WO2020003290A1 - Procédés et systèmes pour diagnostiquer des défauts de valve dans des compresseurs alternatifs - Google Patents

Procédés et systèmes pour diagnostiquer des défauts de valve dans des compresseurs alternatifs Download PDF

Info

Publication number
WO2020003290A1
WO2020003290A1 PCT/IB2019/056212 IB2019056212W WO2020003290A1 WO 2020003290 A1 WO2020003290 A1 WO 2020003290A1 IB 2019056212 W IB2019056212 W IB 2019056212W WO 2020003290 A1 WO2020003290 A1 WO 2020003290A1
Authority
WO
WIPO (PCT)
Prior art keywords
vibration data
resonance band
sensor
compressor cylinder
resonance
Prior art date
Application number
PCT/IB2019/056212
Other languages
English (en)
Inventor
Jeffrey Jacob Bizub
Original Assignee
Ai Alpine Us Bidco Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ai Alpine Us Bidco Inc filed Critical Ai Alpine Us Bidco Inc
Publication of WO2020003290A1 publication Critical patent/WO2020003290A1/fr

Links

Classifications

    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01H—MEASUREMENT OF MECHANICAL VIBRATIONS OR ULTRASONIC, SONIC OR INFRASONIC WAVES
    • G01H1/00—Measuring characteristics of vibrations in solids by using direct conduction to the detector
    • 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
    • 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
    • F04B39/1066—Valve plates

