阅读说明：本技术 一种压缩机润滑系统性能检测和故障预警的方法 (Method for performance detection and fault early warning of compressor lubrication system ) 是由 刘文军 侯小兵 黄远明 叶君超 王有朋 于 2021-08-24 设计创作，主要内容包括：本发明提供了一种压缩机润滑系统性能检测和故障预警的方法,流量、温度等均采用无接触式的测量方式避免了对被测流体的污染,且无需对润滑系统的管路进行破坏,便可完成性能检测和分析；可实现油泵实际排量、油冷器换热系数和冷却效率、油滤器过滤精度、油品质量等的在线测试与分析,形成压缩机润滑系统的在线监测与故障诊断和定位的方法；通过定期监测润滑系统性能,可分析预测各零部件的使用寿命和油品更换周期,实现润滑系统的故障预警；测试简单方便,对润滑系统的性能检测过程,压缩机不必停机,便可完成测试。(The invention provides a method for performance detection and fault early warning of a compressor lubricating system, wherein the flow, the temperature and the like are measured in a non-contact mode, so that the pollution to a measured fluid is avoided, and the performance detection and analysis can be completed without damaging a pipeline of the lubricating system; the online test and analysis of the actual discharge capacity of the oil pump, the heat exchange coefficient and cooling efficiency of the oil cooler, the filtering precision of an oil filter, the oil quality and the like can be realized, and the online monitoring, fault diagnosis and positioning method of the compressor lubricating system is formed; the performance of the lubricating system is monitored at regular intervals, so that the service life of each part and the oil product replacement period can be analyzed and predicted, and the fault early warning of the lubricating system is realized; the test is simple and convenient, and the performance of the lubricating system can be tested without stopping the compressor.)

1. A performance detection and fault early warning method for a compressor lubricating system is characterized by comprising the following steps: the system comprises a compressor lubricating system formed by serially connecting and communicating a compressor oil tank (1), an oil pump (2), a heater (3), an oil cooler (4) and an oil filter (6), wherein the performance of the compressor lubricating system is detected by the displacement performance of the oil pump (2), the leakage of the lubricating system is detected, the heating performance of the heater (3) is detected, the cooling performance of the oil cooler (4) is detected and the filtering performance of the oil filter (6) is detected, thereby carrying out fault early warning on each part according to the detection data of each part.

2. The method for performance detection and fault warning of a compressor lubrication system as claimed in claim 1, wherein: the detection steps of the displacement performance of the oil pump (2) are as follows:

s1, after the lubricating system runs stably, measuring the flow Q1 at the outlet of the oil pump (2) through a flow sensor;

s2, comparing the flow Q1 at the outlet of the oil pump (2) with the rated flow of the oil pump (2), and analyzing whether the discharge capacity of the oil pump (2) reaches a design index or not;

s3, judging the performance attenuation condition of the oil pump (2), predicting the service life of the oil pump (2), and early warning the occurrence of the fault of the oil pump (2).

3. The method for performance detection and fault warning of a compressor lubrication system as claimed in claim 1, wherein: the leakage detection steps of the lubrication system are as follows:

a1, a flow sensor measures the flow Q1 at the outlet of the oil pump (2) and the flow Q3 at the outlet of the oil filter (6);

a2, calculating the flow difference between Q1 and Q3 to judge the leakage amount of the lubricating system, wherein the leakage amount is Q1-Q3;

a3, obtaining a decay curve of the performance of the oil pump (2) and the wear leakage condition of a lubricating system through regular monitoring of the actual outlet flow Q1 of the oil pump (2) and leakage quantities Q1-Q3;

a4, thereby predicting how long the displacement of the oil pump (2) will decay to the requirement of the minimum oil supply amount in the future, namely realizing the prediction of the service life of the oil pump (2), and sending early warning information when the displacement of the oil pump (2) is about to be less than the minimum oil supply amount.

4. The method for performance detection and fault warning of a compressor lubrication system as claimed in claim 1, wherein: the heating performance detection steps of the heater (3) are as follows:

b1, measuring the temperature T3 at the outlet of the heater (3) through a temperature sensor, continuously measuring for a period of time, and drawing a graph by taking the measured time as a horizontal axis and the detected temperature T3 as a vertical axis, thereby obtaining an actual temperature rise curve and a heating rate of the heater (3);

b2, thereby calculating the time required for the lubricating oil to be heated to the preset temperature and providing measured data for analyzing the performance of the heater (3);

b3, comparing the graphs detected for a plurality of times, judging the performance attenuation condition of the heater (3), predicting the service life of the heater (3) and giving an early warning about the fault of the heater (3).

