Performance test system and test method for self-circulation running water vapor compressor

Abstract

The invention relates to a self-circulation running water vapor compressor performance test system and test method. Specifically, the system comprises a steam input system, a steam pressurization system, a buffer and storage system, a steam recovery system, an intelligent control system, an optional steam compressor water replenishing system, an optional condensate water recovery system and an optional internal oil cooling system. According to the self-circulation running water vapor compressor performance testing system, only a small amount of external steam needs to be input in the initial starting stage, and after the stable state is achieved, complete self-circulation running can be achieved. The steam consumption is reduced, the overall economical efficiency and the energy utilization rate of the system are improved, and the operation reliability is high.

Description

Technical Field

[0001] This application relates to the fields of energy conservation, environmental protection and heat pump technology, and specifically relates to a performance test system and test method for a self-circulating steam compressor. Background Art

[0002] In the current field of steam compressor performance testing, there are still many bottlenecks and challenges in the existing technology that urgently need to be broken through.

[0003] Existing steam compressor test systems usually rely on electric heating devices or additional heat pump systems to provide external heat sources. For example, in the patent CN114034342B "A Performance Test System and Its Control Method for a Twin-Screw Steam Compressor", electric heating is used to heat the hot water in the water tank, and then steam is generated by flash evaporation to provide heat source conditions for the steam compressor. However, such methods rely on a large amount of electric energy to drive, greatly increasing the overall energy consumption, complexity and initial investment of the system. Moreover, both electric heating and heat pump systems have relatively slow response speeds, and the system preheating startup time is long. In scenarios where rapid temperature adjustment is required, it is difficult to adapt to rapidly changing test requirements, thereby affecting the reliability of test results and the flexibility of the system.

[0004] Existing steam compressor test systems usually do not configure efficient steam recovery devices, and the discharged steam cannot be recycled, resulting in energy waste. Even if some systems consider condensate recovery, for example, the related patent CN116241430A "A Test System for a Water-Working Medium Compressor Based on Thermal Self-Balancing and Its Working Method" introduces a heat recovery mechanism, but due to limited heat exchanger performance, the recovery efficiency is still low, and a large amount of heat is lost during the condensate recovery process. Moreover, such systems generally have problems of complex structure, high cost and large equipment volume, and it is difficult to meet the needs of small and medium-sized enterprises or laboratories for low-cost and high-performance test platforms.

[0005] Existing steam compressor test systems usually ignore the common pressure fluctuations in traditional industrial steam pipe networks. The existing technology lacks effective measures to suppress these transient fluctuations in design and fails to provide an effective pressure stabilizing device, thereby reducing the adaptability and stability of the system in multi-condition test environments.

[0006] Existing steam compressor test systems usually cool the compressor lubricating oil by adding an external fan. This method not only fails to effectively recover the waste heat in the lubricating oil but also leads to an additional increase in system energy consumption.

[0007] In addition, existing steam compressor test systems generally adopt manual operation or simple PLC control, with relatively low levels of automation and intelligence. It is difficult to flexibly simulate and adjust various complex test conditions, which limits the adaptability of the system to changing conditions in practical applications, and further affects the comprehensiveness, accuracy, and reliability of test data.

[0008] In practical applications, steam compressor test systems often struggle to accurately simulate various complex operating conditions. Existing technologies lack professional test systems with strong versatility and stability that can accurately simulate various conditions.

[0009] Therefore, there is an urgent need in the field to develop a performance test system and method for steam compressors with self-circulating operation to overcome the above technical defects, improve the comprehensive performance, energy-saving benefits, and intelligence level of steam compressor performance test systems, so as to meet the urgent needs of modern test platforms for high efficiency, multi-condition adaptability, and low energy consumption. Summary of the Invention

[0010] The purpose of this application is to provide a self-circulating operation steam compressor performance test system based on pipeline steam and energy-saving. Specifically, the self-circulating operation steam compressor performance test system of this application can use the industrial steam network as a heat source, and can include a steam return pipeline and an intelligent flow control system. Only a small amount of external steam needs to be input at the initial startup. After reaching a stable state, full self-circulating operation can be achieved.

[0011] The purpose of this application also lies in providing a steam compressor performance test method using the above-mentioned self-circulating operation steam compressor performance test system.

[0012] To solve the above technical problems, this application provides the following technical solutions.

[0013] In the first aspect, this application provides a self-circulating operation steam compressor performance test system, which includes: A steam input system, including a first buffer tank connected to the industrial steam network, for introducing steam into the self-circulating operation steam compressor performance test system as a heat source; A steam compression system, including a steam compressor, with the input end of the steam compressor connected to the first buffer tank and the output end connected to the second buffer tank; A buffering and storage system, including a first buffer tank and a second buffer tank connected to each other; A steam recovery system, including a second buffer tank, for transporting steam to the industrial steam network and the first buffer tank; An intelligent control system, including an intelligent controller and temperature sensors, pressure sensors, flow sensors, and liquid level sensors installed on each pipeline.

[0014] In an embodiment of the first aspect, the self - circulating steam compressor performance test system further includes: A steam compressor water replenishing system, including a water tank and a heat exchanger. The water tank is connected to the heat exchanger, and the heat exchanger is connected to the steam compressor; A condensate recovery system, including a water tank. The water tank is connected to a first buffer tank and a second buffer tank for recovering condensate.

[0015] In an embodiment of the first aspect, the self - circulating steam compressor performance test system further includes: An internal oil cooling system, including a heat exchanger, an oil tank and an oil pump. The heat exchanger, the oil tank and the steam compressor are connected in a cycle, and the oil pump is arranged on the pipeline connecting the oil tank and the steam compressor.

[0016] In an embodiment of the first aspect, in the steam input system, one end of the first pipeline is connected to the industrial steam network. Along the direction away from the industrial steam network, a first stop valve, a filter, a first steam pressure reducing valve and a check valve are sequentially arranged on the first pipeline. The other end of the first pipeline can be connected to the second pipeline and finally connected to the first buffer tank of the buffer and storage system.