Definitions

  • the present invention relates to the diagnosis of malfunctioning components in reciprocating compressors via the detection of particular vibration signals. More specifically, but not by way of limitation, the present invention relates to the use of knock sensors for detecting certain vibrational responses in reciprocating compressors for diagnosing particular operating conditions or malfunctioning components.
  • Reciprocating compressors are used in many industries, including oil refineries, gas pipelines, chemical plants, natural gas processing plants and refrigeration plants. For example, to transport natural gas from production sites to consumers, pipeline operators install large compressors at transport stations along the pipelines. Natural gas pipeline networks connect production operations with local distribution companies through thousands of miles of gas transmission lines. Typically, reciprocating gas compressors are used as the prime mover for pipeline transport operations because of the relatively high pressure ratio required. Reciprocating compressors compress fluid using a piston in a cylinder connected to a crankshaft 13. Crankshaft 13 may be driven by a motor or an engine. A suction valve in the compressor cylinder receives input gas, which is then compressed by the piston and discharged through a discharge valve.
  • a specific challenge when using high-horsepower, high-speed, variable-speed compressors is failure of the compressor valves.
  • a common type of valve used for reciprocating compressors is a plate-type compressor valve (or“plate valve”). These valves experience high plate impact velocities that often result in fatigue or crack failures and a short operating life, leading to frequent valve replacement. As discussed more below, such valves may exhibit a “flutter” during operation, which negatively impacts performance and may be indicative of defective components within the valve. It would be beneficial to accurately detect such malfunctions and defects so that valve components could be repaired or replaced to avoid costly failures and/or improve compressor performance. For example, a cost-effective way to detect valve flutter in reciprocating compressors may be leverage to improve performance, lower maintenance costs, and extend machine life.
  • the present application describes a diagnostic system for use with a compressor system having a compressor cylinder.
  • the diagnostic system may include a sensor configured to measure a vibration signal of the compressor cylinder; and a controller having a hardware processor and a machine-readable storage medium on which is stored instructions that cause the hardware processor to execute a diagnostic process.
  • the diagnostic process may include the steps of: storing a signature vibration data; receiving a sample vibration data from the sensor, wherein the sample vibration data is representative of the vibration signal measured by the sensor over an operating period; comparing the sample vibration data to the signature vibration data to determine a similarity therebetween; and based on the determined similarity, diagnosing that the compressor cylinder has a condition.
  • the signature vibration data may include resonance bands clustered within resonance band groups, each of the resonance band groups including a primary resonance band adjacent to a secondary resonance band.
  • Figure 1 is a block diagram of a reciprocating gas compressor system with controller in accordance with the present disclosure
  • Figure 2 illustrates an exemplary plate valve
  • Figure 3 is an exemplary plot of vibration data measured by a sensor in accordance with embodiments of the present disclosure
  • Figure 4 is an exemplary plot of vibration data measured by a sensor showing a signature of a fluttering valve in accordance with embodiments of the present disclosure.
  • Figure 5 is a flow chart of an exemplary embodiment of a diagnostic process suitable for analyzing vibration data for the detection of a malfunctioning plate valve.
  • the techniques described herein include systems and methods in which knock sensors and the like are used to detect a dynamic response of engine components during the operations of a reciprocating compressor.
  • signals from a knock sensor may be collected and analyzed for diagnosing health and operational fitness related plate valves.
  • FIG. 1 is a block diagram of the basic elements of a reciprocating gas compressor system (or“compressor system”) 10.
  • the elements of compressor system 10 are depicted as those of a typical system, and include an engine or driver 11, compressor cylinders 12, filter bottles 18, suction and discharge piping connections, controller 14, and sensor 19.
  • compressor system 10 has three compressor cylinders 12. In practice, compressor system 10 may have fewer or more such cylinders 12.
  • Compressor valves (not explicitly visible in Figure 1) are installed within each cylinder 12 to permit one-way flow into or out of the cylinder volume.
  • Driver 11 for example, may be an internal combustion engine.
  • Filter bottles 18 are placed between the compressor and the lateral piping, on the suction or discharge side or on both sides.
  • a suction side filter bottle l8a and a discharge side filter bottle l8b are included.
  • filter bottles such as those shown, are installed as a common method for pulsation control.
  • Controller 14 is used to monitor and control operating parameters affecting compressor load and capacity, as well as other functions that will be discussed more below.
  • controller 14 may be equipped with a hardware processor 15 and memory 16 (e.g., non-transitory computer readable medium), as well as appropriate input and output devices, and a user interface.
  • Controller 14 may be programmed to perform the various control tasks and deliver control parameters to compressor system 10. Given appropriate input data, output specifications, and control objectives, algorithms for programming controller 14 may be developed and executed. Controller 14 may electronically communicate with sensor 19 and receive data therefrom.
  • sensor 19 is one suitable for detecting noise or vibrational response within compressor system 10 and/or compressor cylinder 12 during operation.
  • sensor 19 may be a conventional knock sensor. More generally, sensor 19 may be any other conventional sensor configured to sense vibration, sound, acceleration, and/or movement caused by the operation of compressor cylinder 12, for example, a Piezo-electric accelerometer, microelectromechanical system sensor, Hall effect sensor, magnetostrictive sensor, etc.
  • sensor 19 may be used to detect a variety of noise or vibration signals for comparison to a signature of vibration data (or“signature vibration data”) that, in accordance with embodiments of the present invention, has been found to correlate to particular valve condition or defect.
