Research On Fault Mechanism, Diagnosis And Treatment Of Integrally Geared Compressor Complex System

Integrally geared compressors are key components of processing industries. They are applied extensively in refineries, chemical plants, and other fields because of their compact structure, high efficiency, and wide performance. However, due to the unstability and frequent failure of the integrally geared compressor made by Chinese enterprises, this kind of compressor is purchased from abroad. So, it is necessary to investigate the fault mechanism, diagnosis and treatment of integrally geared compressor,which can provide the theoretical basis and key technology for the efficient,reliable and intelligent of the integrally geared compressor.This paper is supported by the National 973 project "Research on high efficiency, reliability and intelligence of advanced compressors" and Sinopec's project "Development and application of key technology of mechanical vapor compression". The research object is integrally geared compressor. Firstly, the dynamic theory of geared rotor-bearing system is studied. Secondly,theoretical and experimental research on critical load fault discovered by academician Jinji Gao has been carried out. Then, the mechanism of the surge has been investigated by CFD, and the early warning, detection and control method of surge have been put forward. Finally, an intelligent monitoring and control system has been developed for the integrally geared compressor in MVR wastewater treatment plant. The main contents of this paper are as follows:In order to solve the problem of the lack of the dynamic design method for the geared rotor-bearing system of integrally geared compressor in China,the dynamic analysis method of geared rotor-bearing system has been presented based on the finite element method. The accuracy of the proposed method is verified by comparing with a variety of methods.With the critical load failure of the integrally geared compressor,unbalance responses of the coupling system have been solved by using the proposed method of dynamic analysis. The failure mechanism of the critical load has been revealed based on the comparision between the simulation results and experimental results. The design method of the integrally geared compressor has been proposed and the design software has been compiled by Matlab.In order to solve the surge of the centrifugal compressor, the early warning, detection and control methods have been investigated. Firstly, the mechanism of surge is analyzed by fluid dynamics modeling. Secondly, an early warning and detection method based on beta distribution, trend filtering and variable mode decomposition has been proposed. Then, the experiment and optimization of anti-surge limit of anti-surge system have been implemented by using the vibration analysis method on an actual centrifugal compressor. Finally, the surge control strategy has been proposed and experimentally verified.Aiming at the integrally geared compressor of MVR waste water treatment device, the critical load failure has been effectively avoided by using dynamic design method of the integrally geared compressor. A monitoring and control system can be used in explosion-proof environment has been developed.