Fast-assembly movable type differential pressure utilization power generation system

Abstract

The invention discloses a fast-assembly movable type differential pressure utilization power generation system which comprises a main machine module, a skid-mounted module, a differential pressure utilization power generation module, a differential pressure utilization power generation module, a differential pressure utilization power generation module, a power generation module and a differential pressure utilization power generation power generation module, and the main machine module is composed of a high-speed steam turbine and a high-speed permanent magnet generator which are coaxially connected. Comprising a high-rigidity chassis formed by welding, a box body covering the high-rigidity chassis, a ventilation module arranged at the top of the box body, an air inlet module located at the front end of the box body, and a control module and a power transmission and distribution module which are arranged in the box body; an elastic support module; a double-layer belleville spring set is arranged in each elastic supporting unit, the host module is rigidly fixed to a high-rigidity bottom frame of the skid-mounted module through bolts, and the power transmission and distribution module is directly connected with the output end of the high-speed permanent magnet generator through a copper bar. High-pressure steam is utilized to obtain power through the high-speed steam turbine, the high-speed permanent magnet generator is driven to generate electricity, meanwhile, the steam is discharged at low temperature and pressure after passing through the turbine, and the steam turbine is utilized to replace a temperature and pressure reducer to achieve temperature and pressure reduction of the steam.

Description

Technical Field

[0001] The present invention relates to the field of residual pressure power generation, and particularly to a quick-installation mobile differential pressure utilization power generation system. Background Art

[0002] At present, there are generally problems in differential pressure utilization power generation systems: First, the equipment has a large external dimension, which is difficult to arrange in the original factory building, the cost of building a new factory building is high, and it is difficult to solve the problem of factory building land; Second, the equipment system is complex and involves the cooperation of multiple majors such as process, equipment, instrument control, and electricity; Third, the equipment has high requirements for civil engineering foundations, high construction costs, and long construction periods; Fourth, the investment recovery period is long, and some projects with short or uncertain operation periods cannot be launched. Summary of the Invention

[0003] The purpose of the present invention is to provide a quick-installation mobile differential pressure utilization power generation system to solve the foregoing problems existing in the prior art.

[0004] To achieve the above purpose, the technical solution adopted by the present invention is as follows:

[0005] A quick-installation mobile differential pressure utilization power generation system includes:

[0006] A main engine module, which is composed of a high-speed steam turbine and a high-speed permanent magnet generator connected coaxially. The high-speed steam turbine is of a reaction turbine structure, with a designed speed range of 6000 - 10000 rpm, and the turbine blades are integrally formed with 15CrMoV high-temperature resistant alloy;

[0007] A skid-mounted module, including a high-rigidity chassis formed by welding, a box body covering the high-rigidity chassis, a ventilation module arranged on the top of the box body, an air inlet module located at the front end of the box body, and a control module and a power transmission and distribution module arranged in the box body;

[0008] An elastic support module, including three independently level-adjustable elastic support units; each elastic support unit is internally provided with a double-layer disc spring group, the spring group stiffness coefficient is 500 - 800 N / mm, and the level-adjusting response time ≤ 30 seconds;

[0009] The main engine module is rigidly fixed to the high-rigidity chassis of the skid-mounted module through bolts. The power transmission and distribution module is directly connected to the output end of the high-speed permanent magnet generator through copper bars. The control module and the power transmission and distribution module are arranged side by side at the tail end of the high-speed permanent magnet generator. The air inlet module and the ventilation module form a forced convection heat dissipation path in the box body through a serpentine diversion air duct, and the heat dissipation efficiency ≥ 200 W / m 2 ·K.

[0010] Furthermore, the steam inlet flange of the high-speed steam turbine is adapted to DN150 - DN300 pipeline interfaces, the exhaust port pressure range is 0.3 - 0.8 MPa, and the direction of the exhaust port flange can be rotated and positioned 360° around the axis, and a 0.5 mm thick Stellite alloy layer is surfacing welded on the flange sealing surface.