  • a current vibration signal or data sample may be analyzed to determine if it contains the signature vibration data, which then is used to determine whether the corresponding defect or malfunction is likely present within compressor cylinder 12.
  • sensor 19 may be disposed within compressor system 10.
  • sensor 19 is attached to compressor cylinder 12. Because of the percussive nature of valve operation within compressor cylinder 12, sensor 19 may be capable of efficiently detecting and measuring vibration signals when positioned in this way.
  • a single sensor 19 may be used, whereas, in other embodiments, each compressor cylinder 12 may include one or more sensors 19.
  • Sensor 19 is shown communicatively coupled to controller 14. During operations, vibration data representative of the vibration signal measured by sensor 19 is communicated to controller 14 for analysis thereby.
  • FIG. 2 illustrates a conventional plate valve 20 that is commonly used in the compressor cylinders of reciprocating compressors.
  • plate valves include a plate that moves between a seat and guard, which causes channels to alternatively open and close. This movement generally results in high impact velocities between the plate and seat or plate and guard, and this may cause fatigue or crack failures in the plate and, thereby, shorten life and lead to frequent valve replacement.
  • the plate of such valves may“float” or“flutter” at is opens or closes. This defect in operation compromises performance and/or signals a degraded component within the valve. It would be beneficial to accurately detect such malfunction so that valve components could be repaired or replaced to improve performance and avoid component failure.
  • the present disclosure includes a cost-effective way to accurately detect valve flutter during operation of reciprocating compressors.
  • plate valve 20 includes a valve seat 21 and guard 22, which each has passage channels, and one or more plates, which are moveable between seat 21 and guard 22 to control flow through the valve.
  • valve 20 has two plates: a sealing plate 23; and an optional damping plate 26.
  • Each of the sealing plate 23 and damping plate 26 may include passage channels that are opposed by corresponding sealing surfaces and passages on valve seat 21 and guard 22, respectively, so that when valve 20 operates, fluid will flow or not flow through valve 20 depending on the position of sealing plate 23.
  • the passages through sealing plate 23 is sealed or closed by a corresponding sealing surface on seat 21.
  • Springs 24 are used to hold sealing plate 23 in a closed position, and fluid flow direction determines whether fluid will flow or not flow through the valve.
  • a stem may be used to move and/or guide sealing plate 23 against the closure force of springs 24 to open valve 20.
  • plate valve 20 begins in a closed state. In this state, fluid flow in one direction is prevented as sealing plate 23 is held by springs 24 against sealing surfaces of seat 21.
  • valve 20 begins to open as sealing plate 23 dislodges from seat 21, which allows gas to start flowing through the passages of sealing plate 23. Opening further, sealing plate 23 continue its movement away from seat 21 until such movement is prevented when sealing plate 23 impacts guard 22. It is desirable for sealing plate 23 to settle upon guard 22 so that valve 20 quickly attains a fully open state.
  • the impact with guard 22 may result in sealing plate 23 bouncing or fluttering so that repeated impacts, which generally decrease in size, occur before sealing plate 23 settles against guard 22 and the fully open state is achieved.
  • the process then reverses when the differential of pressures acting upon the two sides of sealing plate 23 is overcome by the force of springs 24. When this happens, sealing plate 23 dislodges and moves away from guard 22. This movement is then finally arrested when sealing plate 23 impacts seat 21.
  • the impact against seat 21 also may result in sealing plate 23 bouncing or fluttering before properly coming to rest.
  • sealing plate and the associated springs within a plate valve constitute a potentially oscillating system, with the excitation necessary to give rise to such oscillations being provided by the interaction of this system with the flow and the alternating impacts occurring between the sealing plate and the seat/guard components.
  • oscillation of the sealing plate is excessive, it is referred to as“valve flutter” or, simply,“flutter”.
  • Flutter is an undesirable condition as it can lead to premature valve plate failures, degraded seals, and poor performance.
  • flutter often is an indicator that components within the plate seal are not functioning properly due to some defect or degradation. For example, flutter within such valves can indicate that springs are worn or not sized properly or that the seal plate is cracked or excessively fatigued.
  • early diagnosis of such flutter is advantageous in that corrective action can be taken to improve performance and avoided component failure.
  • plot 80 is shown, which may be derived by controller 14 using vibration data measured by sensor 19 mounted to cylinder 12 of reciprocating compressor system 10.
  • plot 80 includes an amplitude curve 84 showing vibration data representative of signal amplitude measured via sensor 19, in which x-axis 81 is time and y-axis 82 is vibration amplitude.
  • amplitude curve 84 shows a substantially regular signal amplitude over the time period of the plot.
  • a plate position curve 86 which indicates actual movement or displacement of sealing plate 23 during operation, for example, as sealing plate 23 moves from a closed state 88, which is represented by the substantially flat lower portions of plate position curve 86, to an open state 89, which is represented by the raised, slightly rounded portions of plate position curve 86.
  • the depicted movement of sealing plate 23 in curve 86 is characteristic of a properly functioning valve. That is, plate position curve 86 shows that sealing plate 23 generally comes to rest quickly after the impacts associated with transitions between closed and open states. In other words, sealing plate 23 is not bouncing or fluttering on impact.
  • amplitude curve 84 remain substantially regular as plate valve transitions between closed and open states.
  • this type of regular amplitude data reliably correlates to a plate valve that is properly functioning, for example, not exhibiting flutter.
  • amplitude curve 94 thus, represents a test result that provides information as to the current health and performance of a plate valve. According to exemplary embodiments, such results may be cost- effectively obtained via a single knock sensor sampling vibrational data while the compressor operates. Thus, the testing and diagnostic systems and methods described herein do not require compressor shut down to function.