5. The method for performance detection and fault warning of a compressor lubrication system as claimed in claim 1, wherein: the cooling performance detection steps of the oil cooler (4) are as follows:

c1, respectively measuring the lubricating oil flow Q1 of the shell side of the oil cooler (4), the lubricating oil inlet temperature T3 of the shell side of the oil cooler (4) and the lubricating oil outlet temperature T4 of the shell side of the oil cooler (4) through a flow sensor and a temperature sensor, and obtaining the actual heat load of the oil cooler (4) through calculation;

c2, measuring the inlet temperature T5 of cooling liquid, the outlet temperature T6 of the cooling liquid and the flow Q2 of the cooling liquid on the tube side of the oil cooler (4), and obtaining the heat taken away by the cooling liquid in unit time;

c3, calculating the actual heat exchange coefficient and cooling efficiency of the oil cooler (4) according to the temperature and flow data of the measured tube side fluid and shell side fluid, and judging whether the heat exchange performance of the oil cooler (4) reaches the design standard or not;

c4, if the heat exchange performance of the oil cooler (4) is lower than a design value, sending early warning information, and meanwhile, providing a basis for fault positioning and judgment;

c5, analyzing the degree of scale formation of the tube pass according to the actual heat exchange coefficient and the cooling efficiency of the oil cooler, and providing a basis for the period of scale removal and cleaning of the oil cooler (4).

6. The method for performance detection and fault warning of a compressor lubrication system as claimed in claim 1, wherein: the filtering performance detection steps of the oil filter (6) are as follows:

d1, a pressure gauge interface at the outlet of the oil filter (6) is connected with a pressure reducing device (7) and a particle counter (8);

d2, decompressing the lubricating oil filtered by the oil filter (6) by a decompressor (7), and then entering a particle counter (8) so that the particle counter (8) analyzes the lubricating oil sample to obtain the filtering precision of the oil filter (6), thereby judging the filtering performance of the oil filter (6).

7. The method for performance detection and fault early warning of the compressor lubricating system according to any one of claims 2 to 5, characterized in that: the flow sensor adopts an indirect mode for detection, the flow sensor is not in direct contact with the measured fluid, so that the pollution to the measured fluid is avoided, and the flow sensor is detachable;

the flow sensor is fixed on a pipeline of the lubricating system through a hoop bracket, so that a detection part of the flow sensor is tightly attached to the pipe wall to detect fluid in the pipeline.

8. The method for performance detection and fault early warning of the compressor lubricating system according to any one of claims 2 to 5, characterized in that: the temperature sensor adopts a hot wire belt temperature sensor which is fixed on the pipe wall of a temperature measuring point, and a circle of heat insulation protective layer is wound on the outer side of the hot wire belt temperature sensor;

the temperature sensor adopts an infrared temperature measuring gun which measures the temperature of the pipe wall of the temperature measuring point, thereby avoiding direct contact with the measured fluid.

Technical Field

The invention relates to the field of compressor lubrication systems, in particular to a method for performance detection and fault early warning of a compressor lubrication system.

Background

The natural gas compressor lubricating system is a key link for guaranteeing the normal operation of the compressor, can effectively reduce the abrasion of a friction pair, and can reduce the working temperature of parts. In actual use, the natural gas compressor lubricating system only depends on two parameters of oil temperature and oil pressure to judge whether the lubricating system works normally. However, whether the actual flow of an oil pump outlet in the lubricating system reaches the rated flow, the heat exchange efficiency of an oil cooler, whether the quality of a lubricating oil product meets requirements and the like is basically not detected, the lubricating oil is replaced in a specified time only by experience, and certain over-design and waste phenomena exist. In order to ensure the long-term stable operation of the compressor lubrication system, the lubrication system newly manufactured needs to be tested to judge whether various parameters of the lubrication system can meet the design standards, so as to provide reliable detection data for the compressor manufacturer. The lubricating system used for a certain period of time also needs to be detected to judge whether various performance parameters can meet the working requirements, and the fault of the lubricating system is early warned in advance. However, the existing detection method usually needs to destroy the existing pipeline of the lubricating system, and the test can be completed only by modifying the pipeline under the state that the compressor is completely stopped, so that the efficiency is low, and time and labor are wasted. If a contactless, convenient measuring method could be provided, the trouble of shutting down and modifying the pipeline could be eliminated.

