring unit can also be configured in such a way that, given certain conditions, the turbomachine is switched off automatically, for example if a critical situation is determined on the basis of the calculated state values and evaluation criteria.
  • the actions can also be staggered in time or hierarchy.
  • the method according to the invention makes it possible to detect incorrect states or wear conditions at an early stage, which hitherto could not be detected.
  • Examples include a high Axialkraftbelastung the thrust bearing, misalignment of the bearing, oil charcoal construction on a
  • FIG. 1 shows a schematic diagram of a turbomachine with a monitoring unit
  • FIG. 2 shows a schematic diagram of a turbomachine with an alternative implementation of a monitoring unit
  • Fig. 3 partial models and their connection
  • FIG. 1 schematically shows the coupling of a monitoring unit 20 to a system 10 to be monitored, which contains the turbomachine, its auxiliary systems and other systems which generate measured data for the monitoring task.
  • this system to be monitored is referred to below as "turbomachine 10."
  • the monitoring unit 20 has a calculation unit 22 in which calculations are performed.
  • the models on which the calculations are based may include a plurality of partial models 24.
  • the monitoring unit 20 comprises an evaluation processing unit 26 in which evaluations are carried out.
  • the turbomachine 10 comprises a plurality of subsystems 12, which may be physically delimitable subsystems of the machine, for example axial and radial bearings, barrier oil system or lubricating oil system.
  • Submodels 24 on which the calculation is based may be models of the respective subsystems 12 of the machine. However, a subsystem 12 can also be imaged with the aid of several submodels 24, so that the number of submodels 24 can be significantly greater than the number of subsystems 12.
  • the monitoring unit 20 receives relevant process parameters 14 from the turbomachine 10.
  • the parameters 14 can be transmitted directly, as indicated in the right-hand part of the graph.
  • the parameters 14 may also initially be supplied to a system 30 for storing and processing the relevant process parameters, in particular an operating data information system. From this system, processed parameters 16 are transmitted to the monitoring unit 20.
  • state values 28 are determined in the monitoring unit 20, by means of which state of the turbomachine can be evaluated in the evaluation unit 26.
  • status values 28 and evaluation results 29 are transmitted to a display device 40, for example a display of a data processing device.
  • Fig. 2 shows an alternative form of implementation of the method according to the invention.
  • the submodels 24 of the calculation unit 22 and the evaluation unit 26 are implemented as function blocks in a process control system 50.
  • the system 30 for storing and processing the relevant process parameters and the display device 40 are also part of the process control system 50. Suitable process control systems and their information technology coupling to a turbomachine are known to the person skilled in the art.
  • FIG. 3 shows a scheme of the individual submodels, the numbers meaning:
  • vibration model that contains data from vibration sensors, e.g. Frequency spectra of the vibrations, as part of the relevant process parameters receives.
  • This model applies to the alignment model, the shaft seal model, the clutch model, the rotor model, the axial and radial bearing model and the housing model.
  • the reference numeral 246 denotes the so-called barrier oil system.
  • the barrier oil system serves to degas the cooling oil, to cool it, to clean it and to supply the shaft seals in a controlled manner.
  • the barrier oil system was subdivided into several submodels, the submodel for oil reservoir, the oil filter submodel, the oil pump submodel, the oil cooler submodel, the barrier oil seal submodel and the valves and control valves submodel.
  • the modeling of the submodels of the barrier oil tank, the oil pumps, the oil cooler and the valves and control valves follow the well-known modeling approaches such as mass and energy balance, heat transfer law for oil cooler, characteristics for pump and valves.
  • the oil filter was mapped by the physical model described below.
  • the oil filter is used to remove impurities in the oil. These impurities may be e.g. Abrasion particles, carbon particles or precipitating additives.
  • a significant increase in contaminants indicates a problem in the barrier oil system such as localized temperature increases of the oil or insufficient lubrication with metal abrasion.
  • the oil filter model is advantageously useful for monitoring contaminant status and alerting for significant changes.
  • volume flow V des oil through the filter.
  • a calculated value could also be used by dividing the measured oil mass flow by the oil density.
  • a specific filter parameter k is determined as a state value that can not be detected metrologically. If the value of the filter parameter decreases over time, this is an indicator of increased filter resistance, for example due to particulate build-up. Therefore, the current state and the time until the necessary replacement of the filter can be judged by the evaluation of the filter parameter determined by the model.
  • a warning message is raised if the value of the filter parameter or the rate of change of the filter parameter exceeds the limit. The warning message may indicate increased wear and particulate buildup or a rapid change in oil quality, such as coking. In this way, important components, in this case the oil filter and the oil quality, can be monitored for the safe operation of the turbomachine with the aid of the method according to the invention.
  • the subset of the barrier oil seal includes as balance space the oil distribution passages in the turbomachinery and the seal element itself, in this example a combined floating ring mechanical seal.
  • the inlet temperature of the barrier oil As relevant process parameters, the following were selected for the barrier oil seal: the inlet temperature of the barrier oil,
  • the volume flow of the barrier oil can also be measured and used as a process parameter.
  • the mass flow can be calculated from the volume flow and the temperature-dependent density of the oil.
  • the temperature-dependent specific Heat capacity of the oil and the temperature-dependent viscosity of the oil required were taken from maps for the oil used.
  • the underlying model approaches are a mass balance and an energy balance that takes into account the following energy inputs: the friction in the oil gap of the sealing element at the floating ring, the internal friction of the oil through contact with rotating surfaces and dissipation, the heat input through the housing wall of the oil channels, the heat input via the rotor shaft and the heat input from the mechanical seal.
  • the respective energy components were modeled as a function of several process parameters and adapted to historical measurement data from the normal operation of the turbomachine.