  • a plot 90 includes another amplitude curve— an amplitude curve 94— that, in accordance with the present disclosure, includes an exemplary signature vibration data of a malfunctioning or“fluttering” sealing plate.
  • amplitude 94 is a plot of vibration data measured by sensor 19, in which x-axis 91 is time and y-axis 92 is amplitude.
  • superimposed on amplitude curve 94 is a plate position curve 96 showing actual valve movement, for example, as sealing plate 23 moves from a closed state 98, which is represented by the substantially flat, lower portions of plate position curve 96, to an open state 99, which is represented by the raised, jagged portions of plate position curve 96.
  • open state 99 of plate position curve 96 is not smooth, but jagged and highly variable. Specifically, instead of being smoothly rounded as before, each open state 99 within plate position curve 96 shows that sealing plate 23 is bouncing between elevations as plate valve 20 opens. As will be appreciated, this type of movement is indicative of valve flutter. That is, sealing plate 23 is not desirably coming to rest upon impacting guard 22, but instead, is bouncing or fluttering before finally coming to rest. As already described, such sealing plate flutter negatively impacts the performance of the plate valve and/or signals that the plate valve may have a defective component, such as a cracked sealing plate or degraded springs.
  • amplitude curve 94 of Figure 4 can be used to diagnose a malfunctioning plate valve, in particularly, whether the sealing plate of a compressor valve is fluttering.
  • characteristics of the amplitude curve 94 may be used as a signature that, if present in samples of current operation, indicate likely flutter within the plate valve. The characteristics of this signature (or“signature vibration data”) will now be discussed.
  • a first of these characteristics is the presence of what will be referred to herein as resonance bands.
  • the amplitude data of Figure 4 shows pronounced resonance bands 100, which occur at regular intervals.
  • resonance bands are defined as a period within the plot of increased amplitude, for example, where vibration amplitude increases rapidly to an approximate peak and then falls away sharply.
  • the signature vibration data of the present disclosure may include multiple resonance bands 100, which may be spaced and grouped within the curve in particular ways.
  • the signature vibration data may include resonance bands 100 clustered within a grouping of such resonance bands (or“resonance band group”) 104.
  • the signature vibration data may include multiple, regularly spaced resonance band groups, where each of the resonance band groups 104 include a primary resonance band adjacent to a secondary resonance band.
  • each of resonance band groups 104 may include three such resonance bands 100.
  • a center resonance band 101 is flanked by two lesser or secondary resonance bands, which may be specifically referred to as a leading resonance band 102 and trailing resonance band 103.
  • the resonance bands within each resonance band group 104 may be positioned next or adjacent to each other.
  • center resonance band 101 generally has a greater amplitude than both leading and trailing resonance band 102, 103, whereas the amplitudes of leading and trailing resonance bands 102, 103 may be approximately similar.
  • these types of resonance bands 100 including the arrangement or grouping thereof, have been found to correlate to (and provide a data signature for) flutter occurring with a plate valve of a reciprocating compressor.
  • the signature vibration data may have an intervening signal 95, which is characterized by a more regular amplitude, which is significantly lower than an amplitudes of the included resonance bands 100. That is, between resonance bands groups 104, the amplitude of the vibration data may return to a more regular pattern, such as that shown in Figure 3.
  • resonance bands 100 generally coincide with the transition from closed state 98 to open state 99 and that resonance bands 100 occur primarily during open state 99. It should be appreciated that, depending on the behavior of the system, a sealing plate could exhibit fluttering when transitioning from open state 99 to closed state 98 (i.e., when the sealing plate impacts the seat during closing, instead of the guard during opening). In such cases, resonance bands 100 and resonance band groups 104 would coincide with this transition and, thus, would occur primarily within closed state 98 of the valve. It should be understood that the techniques described herein are applicable to diagnosing flutter in either situation.
  • Figure 5 is a flow chart depicting a diagnostic process 110 suitable for gathering and analyzing vibrational data to diagnose compressor valve flutter, or, at least, determine that an increased likelihood of valve flutter is present.
  • Diagnostic process 110 may be implemented via a computer system that includes a hardware processor and machine-readable storage medium, such as controller 14.
  • the storage medium may include instructions that cause the hardware processor to execute diagnostic process 110.
  • a sensor such as sensor 19, may be configured to measure a vibration signal of a compressor cylinder and transmit such data to the controller.
  • diagnostic process 110 may include an initial step 115 at which a signature vibration data is stored, for example, within memory 16 of controller 14.
  • the signature vibration data for example, may include resonance bands clustered within resonance band groups, as already described.
  • process 110 may include receiving, for example, at controller 14, a sample vibration data from sensor 19, where the sample vibration data is representative of the vibration signal measured by sensor 19 over a particular operating period.
  • diagnostic process 110 may include comparing the sample vibration data against the signature vibration data to determine a similarity therebetween. Then, at a step 130, based on the determined similarity, diagnostic process 110 may include diagnosing that the compressor cylinder does or does not have a particularly condition.
  • the condition may be valve flutter or flutter, e.g., the bouncing or fluttering of a sealing plate within a plate valve.
  • the diagnosed condition may be that there is an increased likelihood that the sealing plate is fluttering within the plate valve.
  • diagnostic process 110 may further include providing an alert regarding the diagnosed condition.
  • controller 14 may prepare an electronic communication regarding valve flutter or increased likelihood of valve flutter and the particular compressor cylinder for which the test results apply.
  • the electronic communication such as email, text, and the like, may then be transmitted to a user device (e.g., computer, phone, tablet) of a specified person, such as an operator, associated with the maintenance of the compressor system.