Disclosure of Invention

The invention mainly aims to provide a method for detecting the performance and early warning faults of a compressor lubricating system, which solves the problems that the performance of each part in the compressor lubricating system cannot be directly and effectively detected, the detection is carried out one by one only under the conditions of damaging a lubricating pipeline and stopping the compressor lubricating system, and the detection efficiency is low and wastes time and labor.

In order to solve the technical problems, the technical scheme adopted by the invention is as follows: the system comprises a compressor lubricating system formed by serially connecting and communicating an oil tank, an oil pump, a heater, an oil cooler and an oil filter, wherein the performance detection of the compressor lubricating system comprises the displacement performance detection of the oil pump, the leakage detection of the lubricating system, the heating performance detection of the heater, the cooling performance detection of the oil cooler and the filtering performance detection of the oil filter, and thus, the fault early warning is carried out on each part according to the detection data of each part.

The detection steps of the displacement performance of the oil pump are as follows:

s1, after the lubricating system runs stably, measuring the flow Q1 at the outlet of the oil pump through a flow sensor;

s2, comparing the flow Q1 at the outlet of the oil pump with the rated flow of the oil pump, and analyzing whether the discharge capacity of the oil pump reaches a design index or not;

and S3, judging the attenuation condition of the oil pump performance, predicting the service life of the oil pump, and early warning the occurrence of the oil pump fault.

The leakage detection steps of the lubrication system are as follows:

a1, measuring the flow Q1 at the outlet of the oil pump and the flow Q3 at the outlet of the oil filter by a flow sensor;

a2, calculating the flow difference between Q1 and Q3 to judge the leakage amount of the lubricating system, wherein the leakage amount is Q1-Q3;

a3, obtaining an attenuation curve of the oil pump performance and the abrasion leakage condition of a lubricating system through regular monitoring of the actual flow Q1 of an oil pump outlet and leakage quantities Q1-Q3;

a4, thereby predicting how long the oil pump displacement will decay to the minimum oil supply requirement in the future, realize the prediction of oil pump life promptly, send early warning information when the oil pump displacement is about to be less than minimum oil supply.

The heating performance detection steps of the heater are as follows:

b1, measuring the temperature T3 at the outlet of the heater through a temperature sensor, continuously measuring for a period of time, and drawing a curve graph by taking the measuring time as a horizontal axis and the detected temperature T3 as a vertical axis so as to obtain an actual temperature rise curve and a heating rate of the heater;

b2, thereby calculating the time required for the lubricating oil to be heated to the preset temperature and providing measured data for analyzing the performance of the heater;

and B3, comparing the graphs detected for multiple times, judging the performance attenuation condition of the heater, predicting the service life of the heater and giving an early warning about the fault of the heater.

The cooling performance detection steps of the oil cooler are as follows:

c1, respectively measuring the lubricating oil flow Q1 of the oil cooler shell pass, the lubricating oil inlet temperature T3 of the oil cooler shell pass and the lubricating oil outlet temperature T4 of the oil cooler shell pass through a flow sensor and a temperature sensor, and obtaining the actual heat load of the oil cooler through calculation;

c2, measuring the inlet temperature T5, the outlet temperature T6 and the flow Q2 of the cooling liquid of the tube pass of the oil cooler, thus obtaining the heat taken away by the cooling liquid in unit time;

c3, calculating the actual heat exchange coefficient and cooling efficiency of the oil cooler according to the temperature and flow data of the measured tube side fluid and shell side fluid, and judging whether the heat exchange performance of the oil cooler meets the design standard;

c4, if the heat exchange performance of the oil cooler is lower than a design value, sending early warning information, and meanwhile providing a basis for fault positioning and judgment;

c5, analyzing the degree of scaling of the tube side of the oil cooler according to the actual heat exchange coefficient and the cooling efficiency of the oil cooler, and providing a basis for the period of descaling and cleaning of the oil cooler.

The steps for detecting the filtering performance of the oil filter are as follows:

d1, a pressure gauge interface at the outlet of the oil filter is connected with a pressure reducing device and a particle counter;

d2, after the pressure of the lubricating oil filtered by the oil filter is reduced by a pressure reducing device, the lubricating oil enters a particle counter, so that the particle counter analyzes the lubricating oil sample, the filtering precision of the oil filter is obtained, and the filtering performance of the oil filter is judged.