[0017] In an embodiment of the first aspect, in the steam boosting system, the third pipeline is used to connect the first buffer tank and the steam compressor, and the fourth pipeline is used to connect the steam compressor and the second buffer tank. A third pressure sensor, a third temperature sensor, a first flow regulating valve and a first flow sensor are installed on the third pipeline. A third stop valve, a fourth pressure sensor, a fourth temperature sensor and a second flow sensor are installed on the fourth pipeline.

[0018] In an embodiment of the first aspect, in the buffer and storage system, the first buffer tank is connected to the industrial steam network through the second pipeline and the first pipeline. The first buffer tank is also connected to the water tank through the ninth pipeline and the tenth pipeline. The second buffer tank is connected to the water tank through the eighth pipeline and the tenth pipeline. In addition, the first buffer tank is connected to the input end of the steam compressor through the third pipeline, and the second buffer tank is connected to the output end of the steam compressor through the fourth pipeline.

[0019] In an embodiment of the first aspect, in the steam recovery system, the fifth pipeline is used to connect the second buffer tank and the electronically controlled three - way flow regulating valve, the sixth pipeline is used to connect the electronically controlled three - way flow regulating valve and the industrial steam network, and the seventh pipeline is used to connect the electronically controlled three - way flow regulating valve and the second pipeline and finally connected to the first buffer tank. A third flow sensor is installed on the fifth pipeline, a sixth pressure sensor is installed on the sixth pipeline, and a fourth flow sensor, a sixth temperature sensor and a seventh pressure sensor are installed on the seventh pipeline.

[0020] In an embodiment of the first aspect, the steam pressurization system further includes a torque meter for real-time monitoring of the working torque of the steam compressor.

[0021] In the second aspect, the present application provides a method for testing the performance of a steam compressor, which is applied to the self-circulating steam compressor performance testing system as described in the first aspect. The testing method includes the following steps: S1: Put the steam input system into a pre-operating state to ensure the supply of a suitable heat source, and put the internal oil cooling system into a pre-inspection state to ensure that the lubricating oil has suitable fluidity and stability. At the same time, start the steam compressor water replenishing system to ensure stable water supply and meet the water replenishing conditions required by the steam pressurization system; S2: After the intelligent control system confirms that the heat source, lubricating oil, and water supply meet the operating parameters required for the test, start the steam pressurization system, and the buffer and storage system starts to work. Subsequently, start the steam recovery system and the condensate recovery system until the test is completed. In this embodiment, the accuracy of the flow rate is verified by comparing the feedback data of the first flow sensor and the second flow sensor.

[0022] In an embodiment of the second aspect, a small amount of external steam is input at the initial stage of starting the self-circulating steam compressor performance testing system. Once the stable state is reached, no external steam needs to be input anymore.

[0023] Compared with the prior art, the positive effect of the present invention is that the present invention provides an energy-efficient industrial steam heat source system. By directly introducing the industrial steam pipeline network as the heat source, the traditional electric heating device or the additional heat pump system is abandoned, significantly simplifying the equipment structure, reducing the initial construction cost, reducing the operating energy consumption of the system, and improving the overall economy. At the same time, by adopting the pressure feedback regulating device, the outlet pressure can be monitored in real time and accurately regulated, quickly responding to the change of working conditions, shortening the preheating time, and improving the test efficiency. This system can not only meet the multi-condition test requirements of different types of steam compressors, but also provide an efficient and flexible solution, significantly improving the overall performance and economy.

[0024] The present invention provides a steam return pipeline and an intelligent flow control system, which realizes the efficient recycling of steam through innovative design. The system can dynamically adjust the flow rate of the returned steam according to real-time requirements. At the initial stage of startup, the system only relies on a small amount of external steam. Once the stable state is reached, it can achieve full self-circulating operation, significantly reducing the dependence on external steam. At the same time, by returning the excess steam to the pipeline network, steam waste is effectively avoided, and the energy utilization efficiency is improved. This design not only greatly reduces the steam consumption, but also improves the overall economy and energy utilization rate of the system, with significant energy-saving effects.

[0025] In the present invention, a buffer tank is designed as a pressure stabilizing device in the industrial steam pipe network, effectively solving the common pressure fluctuation problem in the steam pipe network. The buffer tank can quickly absorb and relieve the transient impact caused by steam pressure fluctuations, ensuring that the system maintains a stable pressure and temperature during operation. This design significantly improves the data reliability during the test process, enhances the overall stability of the system, ensures high efficiency and reliability under long-term operation, and further optimizes the performance of the system.

[0026] The present invention introduces an oil-cooled heat exchange pipeline, which uses the waste heat of the lubricating oil generated during the operation of the compressor for preheating the makeup water of the steam compressor system, realizing the cascaded recovery of energy. This design effectively reduces the overall energy consumption of the system, improves the energy utilization efficiency, and conforms to the current technological development trend of energy conservation and environmental protection.

[0027] The intelligent control system carried by the present invention integrates multi-parameter real-time monitoring and intelligent collaborative control functions. It can collect and process key parameters such as temperature, pressure, and flow rate during the test process in real time, and accurately adjust the operating states of each subsystem according to the feedback signals. The system automatically optimizes the operating strategy according to different test requirements, not only improving the automation level and operating efficiency of the system, but also effectively reducing the errors caused by human intervention. The intelligent design significantly improves the accuracy and stability of the test data, ensures the high precision and high reliability of the test process, and further optimizes the overall performance and operation convenience.