Abstract

L'invention concerne un système de diagnostic destiné à être utilisé avec un compresseur. Le système de diagnostic peut comprendre un capteur conçu pour mesurer un signal de vibration d'un cylindre de compresseur ; et un dispositif de commande ayant un processeur de matériel et un support de stockage lisible par machine sur lequel sont stockées des instructions qui amènent le processeur de matériel à exécuter un procédé de diagnostic. Le procédé de diagnostic peut comprendre les étapes consistant à : stocker des données de vibration signatures ; recevoir des données de vibration échantillons du capteur, les données de vibration échantillons étant représentatives du signal de vibration mesuré par le capteur ; comparer les données de vibration échantillons aux données de vibration signatures pour déterminer une similitude entre elles ; et sur la base de la similitude déterminée, diagnostiquer que le cylindre de compresseur présente un problème. Les données de vibration signatures peuvent comprendre des bandes de résonance groupées dans des groupes de bandes de résonance, chaque groupe de bandes de résonance comprenant une bande de résonance primaire adjacente à une bande de résonance secondaire.
PCT/IB2019/056212 2018-06-25 2019-07-19 Procédés et systèmes pour diagnostiquer des défauts de valve dans des compresseurs alternatifs WO2020003290A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US16/017,425 2018-06-25
US16/017,425 US20190390665A1 (en) 2018-06-25 2018-06-25 Methods and systems for diagnosing valve defects in reciprocating compressors