In the preferred scheme, the flow sensor adopts an indirect mode for detection, the flow sensor is not in direct contact with the measured fluid, so that the pollution to the measured fluid is avoided, and the flow sensor is detachable;

the flow sensor is fixed on a pipeline of the lubricating system through a hoop bracket, so that a detection part of the flow sensor is tightly attached to the pipe wall to detect fluid in the pipeline.

In the preferred scheme, the temperature sensor is a hot wire belt temperature sensor which is fixed on the pipe wall of a temperature measuring point, and a circle of heat insulation protective layer is wound on the outer side of the hot wire belt temperature sensor;

the temperature sensor adopts an infrared temperature measuring gun which measures the temperature of the pipe wall of the temperature measuring point, thereby avoiding direct contact with the measured fluid.

The invention provides a method for performance detection and fault early warning of a compressor lubricating system, which has the following beneficial effects:

1) the flow, the temperature and the like are measured in a non-contact manner, so that the pollution to the measured fluid is avoided, and the performance detection and analysis can be completed without damaging a pipeline of a lubricating system;

2) the online test and analysis of the actual discharge capacity of the oil pump, the heat exchange coefficient and cooling efficiency of the oil cooler, the filtering precision of an oil filter, the oil quality and the like can be realized, and the online monitoring, fault diagnosis and positioning method of the compressor lubricating system is formed;

3) the performance of the lubricating system is monitored at regular intervals, so that the service life of each part and the oil product replacement period can be analyzed and predicted, and the fault early warning of the lubricating system is realized;

4) the test is simple and convenient, and the performance of the lubricating system can be tested without stopping the compressor.

Drawings

The invention is further illustrated by the following examples in conjunction with the accompanying drawings:

FIG. 1 is a flow chart of the present invention;

in the figure: a compressor oil tank 1; an oil pump 2; a heater 3; an oil cooler 4; a temperature control valve 5; an oil filter 6; a pressure reducing device 7; a particle counter 8.

Detailed Description

Example 1

As shown in figure 1, the method for detecting the performance and early warning the faults of the compressor lubricating system comprises the compressor lubricating system which is formed by serially connecting and communicating a compressor oil tank 1, an oil pump 2, a heater 3, an oil cooler 4 and an oil filter 6, wherein the performance detection of the compressor lubricating system comprises the discharge capacity performance detection of the oil pump 2, the leakage detection of the lubricating system, the heating performance detection of the heater 3, the cooling performance detection of the oil cooler 4 and the filtering performance detection of the oil filter 6, and the fault early warning is carried out on each part according to the detection data of each part.

The steps of detecting the displacement performance of the oil pump 2 are as follows:

s1, after the lubricating system runs stably, measuring the flow Q1 at the outlet of the oil pump 2 through a flow sensor;

s2, comparing the flow Q1 at the outlet of the oil pump 2 with the rated flow of the oil pump 2, and analyzing whether the discharge capacity of the oil pump 2 reaches a design index or not;

and S3, judging the performance attenuation condition of the oil pump 2, predicting the service life of the oil pump 2, and early warning the occurrence of the fault of the oil pump 2.

The leakage detection steps of the lubrication system are as follows:

a1, a flow sensor measures the flow Q1 at the outlet of the oil pump 2 and the flow Q3 at the outlet of the oil filter 6;

a2, calculating the flow difference between Q1 and Q3 to judge the leakage amount of the lubricating system, wherein the leakage amount is Q1-Q3;

a3, obtaining a damping curve of the performance of the oil pump 2 and the abrasion leakage condition of a lubricating system by regularly monitoring the actual outlet flow Q1 of the oil pump 2 and the leakage quantities Q1-Q3;

a4, thereby predicting how long the displacement of the oil pump 2 will decay to the requirement of the minimum oil supply amount in the future, namely realizing the prediction of the service life of the oil pump 2, and sending early warning information when the displacement of the oil pump 2 is about to be less than the minimum oil supply amount.

The heating performance detection steps of the heater 3 are as follows:

b1, measuring the temperature T3 at the outlet of the heater 3 through a temperature sensor, continuously measuring for a period of time, and drawing a graph with the measured time as the horizontal axis and the detected temperature T3 as the vertical axis, thereby obtaining the actual temperature rise curve and the heating rate of the heater 3;

b2, thereby calculating the time required for the lubricating oil to be heated to the preset temperature and providing measured data for analyzing the performance of the heater 3;

b3, comparing the graphs detected for a plurality of times, thereby judging the performance attenuation condition of the heater 3, predicting the service life of the heater 3 and giving an early warning about the fault of the heater 3.