[0011] Furthermore, the high-rigidity chassis adopts a welded frame structure of H-shaped steel and channel steel, and a composite transportation interface of a forklift slot and a lifting ear plate is set at the bottom, and the overall natural frequency of the chassis is ≥80 Hz.

[0012] Furthermore, each support unit of the elastic support module is provided with an M30 adjusting bolt at the bottom, the adjusting stroke is ±15 mm, and the pre-compression amount of the disc spring group is 10% - 15% of the total height.

[0013] Furthermore, the power transmission and distribution module includes a vacuum circuit breaker, a current transformer and an overvoltage protector. The opening and closing signals of the vacuum circuit breaker are connected to the relay module of the control module through hard wiring, and the thickness of the silver plating layer on the contacts of the vacuum circuit breaker is 8 - 12 μm.

[0014] Furthermore, the PLC of the control module is configured with the Modbus TCP communication protocol, and integrates the signal acquisition channels of vibration sensors and temperature sensors. The alarm threshold of the vibration sensor is 4.5 mm / s, and the delay time for the PLC to execute the shutdown response to the vibration overrun signal is ≤50 ms.

[0015] Furthermore, the ventilation module includes an axial flow fan and a fairing. The air volume of the axial flow fan is 2000 - 3000 m 3 / h, the outlet direction of the fairing is adjustable and is equipped with a rain-proof louver structure, and the opening and closing angle of the louver is controlled by an electric push rod.

[0016] Furthermore, double-layer sound insulation boards are provided on the side walls of the box. The inner layer is a 50 mm thick glass wool layer, and the outer layer is a 1.5 mm galvanized steel plate punching panel. The internal noise of the box is ≤75 dB(A)@1m.

[0017] Furthermore, the system is applicable to the bypass of oil and gas pipeline pressure reducing valves and the surplus pressure power generation scenarios in chemical plants, and the continuous operation efficiency is ≥35% within the inlet pressure difference range of 0.5 - 2.5 MPa.

[0018] The beneficial effects of the present invention are as follows: The present invention discloses a quick-installation mobile differential pressure utilization power generation system, including: a main engine module composed of a high-speed steam turbine and a high-speed permanent magnet generator connected coaxially. The high-speed steam turbine is of a reaction turbine structure. A skid-mounted module includes a high-rigidity chassis formed by welding, a box body covering the high-rigidity chassis, a ventilation module arranged on the top of the box body, an air inlet module located at the front end of the box body, and a control module and a power transmission and distribution module arranged inside the box body; an elastic support module includes three independently level-adjustable elastic support units; each elastic support unit is internally provided with a double-layer disc spring group. The main engine module is rigidly fixed to the high-rigidity chassis of the skid-mounted module through bolts. The power transmission and distribution module is directly connected to the output end of the high-speed permanent magnet generator through a copper busbar. The control module and the power transmission and distribution module are arranged side by side at the tail end of the high-speed permanent magnet generator. The air inlet module and the ventilation module form a forced convection heat dissipation path inside the box body through a serpentine air guide duct, and the heat dissipation efficiency is ≥ 200W / m 2 ·K. The present invention utilizes high-pressure steam to obtain power through a high-speed steam turbine, driving a high-speed permanent magnet generator to generate electricity. At the same time, the steam is discharged at a lower temperature and pressure after passing through the turbine and is discharged into the industrial heat network. The steam turbine is used to replace the desuperheating and pressure-reducing valve to realize the cooling and pressure reduction of the steam. The installation efficiency of the present invention is improved: the modular design shortens the on-site installation time to within 4 hours, and the leveling accuracy reaches ±2mm; the operation stability is enhanced: the heat dissipation efficiency of the serpentine air duct is increased by 40% compared with the straight ventilation duct, and the high-temperature creep rate of the turbine blades is reduced by 30%; the maintenance cycle is extended: the Stellite alloy sealing layer extends the flange life to more than 2 years, reducing the shutdown and maintenance frequency. Brief Description of the Drawings

[0019] Figure 1 is the overall structural schematic diagram of a quick-installation mobile differential pressure utilization power generation system of the present invention;

[0020] Figure 2 is the structural schematic diagram of another embodiment of the quick-installation mobile differential pressure utilization power generation platform of the present invention;

[0021] Figure 3 is the elastic support layout schematic diagram of the quick-installation mobile differential pressure utilization power generation platform of the present invention.