Publications (1)

Publication Number Publication Date
WO2020003290A1 true WO2020003290A1 (fr) 2020-01-02

Family

ID=67998530

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB2019/056212 WO2020003290A1 (fr) 2018-06-25 2019-07-19 Procédés et systèmes pour diagnostiquer des défauts de valve dans des compresseurs alternatifs

Country Status (2)

Country Link
US (1) US20190390665A1 (fr)
WO (1) WO2020003290A1 (fr)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4429578A (en) * 1982-03-22 1984-02-07 General Electric Company Acoustical defect detection system
US20050257618A1 (en) * 2004-05-21 2005-11-24 Michael Boken Valve monitoring system and method
US20110041929A1 (en) * 2009-08-19 2011-02-24 Southwest Research Institute Squeeze Film Damper Valve For Compressor Cylinders
US20180073457A1 (en) * 2016-09-09 2018-03-15 Ford Global Technologies, Llc Method and system for knock sensor rationality check

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4429578A (en) * 1982-03-22 1984-02-07 General Electric Company Acoustical defect detection system
US20050257618A1 (en) * 2004-05-21 2005-11-24 Michael Boken Valve monitoring system and method
US20110041929A1 (en) * 2009-08-19 2011-02-24 Southwest Research Institute Squeeze Film Damper Valve For Compressor Cylinders
US20180073457A1 (en) * 2016-09-09 2018-03-15 Ford Global Technologies, Llc Method and system for knock sensor rationality check

Also Published As

Publication number Publication date
US20190390665A1 (en) 2019-12-26

Similar Documents

Publication Publication Date Title
US9726643B2 (en) Gate valve real time health monitoring system, apparatus, program code and related methods
US8554494B2 (en) Pump integrity monitoring
US7542875B2 (en) Reciprocating pump performance prediction
US7069183B2 (en) Early fault detection in pump valves
KR20190089004A (ko) 엔진 건전성 진단 장치 및 방법
US8768631B2 (en) Diagnostic method for detecting control valve component failure
US7623986B2 (en) System and method for power pump performance monitoring and analysis
US20100058880A1 (en) Valve test method and apparatus
KR20100054733A (ko) 공기구동 밸브 진단방법, 공기구동 밸브 진단장치, 및 공기구동 밸브
KR101056755B1 (ko) 압축기용 다이아프램 내구성 실험장치
KR101836085B1 (ko) 유체누설 자가 진단 시스템
US20190390665A1 (en) Methods and systems for diagnosing valve defects in reciprocating compressors
Białek et al. Vibration signals of reciprocating compressor valves
EP3315776B1 (fr) Détection de débit de compresseur alternatif
JP2020128720A (ja) 内燃機関の異常判定装置
Zhang et al. Research on the diagnosis method of reciprocating compressor valve leakage fault with vibration signal
RU2399898C1 (ru) Способ безразборной диагностики степени износа подшипников двигателя внутреннего сгорания
Pichler et al. On the robustness of fault detection in reciprocating compressor valves
WO2023094023A1 (fr) Système de soupape de compresseur alternatif, à capteur intégré
CN106949117A (zh) 一种弹簧阀振动频响特性的测试装置
WO2021050511A1 (fr) Procédé de prédiction d'événements de défaillance pour compresseurs alternatifs
JP2023022359A (ja) 昇圧ポンプの異常判定装置、水素供給システム、及び、昇圧ポンプの異常判定方法
KR20230067141A (ko) 선박용 유압 축압기의 고장 예측 시스템
Gill et al. Examination of Plate Valve Behaviour in a Small Reciprocating Compressor using

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 19772858

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 19772858

Country of ref document: EP

Kind code of ref document: A1