[0028] In summary, through a series of technological innovations and optimizations, the present invention breaks through multiple limitations of the traditional test system, realizes the simplification of the equipment structure, the maximization of energy utilization, the significant improvement of the test efficiency, and the accurate guarantee of data accuracy. This system provides a more efficient, energy-saving, and intelligent solution for the performance test of steam compressors, not only optimizing the overall operating efficiency, but also greatly improving the automation and reliability of the system, meeting the requirements of modern industry for high-efficiency, green, and intelligent technologies. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to more clearly illustrate the implementation manners of the embodiments of the present application, the relevant drawings will be briefly introduced below. It can be understood that the drawings described below are only used to illustrate some implementation manners of the embodiments of the present application, and those of ordinary skill in the art can also obtain many other technical features and connection relationships not mentioned in this text based on these drawings.

[0030] Figure 1 Schematic diagram showing a steam compressor performance test system with self-circulation operation of an embodiment of the present application.

[0031] In the drawings, the meanings of the respective reference numerals are as follows: 11 First stop valve, 12 Filter, 13 First steam pressure reducing valve, 14 First pressure sensor, 15 First temperature sensor, 16 Check valve, 17 First buffer tank, 18 First safety valve, 19 Second temperature sensor, 20 Second pressure sensor, 21 Second stop valve, 22 Third pressure sensor, 23 Third temperature sensor, 24 First flow regulating valve, 25 First flow sensor, 26 Steam compressor, 27 Torque meter, 28 Motor, 29 Third stop valve, 30 Fourth pressure sensor, 31 Fourth temperature sensor, 32 Second flow sensor, 33 Second buffer tank, 34 Second safety valve, 35 Fifth temperature sensor, 36 Fifth pressure sensor, 37 Third flow sensor, 38 Electrically controlled three-way flow regulating valve, 39 Sixth pressure sensor, 40 Fourth stop valve, 41 Fourth flow sensor, 42 Second steam pressure reducing valve, 43 Sixth temperature sensor, 44 Seventh pressure sensor, 45 First steam trap, 46 Fifth stop valve, 47 Sixth stop valve, 48 Second steam trap, 49 Seventh stop valve, 50 Water purifier, 51 First liquid level sensor, 52 Eighth pressure sensor, 53 Seventh temperature sensor, 54 Water tank, 55 Water pump, 56 Fifth flow sensor, 57 Second flow regulating valve, 58 Heat exchanger, 59 Eighth stop valve, 60 Eighth temperature sensor, 61 Ninth temperature sensor, 62 Second liquid level sensor, 63 Oil tank, 64 Oil pump, 65 Third flow regulating valve, 66 Ninth pressure sensor, 67 Sixth flow sensor; 111 First pipeline, 112 Second pipeline, 113 Third pipeline, 114 Fourth pipeline, 115 Fifth pipeline, 116 Sixth pipeline, 117 Seventh pipeline, 118 Eighth pipeline, 119 Ninth pipeline; 120 Tenth pipeline, 121 Eleventh pipeline, 122 Twelfth pipeline; 80 Intelligent controller. Detailed implementation manners

[0032] Unless otherwise defined, the technical terms or scientific terms used in this specification and claims shall have the ordinary meanings understood by those of ordinary skill in the technical field to which the present invention belongs. The terms "first", "second", etc. are only used for descriptive purposes and cannot be construed as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, features defined with "first", "second", etc. may explicitly or implicitly include one or more of such features. In the description of the present invention, unless otherwise stated, the meaning of "a plurality" is two or more.

[0033] The technical solutions of the present application will be clearly and completely described below in conjunction with the accompanying drawings and the embodiments of the present application.

[0034] As described above, most of the steam compressor test systems in the prior art rely on electric heating devices or externally configured heat pump systems to provide heat sources. This approach not only leads to complex equipment structures and high initial investments but also significantly increases the operating energy consumption of the system. Electric heating and heat pump systems usually have a problem of response lag during the temperature regulation process, resulting in too long preheating time for the system and making it difficult to effectively meet the requirements of rapidly changing operating conditions.

[0035] The prior art generally lacks an effective mechanism for steam recovery. Even if some systems attempt to adopt a condensate recovery strategy, energy waste is often caused due to heat loss and low heat transfer efficiency during the recovery process.

[0036] The prior art usually ignores the common pressure fluctuations in industrial steam pipe networks. The pressure fluctuations in the steam pipe network will have a direct impact on the compressor performance test, resulting in pressure instability in the system during the transient transition stage, thus interfering with the accuracy and repeatability of the test results.

[0037] In the prior art, the waste heat of the lubricating oil generated during the operation of the compressor fails to be effectively recovered, resulting in energy waste, increasing the energy consumption of the system, and thus affecting the overall system efficiency.

[0038] Most of the existing test systems adopt manual operation or basic PLC control, and their automation and intelligence levels are relatively low. They cannot flexibly cope with changing test conditions and lack the dynamic adaptability to multiple operating conditions. These systems cannot accurately adjust the operating states of each subsystem in real time, resulting in limitations in the accuracy and reliability of test data.

[0039] Therefore, in one embodiment, the present application provides a steam compressor performance test system with self-circulating operation based on pipeline steam. The system may include a steam input system, a steam supercharging system, a steam recovery system, a condensate recovery system, a steam compressor water replenishment system, an internal oil cooling system, a buffer and storage system, and an intelligent control system.

[0040] In one embodiment, the steam input system may include a first stop valve 11, a filter 12, a first steam pressure reducing valve 13, a check valve 16, and corresponding connecting pipes. In addition, a first pressure sensor 14 and a first temperature sensor 15 are installed on the first pipeline 111. The function of the steam input system is to draw steam from the industrial steam pipe network and reduce the pressure to the first buffer tank 17 of the buffer and storage system to provide a stable heat source for the steam supercharging system.