[0022] 1. High-speed steam turbine; 2. High-speed permanent magnet generator; 3. Ventilation module; 4. Box body; 5. High-rigidity chassis; 6. Air inlet module; 7. Control module; 8. Power transmission and distribution module;

[0023] 9. Elastic support module. Detailed Embodiments

[0024] In order to make the purpose, technical solutions and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described here are only used to explain the present invention and are not used to limit the present invention.

[0025] Refer to Figure 1 、 Figure 2 and Figure 3 A quick-installation mobile differential-pressure utilization power generation system shown, comprising: a main engine module, which consists of a high-speed steam turbine 1 and a high-speed permanent magnet generator 2 connected coaxially. The high-speed steam turbine 1 is of a reaction turbine structure, with a designed speed range of 6000 - 10000 rpm, and the turbine blades are integrally formed with 15CrMoV high-temperature resistant alloy;

[0026] A skid-mounted module, including a high-rigidity chassis 5 formed by welding, a box body 4 covering the high-rigidity chassis 5, a ventilation module 3 arranged on the top of the box body 4, an air inlet module 6 located at the front end of the box body 4, and a control module 7 and a power transmission and distribution module 8 arranged inside the box body 4;

[0027] An elastic support module 9, including three independently level-adjustable elastic support units; each elastic support unit is internally provided with a double-layer disc spring group, the spring group stiffness coefficient is 500 - 800 N / mm, and the level-adjusting response time ≤ 30 seconds;

[0028] The main engine module is rigidly fixed to the high-rigidity chassis 5 of the skid-mounted module through bolts. The power transmission and distribution module 8 is directly connected to the output end of the high-speed permanent magnet generator 2 through a copper busbar. The control module 7 and the power transmission and distribution module 8 are arranged side by side at the tail end of the high-speed permanent magnet generator 2. The air inlet module 6 and the ventilation module 3 form a forced convection heat dissipation path inside the box body 4 through a serpentine diversion air duct, and the heat dissipation efficiency ≥ 200 W / m 2 ·K.

[0029] I. System overall architecture

[0030] This system adopts a modular three-level integrated design, consisting of a main engine module, a skid-mounted module and an elastic support module 9, and realizes rapid assembly and transportation through standardized interfaces. The system is designed for a differential pressure working condition of 0.5 - 2.5 MPa, and can be deployed in scenarios such as the bypass of a pressure reducing valve in an oil and gas pipeline, the recovery of surplus pressure in a chemical plant, etc., to achieve efficient conversion of surplus pressure energy into electrical energy (conversion efficiency ≥ 35%).

[0031] II. The technical details of each module are described in detail as follows:

[0032] 1. Main engine module

[0033] Core components:

[0034] High-speed steam turbine 1:

[0035] Turbine type: Reaction structure, adopting full-circumference steam admission + convergent-divergent blade flow path design to reduce flow loss;

[0036] Material Technology: The turbine blades (rotating blades / stationary blades) are integrally formed by precision casting using 15CrMoV high-temperature resistant alloy (yield strength ≥ 650 MPa, temperature resistance limit 650 °C). A laser cladded WC-Co coating (thickness 0.3 mm) is added to the blade root part, and the erosion resistance life is increased by 50%;

[0037] Performance Parameters: The designed speed is 6000 - 10000 rpm, the adapted steam pressure is 0.3 - 0.8 MPa, the exhaust port flange supports 360° rotary positioning, a Stellite alloy layer is surfacing welded on the sealing surface (hardness HRC45 - 50, thickness 0.5 mm), and the leakage rate ≤ 0.01%.

[0038] High-Speed Permanent Magnet Generator 2:

[0039] Rotor Structure: Surface-mounted neodymium iron boron permanent magnets (N52 grade), encapsulated by vacuum impregnation process, air-gap magnetic field strength ≥ 1.2 T;

[0040] Cooling Method: The stator winding is internally equipped with spiral copper tubes (outer diameter 6 mm), cooled by circulating softened water, and the temperature rise ≤ 65 K;

[0041] Output Characteristics: Rated voltage 690V ± 5%, power factor 0.95 (lagging), directly connected to the power transmission and distribution module 8 with copper bars, without an intermediate transformer.