  • p 1 loss p V + p GR + p SR
  • P loss is the total power dissipation
  • P V , P GR , P SR are respectively the ventilation, slip ring and floating ring power loss
  • n the speed of the shaft
  • Ap GR the pressure difference across the slip ring
  • 0 m V ⁇ m GR , 0 m SR the average oil temperatures in the ventilation area, on the sliding ring and on the floating ring
  • c v , c GR , c SR of the geometry of the seal dependent constants such as mean ventilation, Gleitring- and floating ring diameter , Length of the ventilation gap, width of the ventilation gap, floating ring width), friction of the coefficient of friction between the sliding ring and the rotor.
  • the amount of heat dissipated by the barrier oil can be calculated as follows:
  • the temperatures of the barrier oil must not be too high. Too high a temperature would make the oil unstable and lead to contamination in the gap and seal failure.
  • the power loss is important information about the heat generated in the turbomachine during operation. To assess the current state of the barrier oil seal and to predict its future behavior, the state values are evaluated as follows.
  • the inlet temperature of the barrier oil was calculated both as a state value and measured as a relevant process parameter, this is a software redundancy described above.
  • the functionality of the temperature sensor and possibly occurring problems in the sealing oil seal could be monitored.
  • An alarm is triggered when the difference between the calculated and measured inlet temperature exceeds a limit.
  • the status value of the outlet temperature of the barrier oil was similarly used for the monitoring.
  • the temperatures of the barrier oil within the barrier oil seal are usually not detected by measurement.
  • the calculated values of these temperatures were compared with their respective limits. By triggering a warning signal when the limit value is exceeded, the operating and maintenance personnel can be informed in good time about high temperatures within the barrier oil seal.
  • the state values of the power loss and the amount of heat were also compared with their respective limits. For example, increasing power dissipation may indicate increasing friction within the seal, which may be due to increased deposition of carbon in the seal. Taking into account the time course of the power loss in this example, the optimal time for a Cleaning the seal to be determined. Likewise, with the help of this information, the driving style can be adjusted so that the time of cleaning is delayed.
  • the thrust bearing holds the rotor in position relative to the housing by absorbing the axial rotor forces.
  • thrust bearings there are various types, e.g. Tilting pad thrust bearing. In all cases, there is a thin film of oil between the two bearing surfaces, which is maintained by hydrodynamic forces.
  • AT denotes the temperature increase when flowing through the bearing
  • m oil flow
  • c ⁇ the heat capacity
  • the axial thrust force including impulse force, compressive force, piston force and frictional force
  • the state values are used in different ways for the diagnosis as follows.
  • Turbo machines are often equipped with several axial distance probes.
  • the axial distance probes are essential for machine safety so that alarm and shutdown limits are set at their values.
  • experience shows that the axial distance probes often display different values shortly after commissioning.
  • the model-related determination of the axial distance on the basis of relevant process parameters measured online offers the possibility of checking the measured values of the axial distance probes in the form of software redundancy. By comparing the measured values and the axial distance determined by the model, damage to the axial distance probes or to the turbomachine can be detected at an early stage.
  • condition values such as the axial thrust force and the thrust bearing load provided insights into the load condition of the turbomachine axial bearing, which was not available in online form during operation. For example, alarm messages can now be generated as soon as the axial thrust load or the axial bearing load reaches specified limit values.
  • Further important information which can be obtained from the state values of the models according to the invention are statements on the efficiency of the turbomachine.
  • the compressor capacity, the efficiency or its temporal change can be related to relevant process parameters such as the gas flow.
  • the consideration of the temporal courses of such relations allow conclusions to be drawn on phenomena such as fouling or erosion in the turbomachine, which may manifest themselves, for example, in a change in the surface roughness or the effectively usable geometries.
  • Machine geometry e.g., number of stages, impeller diameter
  • Power
  • Intake flow rate volume flow or mass flow
  • Pre-rotation position inlet guide position
  • Machine geometry e.g., number of stages, impeller diameter
  • Power
  • Geometry data of the machine setup including position of the thermal wax steam turbine relative to the foundation and position of the protum;
  • Geometric data e.g., rotor dimensions, bearing, shaft forces, and strain joint
  • Differential pressure control oil filter and stuck to valves; Starting oil pressure for quick-acting valve; Monitoring the functional quick-closing oil pressure; ability of sensors and actuators
  • Another advantage of modular modeling is the ease of portability of an already created model to another turbomachine. On the one hand, only the submodels needed for the new model need to be selected. On the other hand, identical or similar submodels with little need for adaptation can be adopted, depending on the structure of the turbomachinery, so that new models or elaborate adjustments need only be made for significantly different subsystems. This approach saves time and money and increases the reliability of the models when using proven, tested submodels.

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Abstract

L'invention concerne un procédé de surveillance basée sur un modèle, d'une turbomachine au moyen d'une unité de surveillance qui capte des paramètres de processus significatifs de la turbomachine, effectue des calculs sur la base de ces paramètres, et détermine comme résultats une ou plusieurs valeurs d'état, sur la base desquelles l'état de la turbomachine peut être évalué, les calculs des valeurs d'état étant effectués sur la base d'un ou de plusieurs modèles physiques d'au moins un système partiel de la turbomachine. Selon l'invention, le ou les systèmes partiels constituent une butée axiale de la turbomachine et la ou les valeurs d'état ou les nombreuses valeurs d'état sont choisies parmi la force de poussée axiale, la sollicitation de la butée et la position axiale de l'arbre.
PCT/EP2011/071682 2010-12-09 2011-12-05 Procédé et dispositif pour la surveillance d'une turbomachine, basée sur un modèle WO2012076427A1 (fr)

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