[0041] In a specific embodiment, as Figure 1As shown, one end of the first pipeline 111 is connected to the industrial steam pipeline network. Along the direction away from the industrial steam pipeline network, the first stop valve 11, the filter 12, the first steam pressure reducing valve 13, and the check valve 16 are sequentially arranged on the first pipeline 111. The other end of the first pipeline 111 can be connected to the second pipeline 112 and finally connected to the first buffer tank 17 of the buffer and storage system.

[0042] In one embodiment, the water vapor boosting system may include a second stop valve 21, a first flow regulating valve 24, a water vapor compressor 26, a torque meter 27, a motor 28, a third stop valve 29, and corresponding connecting pipelines. In addition, a third pressure sensor 22, a third temperature sensor 23, a first flow regulating valve 24, and a first flow sensor 25 are installed on the third pipeline 113. A third stop valve 29, a fourth pressure sensor 30, a fourth temperature sensor 31, and a second flow sensor 32 are installed on the fourth pipeline 114. The function of the water vapor boosting system is to boost the medium-temperature and medium-pressure steam in the first buffer tank 17 of the buffer and storage system into high-temperature and high-pressure steam and store it in the second buffer tank 33 of the buffer and storage system.

[0043] In a specific embodiment, as Figure 1 shown, the third pipeline 113 is used to connect the first buffer tank 17 and the water vapor compressor 26, and the fourth pipeline 114 is used to connect the water vapor compressor 26 and the second buffer tank 33.

[0044] In one embodiment, the steam recovery system may include a third flow sensor 37, an electrically controlled three-way flow regulating valve 38, a fourth stop valve 40, a second steam pressure reducing valve 42, and corresponding connecting pipelines. In addition, a third flow sensor 37 is installed on the fifth pipeline 115, a sixth pressure sensor 39 is installed on the sixth pipeline 116, and a fourth flow sensor 41, a sixth temperature sensor 43, and a seventh pressure sensor 44 are installed on the seventh pipeline 117. The function of the steam recovery system is to recover the high-temperature and high-pressure steam generated by the water vapor boosting system. Through the electrically controlled three-way flow regulating valve 38, a part of it is depressurized into the first buffer tank 17 of the buffer and storage system to form a self-circulation of the water vapor compressor, and the other part of the excess heat is incorporated into the pipeline network through the sixth pipeline 116 to achieve the effective utilization and recycling of energy.

[0045] In a specific embodiment, as Figure 1 shown, the fifth pipeline 115 is used to connect the second buffer tank 33 and the electrically controlled three-way flow regulating valve 38, the sixth pipeline 116 is used to connect the electrically controlled three-way flow regulating valve 38 and the industrial steam pipeline network. The seventh pipeline 117 is used to connect the electrically controlled three-way flow regulating valve 38 and the second pipeline 112 and finally connected to the first buffer tank 17.

[0046] In one embodiment, the condensate recovery system may include a first steam trap 45, a fifth stop valve 46, a sixth stop valve 47, a second steam trap 48 and corresponding connecting pipes. The function of the condensate recovery system is to recover the heat of the condensate in the first buffer tank 17 and the second buffer tank 33 in the buffer and storage system to the water tank 54, thereby increasing the makeup water temperature of the steam compressor.

[0047] In a specific embodiment, as Figure 1 shown, the eighth pipe 118 is used to connect the second buffer tank 33 and the tenth pipe 120 and finally communicate with the water tank 54. The ninth pipe 119 is used to connect the first buffer tank 17 and the tenth pipe 120 and finally communicate with the water tank 54. The first steam trap 45 and the fifth stop valve 46 are provided on the eighth pipe 118. The sixth stop valve 47 and the second steam trap 48 are provided on the ninth pipe 119.

[0048] In one embodiment, the steam compressor makeup water system may include a seventh stop valve 49, a water purifier 50, a water tank 54, a water pump 55, a second flow regulating valve 57 and a heat exchanger 58. A first liquid level sensor 51, an eighth pressure sensor 52 and a seventh temperature sensor 53 are installed on the water tank 54. A fifth flow sensor 56 is installed on the eleventh pipe 121. The function of the steam compressor makeup water system is to provide makeup water for the steam pressurization system, reduce the exhaust temperature while increasing the steam flow, and be connected to the internal oil cooling system through the heat exchanger 58 to recover the heat of the lubricating oil.

[0049] In a specific embodiment, as Figure 1 shown, the eleventh pipe 121 is used to connect the water tank 54 and the heat exchanger 58. The water pump 55, the fifth flow sensor 56 and the second flow regulating valve 57 are provided on the eleventh pipe 121. The water purifier 50 is provided on the pipeline connecting the seventh stop valve 49 and the water tank 54.

[0050] In one embodiment, the internal oil cooling system may include an eighth stop valve 59, a heat exchanger 58, an oil tank 63, an oil pump 64 and a third flow regulating valve 65. A ninth pressure sensor 66 and a sixth flow sensor 67 are installed on the twelfth pipe 122, and a second liquid level sensor 62 and a ninth temperature sensor 61 are installed on the oil tank 63. The function of the internal oil cooling system is to provide oil cooling and lubrication for the steam pressurization system, and at the same time be connected to the steam compressor makeup water system through the heat exchanger 58 to increase the makeup water temperature of the steam pressurization system.

[0051] In a specific embodiment, as Figure 1As shown, the twelfth pipeline 122 is used to connect the oil tank 63 and the water vapor compressor 26. The oil pump 64, the third flow regulating valve 65, the ninth pressure sensor 66 and the sixth flow sensor 67 are sequentially arranged on the twelfth pipeline 122. The heat exchanger 58 is connected to the oil tank 63, and the heat exchanger 58 is connected to the water vapor compressor 26. The eighth stop valve 59 is arranged on the pipeline connecting the heat exchanger 58 and the water vapor compressor 26 to prevent the high-temperature lubricating oil from flowing back into the water vapor compressor 26.