[0042] Installation Method:

[0043] The turbine and the generator are coaxially connected by a high-precision diaphragm coupling (alignment error ≤ 0.02 mm), and the whole is rigidly fixed on the high-rigidity chassis 5 of the skid-mounted module through 12 groups of M24 high-strength bolts (grade 8.8), and the bolt pre-tightening force is controlled at 280 - 300 kN.

[0044] 2. Skid-Mounted Module

[0045] Structural Design:

[0046] High-Rigidity Chassis 5:

[0047] Frame Material: The main beam is made of Q345B H-beam (specification H200×200×8×12), and the cross beam is 16# channel steel. After welding, the whole is annealed to eliminate stress;

[0048] Transportation Interface: The bottom is integrated with a forklift slot (opening height 150 mm, depth 300 mm) and 4 lifting lugs (single lug bearing capacity ≥ 5 tons), the diameter of the lug pin hole is φ50 mm, matching the standard lifting tool;

[0049] Dynamic Characteristics: The first-order natural frequency ≥ 80 Hz (verified by ANSYS modal analysis), avoiding resonance with the turbine operating frequency (100 - 166 Hz).

[0050] Cabinet 4:

[0051] Sound insulation design: The side wall adopts a double-layer structure. The inner layer is 50 mm thick glass wool (bulk density 48 kg / m 3 , NRC ≥ 0.85), and the outer layer is 1.5 mm galvanized punched plate (hole diameter φ3 mm, opening rate 30%). The noise inside the box ≤ 75 dB(A) @ 1 m;

[0052] Sealing and protection: The box door adopts a silicone rubber sealing strip (Shore hardness 50 ± 5), and the protection level is IP54, which can resist dust and spray.

[0053] Heat dissipation system:

[0054] Snake-shaped diversion air duct:

[0055] Airflow path: The axial flow fan (air volume 2000 - 3000 m 3 / h) of the air inlet module 6 introduces cold air into the bottom of the box body 4. After passing through the deflector (tilt angle 30°), it forms a snake-shaped upward airflow and is finally discharged by the rain-proof louvers of the top ventilation module 3;

[0056] Key components: The deflector is made of 6063-T5 aluminum alloy (thickness 2 mm), and the surface is sprayed with a high-temperature resistant ceramic coating (thermal conductivity ≤ 0.8 W / m·K) to ensure uniform air distribution;

[0057] Heat dissipation performance: The measured heat dissipation efficiency ≥ 200 W / m 2 ·K (based on the combined test of thermal imager and anemometer).

[0058] Electrical and control integration:

[0059] Power transmission and distribution module 8:

[0060] Core devices: Vacuum circuit breaker (rated current 1600 A, breaking capacity 50 kA), current transformer (accuracy 0.5S level), overvoltage protector (residual voltage ratio ≤ 2.0);

[0061] Connection process: The copper busbar (TMY-100×10) and the generator output end are hydraulically crimped (crimping pressure 70 MPa), and the contact resistance ≤ 5 μΩ.

[0062] Control module 7:

[0063] Hardware configuration: Siemens S7-1500 PLC, integrated with 16-channel analog input (4 - 20 mA / RTD), 8-channel digital output (relay contact capacity 5 A / 250 VAC);

[0064] Monitoring function:

[0065] Vibration monitoring: Vibration sensors (frequency response range 10 Hz - 10 kHz) are arranged on the turbine bearing housing to collect the effective value of speed in real time (alarm threshold 4.5 mm / s);

[0066] Temperature monitoring: PT100 platinum resistors (accuracy ±0.5 °C) are set at key points such as stator windings and breaker contacts, and the over-temperature alarm thresholds are 155 °C and 90 °C respectively;

[0067] Protection logic: When vibration or temperature exceeds the limit, the PLC triggers the vacuum circuit breaker to trip within 50 ms and activates the audible and visual alarm.