The cooling performance detection steps of the oil cooler 4 are as follows:

c1, respectively measuring the lubricating oil flow Q1 of the shell side of the oil cooler 4, the lubricating oil inlet temperature T3 of the shell side of the oil cooler 4 and the lubricating oil outlet temperature T4 of the shell side of the oil cooler 4 through a flow sensor and a temperature sensor, and obtaining the actual heat load of the oil cooler 4 through calculation;

c2, measuring the inlet temperature T5 of the cooling liquid, the outlet temperature T6 of the cooling liquid and the flow Q2 of the cooling liquid on the tube side of the oil cooler 4, and obtaining the heat taken away by the cooling liquid in unit time;

c3, calculating the actual heat exchange coefficient and cooling efficiency of the oil cooler 4 according to the temperature and flow data of the measured tube side and shell side fluids, and thus judging whether the heat exchange performance of the oil cooler 4 meets the design standard;

c4, if the heat exchange performance of the oil cooler 4 is lower than a design value, sending early warning information, and meanwhile providing a basis for fault positioning and judgment;

c5, analyzing the degree of scale formation of the tube side of the oil cooler according to the actual heat exchange coefficient and the cooling efficiency of the oil cooler, and providing a basis for the period of scale removal and cleaning of the oil cooler 4.

The filtration performance test procedure of the oil filter 6 was as follows:

d1, a pressure gauge interface at the outlet of the oil filter 6 is connected with a pressure reducing device 7 and a particle counter 8;

d2, decompressing the lubricating oil filtered by the oil filter 6 by the decompressor 7, and then entering the particle counter 8, so that the particle counter 8 analyzes the lubricating oil sample, thereby obtaining the filtering precision of the oil filter 6 and judging the filtering performance of the oil filter 6.

In the preferred scheme, the flow sensor adopts an indirect mode for detection, the flow sensor is not in direct contact with the measured fluid, so that the pollution to the measured fluid is avoided, and the flow sensor is detachable;

the flow sensor is fixed on a pipeline of the lubricating system through a hoop bracket, so that a detection part of the flow sensor is tightly attached to the pipe wall to detect fluid in the pipeline. According to the structure, the flow sensor is an ultrasonic flow meter, and is fixed on an oil pipe only by utilizing the clamp bracket, so that the flow of fluid in the pipe can be obtained by enabling the measuring element to be tightly attached to the pipe wall, after the measurement of a certain position is completed, the clamp bracket and the flow sensor can be quickly and conveniently detached, and then the measuring point is fixed to the next pipeline for measurement.

In the preferred scheme, the temperature sensor is a hot wire belt temperature sensor which is fixed on the pipe wall of a temperature measuring point, and a circle of heat insulation protective layer is wound on the outer side of the hot wire belt temperature sensor;

the temperature sensor adopts an infrared temperature measuring gun which measures the temperature of the pipe wall of the temperature measuring point, thereby avoiding direct contact with the measured fluid. According to the structure, the temperature sensor adopts the infrared temperature measuring gun to aim at a pipe wall measuring point near a self-contained thermometer in the lubricating system to obtain the pipe wall temperature, the pipe wall temperature is compared with the temperature reading of fluid in a pipe measured by the thermometer, the conversion coefficient of the wall temperature of the infrared temperature measuring gun pipe and the temperature of the fluid in the pipe is calculated, other temperature measuring points can adopt the coefficient to convert the measured pipe wall temperature into the temperature of the fluid in the pipe, and the measuring mode which is non-contact with the fluid in the pipe, simple and convenient avoids the transformation or the damage to a system pipeline; the hot wire belt temperature sensor is fixed on the pipe wall at the temperature measuring point, and the outer side of the temperature sensor is wound with a circle of heat insulation protective layer, so that the temperature of the pipe wall can be effectively ensured to be consistent with the temperature of fluid in the pipe, the temperature of the fluid in the pipe can be measured without contacting the fluid in the pipe, and the temperature of the fluid can be mutually calibrated with the temperature of the fluid measured by a thermometer arranged on a lubricating system.

The above-described embodiments are merely preferred embodiments of the present invention, and should not be construed as limiting the present invention, and the scope of the present invention is defined by the claims, and equivalents including technical features described in the claims. I.e., equivalent alterations and modifications within the scope hereof, are also intended to be within the scope of the invention.