[0052] In one embodiment, the buffer and storage system may include a first buffer tank 17, a second buffer tank 33, a water tank 54, an oil tank 63, and corresponding connecting pipes. A temperature sensor, a pressure sensor, and a liquid level sensor may be installed on each of the first buffer tank 17, the second buffer tank 33, the water tank 54, and the oil tank 63. The buffer and storage system is used to buffer and store the steam, water or lubricating oil generated in the system, and provide stability for the entire system.

[0053] In a specific embodiment, Figure 1 As shown, the first buffer tank 17 is connected to the industrial steam network through the second pipeline 112 and the first pipeline 111. The first buffer tank 17 is also connected to the water tank 54 through the ninth pipeline 119 and the tenth pipeline 120. The second buffer tank 33 is connected to the water tank 54 through the eighth pipeline 118 and the tenth pipeline 120. In addition, the first buffer tank 17 is connected to the input end of the water vapor compressor 26 through the third pipeline 113, and the second buffer tank 33 is connected to the output end of the water vapor compressor 26 through the fourth pipeline 114. The high-temperature and high-pressure steam from the industrial steam network first flows through the first buffer tank 17, and is input to the water vapor compressor 26 after the pressure is stabilized. The high-temperature and high-pressure steam pressurized by the water vapor compressor 26 is input to the second buffer tank 33. As described above, a part of the high-temperature and high-pressure steam is transported to the industrial steam network through the sixth pipeline 116, and the other part of the high-temperature and high-pressure steam is transported to the first buffer tank 17 through the seventh pipeline 117, completing the steam recovery cycle. The condensed water in the first buffer tank 17 and the second buffer tank 33 is transported to the water tank 54 to preheat the water to be replenished, and then heated by the heat exchanger 58 and transported to the water vapor compressor 26 to complete the condensed water recovery.

[0054] In one embodiment, the intelligent control system includes an intelligent controller 80 and all temperature sensors, pressure sensors, flow sensors and liquid level sensors in the system. The temperature, pressure, flow and liquid level data measured by the above sensors will be transmitted to the intelligent controller 80 in real time, and the intelligent controller 80 will determine the state of each fluid, and then regulate the entire system to achieve the coordinated work of each subsystem, thereby ensuring the safe and stable operation of the water vapor compressor performance test system.

[0055] Next, we will combineFigure 1 A method for testing the performance of a steam compressor that describes a steam compressor performance testing system using the above self-circulating operation.

[0056] Before the formal start of the test, the steam input system first enters the pre-operation state to ensure the stability and safety of steam supply. Specifically, the steam in the high-pressure pipeline is led out through the first stop valve 11 and passes through the filter 12, which is used to effectively intercept possible solid particles or impurities in the pipe network, preventing foreign objects from entering and affecting the normal operation of the first steam pressure reducing valve 13. The first steam pressure reducing valve 13 integrates a pressure feedback adjustment mechanism and can work in coordination with the intelligent controller 80 to continuously monitor and collect the feedback signal from the first pressure sensor 14. Based on the set target pressure value, the intelligent controller 80 precisely adjusts the valve core opening of the first steam pressure reducing valve 13 through a closed-loop control algorithm to ensure that the outlet pressure always remains within a dynamically stable range. When the pressure exceeds the set range, the system quickly restores to the set value by finely adjusting the valve core opening. In addition, the steam input system is also equipped with a first check valve 16 to effectively prevent the steam recovered by the steam recovery system from flowing backward in the pipeline, further improving the operation safety and stability of the system.

[0057] In a specific embodiment, the intelligent controller 80 calculates the deviation (i.e., the error value) between the current outlet pressure and the target pressure by continuously receiving the outlet pressure data fed back by the first pressure sensor 14 and comparing it with the preset target pressure. Based on this error value, the intelligent controller 80 uses a closed-loop control algorithm to calculate the required control amount in real time, and the intelligent controller 80 adjusts the control signal for the valve core opening of the first steam pressure reducing valve 13 according to the calculation result, thereby adjusting the working state of the system. The system continuously monitors and adjusts the outlet pressure of the first steam pressure reducing valve 13 and precisely adjusts the valve core opening through a dynamic feedback mechanism to ensure that the outlet pressure always remains near the target value and within a dynamically stable working range, thereby realizing the efficient and stable operation of the system.

[0058] In the traditional PID (Proportional-Integral-Derivative) control method, the controller adjusts the P, I, and D parameters so that the valve core opening is dynamically adjusted according to the error to achieve stable control of the outlet pressure. However, the parameters of traditional PID control are usually fixed, and when the system working conditions change greatly or there are nonlinear characteristics, it may lead to a decrease in control accuracy or limited dynamic response performance. The intelligent controller 80 of this test system integrates an adaptive PID control algorithm, which can adjust the PID parameters in real time according to the system operation state, making the control strategy adaptable to different working conditions. This method can effectively improve the control accuracy, enhance the robustness of the system to disturbances, and improve the dynamic response performance, ensuring that the outlet pressure always remains within the set stable range, further optimizing the control effect of the system.

[0059] The steam after pressure reduction in the steam input system is transported through the second pipeline 112 to the first buffer tank 17 of the buffer and storage system for pressure stabilization buffering and short-term storage, so as to reduce the impact of pressure fluctuations on the operation of the subsequent system. A first safety valve 18 is equipped inside the tank body. When the pressure in the tank exceeds the set safety threshold, the safety valve will automatically open to quickly release the overpressure steam and prevent the system from being damaged by overpressure or affecting the downstream system.