[0068] 3. Elastic support module 9

[0069] Mechanical structure:

[0070] Support unit: Each unit contains a double-layer disc spring group (outer diameter φ120 mm, single-piece thickness 6 mm, material 60Si2MnA), the stiffness coefficient of the spring group is 500 - 800 N / mm (adjusted by the pre-compression amount), and the maximum load-bearing capacity is 20 tons;

[0071] Leveling mechanism: M30 adjustment bolts (pitch 4 mm, stroke ±15 mm) are set at the bottom, and together with a digital level (accuracy ±0.1 °) to achieve rapid leveling. The leveling time ≤ 30 s, and the level error ≤ ±1.5 mm.

[0072] Vibration damping design:

[0073] The pre-compression amount of the disc spring group is set to 10% - 15% of the total height, so that the natural frequency of the system avoids the turbine operating frequency (100 - 166 Hz), and the vibration transmission rate ≤ 15%.

[0074] III. Typical application scenarios and installation process

[0075] 1. Installation example of the bypass of the oil and gas pipeline pressure reducing valve

[0076] Preparations in advance:

[0077] Measure the size of the pipeline flange interface (DN200), adjust the flange direction of the turbine exhaust port to align with the downstream condensate pipeline, and lock the flange bolts (torque value 450 N·m) after rotation and positioning.

[0078] Rapid leveling:

[0079] Use a laser level to detect the installation foundation, and it is found that the northeast corner is 8 mm lower. Adjust the M30 bolts of the corresponding elastic support unit (rotate 2 turns, lift height 4 mm). After leveling, the system inclination ≤ 0.5‰.

[0080] Performance verification:

[0081] When the inlet pressure difference is 1.8MPa, the turbine speed is 8200rpm, the generator output power is 1.15MW, and the system efficiency is 38.2%; the wind speed inside the heat dissipation duct is 4.2m / s, and the hot spot temperature of box 4 (circuit breaker contact) is 78℃.

[0082] 2. Chemical plant residual pressure power generation scenario

[0083] Steam parameter adaptation:

[0084] The turbine steam inlet flange is adapted to the DN250 pipe. After the sealing surface is welded with Stellite alloy, the leakage rate is 0.007% after being tested by a helium mass spectrometer leak detector, which meets the chemical explosion-proof requirements.

[0085] Intelligent Operation and Maintenance:

[0086] PLC uploads operating data to the central control room through the Modbus TCP protocol, realizing remote start and stop and energy efficiency analysis, and the number of unplanned shutdowns per year is ≤2 times.

[0087] 4. Summary of Technical Advantages

[0088] Rapid deployment: Modular design reduces on-site installation time to 4 hours (traditional systems require more than 24 hours);

[0089] Efficient heat dissipation: The serpentine air duct improves heat dissipation efficiency by 40% compared with the traditional straight exhaust duct, and extends the equipment life by 30%;

[0090] Super strong earthquake resistance: the elastic support module 9 controls the vibration amplitude within 3.5mm / s (the national standard limit is 7.1mm / s);

[0091] Long-term operation: The Stellite alloy sealing layer extends the flange maintenance period to 24 months and reduces operation and maintenance costs by 60%.

[0092] In this embodiment, it should be noted that the host module: a high-speed steam turbine 1 and a high-speed permanent magnet generator 2 are coaxially connected, the turbine blades are integrally formed of 15CrMoV high-temperature resistant alloy, the design speed is 6000-10000rpm, adapted to 0.5-2.5MPa inlet pressure difference, and the continuous operation efficiency is ≥35%;

[0093] Skid-mounted module: The high-rigidity chassis 5 is welded from H-shaped steel and channel steel, with a natural frequency of ≥80Hz. The bottom is integrated with forklift slots and lifting lugs to achieve transportation and rapid positioning;

[0094] Elastic support module 9: Three independent leveling units have built-in double-layer disc spring groups (stiffness coefficient 500-800N / mm), and ±15mm stroke adjustment can be achieved through M30 adjusting bolts. The leveling response time is ≤30 seconds, and the pre-compression amount is 10%-15%.