[0060] Before the test starts, the internal oil cooling system enters the pre-inspection state to ensure that the lubrication system meets the test requirements. The oil tank liquid level is monitored by the second liquid level sensor 62 to ensure sufficient lubricating oil. At the same time, the intelligent controller 80 detects the oil pressure in real time through the ninth pressure sensor 66 to judge whether it reaches the set standard. If the pressure is insufficient, the intelligent controller 80 will automatically start the oil pump 64 and adjust the third flow regulating valve 65 to accurately control the oil pressure to the set value to ensure the fluidity and stability of the lubricating oil. In addition, to effectively suppress the temperature rise of the steam compressor 26 under high load, the system exchanges heat through the heat exchanger 58 with the steam compressor water replenishing system to maintain the outlet lubricating oil temperature within a reasonable range, avoid the adverse effects of overheated lubricating oil on the lubrication effect and oil quality, and effectively reduce the overall operating temperature of the compressor, extend the equipment life and improve the working efficiency.

[0061] The steam compressor water replenishing system starts synchronously to ensure stable water supply for the system and meet the water replenishing conditions required by the steam boosting system. The intelligent controller 80 accurately monitors and adjusts the operating state of the water pump 55 by collecting the feedback signal of the fifth flow sensor 56 in real time. By adjusting the water pump frequency, ensure that the water flow precisely matches the test requirements. In addition, the system is equipped with a water purifier 50 to effectively remove impurities and minerals in the water to ensure the cleanliness of the replenished water. On this basis, the steam compressor water replenishing system and the internal oil cooling system work together to further increase the temperature of the replenished water entering the compressor through the heat exchanger 58, improving the energy utilization rate.

[0062] When the intelligent controller 80 confirms that the heat source conditions, the water replenishment and lubricating oil systems have all met the operating parameters required for the test, the water vapor pressurization system then enters the working state. The system first opens the second stop valve 21 and the third stop valve 29, and slowly starts the water vapor compressor 26 and the motor 28 to ensure a smooth transition of the system to the working state. To accurately match the optimal steam temperature and pressure in the process requirements, the system adopts a variable frequency control strategy, and the intelligent controller 80 adjusts the frequency of the motor 28 in real time to precisely control the rotational speed of the water vapor compressor 26. When the pressure of the fourth pressure sensor 30 is lower than the set value, the intelligent controller 80 automatically increases the frequency of the motor 28 and increases the compressor speed, thereby enhancing the steam pressurization ability. Conversely, when the output pressure reaches or exceeds the set value, the system automatically reduces the frequency of the motor 28 to maintain the stability of the steam pressure and temperature. In a preferred embodiment, the water vapor compressor performance test system with self-circulation operation described herein may also integrate a torque meter 27 to monitor the working torque of the water vapor compressor 26 in real time for calculating the system power. In addition, the intelligent controller 80 checks the accuracy of the flow rate by comparing the feedback data of the first flow sensor 25 and the second flow sensor 32. Finally, the compressed high-temperature and high-pressure steam is delivered to the second buffer tank 33 of the buffer and storage system for subsequent test condition requirements.

[0063] When the steam recovery system starts to work, the water vapor in the second buffer tank 33 is subjected to high-temperature steam recovery under the control of the intelligent controller 80 through the electronically controlled three-way flow regulating valve 38. The system processes the recovered steam in two parts: First, part of the steam passes through the fourth stop valve 40 and is reduced in pressure by the second steam pressure reducing valve 42 in sequence, and then returns to the first buffer tank 17 in the buffer and storage system, realizing the self-circulation of the water vapor pressurization system, significantly reducing the dependence on the external steam pipe network, and thus effectively reducing the system energy consumption. Second, another part of the steam directly returns to the pipe network through the sixth pipe 116 to recover the heat generated during the operation of the water vapor compressor, further optimizing the energy utilization efficiency of the system. Through this intelligent adjustment mechanism, the system only needs to provide a small amount of pipeline steam required at the initial stage of startup, and can achieve self-circulation after the system runs stably, and can recover part of the pipeline steam. Significantly reducing the continuous dependence on the external steam pipe network, thereby reducing the energy consumption and operating costs of the system.

[0064] When the condensate recovery system is working, since condensate is inevitably generated during the buffer storage of steam, the condensate recovery system recovers the condensate generated in the second buffer tank 33 and the first buffer tank 17 through the first steam trap 45 and the second steam trap 48 respectively. When the condensate accumulates to a certain height, the steam trap will automatically open to discharge the condensate in a timely manner. The two streams of condensate are collected into the make-up water tank 54 through the tenth pipe 120. During this process, the heat of the condensate is effectively recovered to increase the temperature of the water tank, thereby increasing the make-up water temperature of the compressor, and at the same time avoiding the waste of the heat of the steam condensate.

[0065] During the operation of the buffer and storage system, due to the pressure fluctuations and instability of the steam, two independent first buffer tanks 17 and second buffer tanks 33 are innovatively designed in this application to ensure the inlet and exhaust stability of the water vapor pressurization system. Specifically, the first buffer tank 17 and the second buffer tank 33 are respectively used to regulate and buffer the steam pressure fluctuations. At the same time, the buffer tank body is equipped with a temperature sensor and a pressure sensor to monitor the working state of the tank body in real time, and implement closed-loop regulation through the intelligent controller 80. When it is detected that the internal pressure of the tank body exceeds the set safety threshold, the intelligent controller 80 will automatically drive the first safety valve 18 and the second safety valve 34 to open to quickly release the overpressure steam until the tank body pressure returns to the safe range, ensuring that the system can maintain a safe and reliable operating state under any working conditions. In addition, the water tank 54 and the oil tank 63 are also provided with liquid level gauges, temperature sensors and pressure sensors for comprehensive monitoring of the liquid level, temperature and pressure. These monitoring devices can ensure that the water and lubricating oil in the water tank 54 and the oil tank 63 are within the appropriate working range, so as to provide the required cooling and lubrication support for the water vapor pressurization system and ensure the operation of the compressor under efficient and safe conditions.

[0066] The intelligent control system is always in a real-time working state, and collects and monitors each feedback signal in real time through the sensors of the above-mentioned subsystems. The sensors can include temperature sensors, pressure sensors, flow sensors, liquid level sensors, etc. These signals provide comprehensive operation data for the system, and the intelligent controller 80 dynamically adjusts the working state through these data feedbacks. Through this fully automated closed-loop control mechanism, the intelligent control system can not only optimize the operation coordination between subsystems, but also ensure the long-term stable operation and high efficiency performance of the water vapor compressor test system.

[0067] In one embodiment, the present invention significantly improves the accuracy of steam measurement through multiple optimization measures, ensuring that the data accuracy of the test system meets the test requirements. First, a double-buffer tank structure is adopted to effectively stabilize the steam flow, reducing the impact of transient fluctuations on the measurement results, thereby improving the measurement accuracy. In addition, the system integrates high-precision sensors, including vortex flow meters, pressure sensors, and temperature sensors, further optimizing the measurement accuracy. Secondly, an adaptive PID control strategy is introduced, enabling the system to quickly respond to steam pressure fluctuations, thereby dynamically adjusting the test environment parameters, reducing system latency, and improving data stability. In addition, flow meters are installed before and after the compressor for real-time cross-checking, further ensuring the accuracy of the data. The present invention is also equipped with an intelligent control system, combined with a dynamic adjustment algorithm, which automatically optimizes the flow rate, pressure, and temperature control strategies according to real-time measurement data, reducing errors caused by external disturbances and improving the measurement accuracy of the system. Based on the above optimization measures, the test system can improve the overall data accuracy by about 10-30%.

[0068] In one embodiment, the present invention realizes a significant reduction in system energy consumption by optimizing the test heat source supply method, adopting variable-frequency drive control, and waste heat recovery technology. Compared with the traditional solution of using electric heating to provide the test heat source, assuming that the system directly uses 1t of steam as the test heat source, the system energy consumption can be reduced by about 720kW. The steam compressor, cooling water pump, and makeup water pump in the test system all adopt variable-frequency drive control, dynamically adjusting the rotation speed according to the real-time working conditions, enabling the equipment to operate at the optimal operating point and reducing unnecessary energy consumption. In addition, the high-temperature steam reflux system can make about 80% of the high-temperature steam return to the first buffer tank after secondary pressure reduction, realizing steam self-circulation, reducing the demand for external steam supply, reducing energy consumption, and improving energy utilization efficiency. At the same time, the system adopts lubricating oil waste heat recovery technology, recovering the waste heat of the high-temperature steam discharged during the test through a high-efficiency heat exchanger and using it to preheat the makeup water entering the compressor. The water temperature can be increased from 25°C to a maximum of 90°C, with a 65°C increase in the makeup water temperature, further improving energy utilization efficiency. Based on the above optimization measures, the test system can achieve an overall energy saving of 20% - 50%.

[0069] In the steam compressor performance test system of the present invention, aiming at the problems of high energy consumption, complex structure, slow response, low energy recovery rate, and limited intelligent level of the control system in the prior art, an efficient, low-consumption, and intelligent test solution is proposed. Through a series of innovative designs and technical improvements, the present invention overcomes the defects of traditional technologies in multiple aspects and realizes a comprehensive improvement in system performance. The specific countermeasures are as follows: In view of the problem that the traditional steam compressor performance test system relies on an electric heating device or a heat pump system to provide an external heat source, the system introduces steam from the industrial steam pipe network through the first pipeline 111 and the first steam pressure reducing valve 13, reduces its pressure to a suitable temperature and pressure range, and buffers and stores it in the first buffer tank 17 to provide a stable heat source for the steam compressor performance test system.

[0070] In view of the deficiency of the steam recovery mechanism in the existing steam compression test system, the present invention innovatively introduces a steam return pipeline. By controlling the electronically controlled three-way flow regulating valve 38 through the intelligent control system, a part of the steam is reduced in pressure and recovered into the first buffer tank 17 through the second steam pressure reducing valve 42, and the other part is directly recovered into the pipe network through the sixth pipeline 116, achieving the effects of reducing energy consumption and improving energy utilization efficiency.

[0071] In view of the common steam pressure fluctuation problem in the industrial pipe network, the present invention innovatively designs two independent buffer tanks, namely the first buffer tank 17 and the second buffer tank 33, which are respectively arranged at the inlet and outlet of the steam boosting system to stabilize the steam pressure fluctuation at the inlet and outlet of the system. A first safety valve 18, a second temperature sensor 19 and a second pressure sensor 20 are arranged on the first buffer tank 17 and connected to the intelligent control system. A second safety valve 34, a fifth temperature sensor 35 and a fifth pressure sensor 36 are arranged on the second buffer tank 33 and connected to the intelligent control system. The system monitors the feedback signals from these sensors in real time and automatically conducts precise regulation to ensure that the pressure is always maintained within the set safety range, achieving the effect of ensuring the safe and stable operation of the system.

[0072] In view of the problem that the waste heat of the lubricating oil in the steam compressor test system in the prior art cannot be effectively utilized, the present invention innovatively designs an internal oil cooling heat recovery pipeline. The oil cooling system is connected to the steam compressor makeup water system through a heat exchanger 58 to achieve efficient recovery of the waste heat of the lubricating oil. The recovered heat is used to increase the makeup water temperature of the steam compressor, thereby optimizing the energy utilization efficiency of the system.

[0073] In view of the deficiency of the intelligent control system in the steam compressor test system in the prior art, the intelligent controller 80 carried by the present invention integrates a multi-parameter real-time monitoring function and an intelligent collaborative control mechanism, collects and processes the feedback signals of each subsystem of the system (such as temperature, pressure, flow rate, liquid level, etc.) in real time, and dynamically adjusts the operating states of each subsystem. Through the closed-loop control algorithm, various key parameters are monitored and precisely adjusted in real time to optimize the collaborative work between each subsystem, achieving the dynamic cooperation and efficient operation of each subsystem within the system.

[0074] The above description of the embodiments is to enable those of ordinary skill in the art to understand and apply this application. It is obvious that those skilled in the art can easily make various modifications to these embodiments and apply the general principles described herein to other embodiments without creative efforts. Therefore, this application is not limited to the embodiments herein, and all improvements and modifications made by those skilled in the art based on the content disclosed in this application without departing from the scope and spirit of this application fall within the scope of this application.

Claims

1. A self-circulating water vapor compressor performance test system, characterized in that: include: A steam input system, comprising a first buffer tank (17) connected to an industrial steam network, for introducing steam as a heat source into the self-circulating water vapor compressor performance test system; A water vapor pressurizing system comprises a water vapor compressor (26), wherein an input end of the water vapor compressor (26) is connected to a first buffer tank (17), and an output end of the water vapor compressor (26) is connected to a second buffer tank (33); A buffer and storage system, comprising a first buffer tank (17) and a second buffer tank (33) connected to each other; A steam recovery system, comprising a second buffer tank (33) for conveying steam to an industrial steam network and a first buffer tank (17); The intelligent control system comprises an intelligent controller (80) and a temperature sensor, a pressure sensor, a flow sensor and a liquid level sensor arranged on each pipeline.

2. The self-circulating water vapor compressor performance testing system according to claim 1, characterized in that: Also includes: A water vapor compressor water replenishment system, comprising a water tank (54) and a heat exchanger (58), wherein the water tank (54) is connected to the heat exchanger (58), and the heat exchanger (58) is connected to the water vapor compressor (26); A condensed water recovery system comprises a water tank (54), wherein the water tank (54) is connected to a first buffer tank (17) and a second buffer tank (33) and is used to recover condensed water.

3. The self-circulating water vapor compressor performance testing system according to claim 2, characterized in that: Also includes: The internal oil cooling system comprises a heat exchanger (58), an oil tank (63) and an oil pump (64); the heat exchanger (58), the oil tank (63) and the water vapor compressor (26) are cyclically connected, and the oil pump (64) is arranged on a pipeline connecting the oil tank (63) and the water vapor compressor (26).

4. The self-circulating water vapor compressor performance testing system according to claim 3, characterized in that: In the steam input system, one end of a first pipeline (111) is connected to an industrial steam network. In a direction away from the industrial steam network, a first stop valve (11), a filter (12), a first steam pressure reducing valve (13), and a check valve (16) are sequentially arranged on the first pipeline (111). The other end of the first pipeline (111) is connected to a second pipeline (112), and is finally connected to a first buffer tank (17) of a buffer and storage system.

5. The self-circulating water vapor compressor performance testing system according to claim 4, characterized in that: In the water vapor pressurizing system, the third pipeline (113) is used to connect the first buffer tank (17) and the water vapor compressor (26), the fourth pipeline (114) is used to connect the water vapor compressor (26) and the second buffer tank (33), the third pressure sensor (22), the third temperature sensor (23), the first flow regulating valve (24) and the first flow sensor (25) are installed on the third pipeline (113), and the third stop valve (29), the fourth pressure sensor (30), the fourth temperature sensor (31) and the second flow sensor (32) are installed on the fourth pipeline (114).

6. The self-circulating water vapor compressor performance testing system according to claim 5, characterized in that: In the buffer and storage system, the first buffer tank (17) is connected to the industrial steam network via the second pipeline (112) and the first pipeline (111); the first buffer tank (17) is also connected to the water tank (54) via the ninth pipeline (119) and the tenth pipeline (120); the second buffer tank (33) is connected to the water tank (54) via the eighth pipeline (118) and the tenth pipeline (120); the first buffer tank (17) is connected to the input end of the water vapor compressor (26) via the third pipeline (113); and the second buffer tank (33) is connected to the output end of the water vapor compressor (26) via the fourth pipeline (114).

7. The self-circulating water vapor compressor performance testing system according to claim 6, characterized in that: In the steam recovery system, the fifth pipeline (115) is used to connect the second buffer tank (33) and the electric-controlled three-way flow regulating valve (38), the sixth pipeline (116) is used to connect the electric-controlled three-way flow regulating valve (38) and the industrial steam network, and the seventh pipeline (117) is used to connect the electric-controlled three-way flow regulating valve (38) and the second pipeline (112), and finally communicate with the first buffer tank (17). The fifth pipeline (115) is equipped with a third flow sensor (37), the sixth pipeline (116) is equipped with a sixth pressure sensor (39), and the seventh pipeline (117) is equipped with a fourth flow sensor (41), a sixth temperature sensor (43) and a seventh pressure sensor (44).

8. The self-circulating water vapor compressor performance testing system according to any one of claims 1 to 7, characterized in that: The water vapor supercharging system further comprises a torque meter (27) for real-time monitoring of the working torque of the water vapor compressor (26).

9. A method for testing the performance of a water vapor compressor, characterized in that: Applicable to the water vapor compressor performance testing system for self-circulating operation as claimed in claim 7 or 8, the water vapor compressor performance testing method comprises the following steps: S1: The steam input system is put into a pre-operation state to ensure that a suitable heat source is supplied, the internal oil cooling system enters a pre-inspection state to ensure that the lubricating oil has suitable fluidity and stability, and the water vapor compressor water replenishment system is started to ensure a stable water supply and meet the water replenishment conditions required by the water vapor boosting system; S2: After the intelligent control system confirms that the heat source, lubricating oil and water supply meet the operating parameters required for the test, the water vapor booster system is started, and the buffer and storage systems begin to work, followed by the steam recovery system and condensate recovery system until the test is completed; The accuracy of the flow rate is checked by comparing the feedback data of the first flow sensor (25) and the second flow sensor (32).

10. The method for testing the performance of a water vapor compressor according to claim 9, wherein: A small amount of external steam is input at the initial start-up of the self-circulating steam compressor performance test system. Once a stable state is reached, no external steam is required.

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