[0095] Serpentine diversion air duct: The air inlet module 6 and the ventilation module 3 form a forced convection path. The air volume of the axial flow fan is 2000 - 3000 m 3 / h, and the heat dissipation efficiency ≥ 200 W / m 2 ·K;

[0096] Stellite alloy seal: A 0.5 mm thick Stellite alloy layer (hardness ≥ HRC40) is surfacing welded on the flange sealing surface of the turbine inlet / exhaust port, with a temperature resistance up to 650 °C and a leakage rate < 0.01%.

[0097] Vibration protection: The PLC collects vibration signals in real time (sampling frequency 10 kHz). When the vibration speed ≥ 4.5 mm / s, the circuit is cut off within 50 ms;

[0098] Sound insulation design: The side walls of the box body 4 adopt a double-layer structure of 50 mm glass wool + 1.5 mm galvanized punched plate, and the internal noise ≤ 75 dB(A) @ 1 m.

[0099] It should be noted that in this embodiment, the inlet and exhaust parameters of the high-speed steam turbine 1 can be customized according to different usage scenarios. The common inlet steam parameters are selected with reference to the common parameters of the existing main heating pipe network, such as 1.6 MPa, 340 °C; 1 MPa, 300 °C, etc., and those selected with reference to common heating boilers are 3.43 MPa, 435 °C; 4.9 MPa, 470 °C, etc. The exhaust parameters are determined according to the heating pipe network at the end of the heat user, and the common ones are 0.8 MPa, 0.49 MPa, 0.275 MPa, etc. The high-speed turbine is a high-speed reaction turbine selected according to the characteristics of small-scale heat sources. The designed speed generally ranges from 6000 to 10000 rpm, which can improve the efficiency of the unit and minimize the equipment volume to facilitate skid-mounted installation

[0100] The high-speed permanent magnet generator 2 is designed with the same speed as the high-speed steam turbine 1 to avoid the efficiency reduction and equipment volume increase caused by adding a gearbox due to speed change.

[0101] The power transmission and distribution module 8 completes the connection and on-off control between the high-speed permanent magnet generator 2 and the external power supply line, and is mainly composed of a circuit breaker and measurement and protection components.

[0102] The ventilation module 3 is equipped with a ventilator, which is the outlet and power unit of forced ventilation, ensuring that the ventilation volume of the box body 4 can take away all the heat dissipated by the equipment. The air inlet module 6 is the air inlet of ventilation. By reasonably selecting the layout positions of the ventilation module 3 and the air inlet module 6, the flow field of the circulating air can be controlled, so that the equipment in the box body 4 can be reasonably cooled.

[0103] The control module 7 consists of a PLC and its attached power module, I / O module, and relay module, and is mainly used to complete the load control of the platform and the monitoring and protection of the operating states of all the equipment on the platform.

[0104] The elastic support module 9 consists of three independent elastic supports. Three points can complete the stable support of a plane, avoiding uneven stress on the frame caused by inconsistent heights of multiple support points. All three support points are elastic support elements, so that even if local settlement occurs in the foundation during the use of the equipment after installation, the loads of each support point can still be kept balanced through the elastic elements.

[0105] Furthermore, in this application, the energy difference between the steam inlet and the steam outlet is converted into kinetic energy by a high-speed turbine, and then by a high-speed permanent magnet generator 2; the forced ventilation of the system is realized through the ventilation module 3, and the wind direction enters the box body 4 from the air inlet module 6 and is discharged from the ventilation module 3; the sound insulation and protection of the system are completed through the box body 4; the ventilation flow field and temperature field of the system are optimized by arranging the position of the air inlet module 6; the integrated packaging of the entire set of equipment of the system is completed through the high-rigidity chassis 5; the operation control of the system is realized through the control module 7; the outgoing line connection and switch control of the generator are realized through the power transmission and distribution module 8; the site adaptability of the system equipment is improved through the elastic support module 9.

[0106] Furthermore, the steam inlet flange of the high-speed steam turbine 1 is adapted to DN150 - DN300 pipeline interfaces, the exhaust port pressure range is 0.3 - 0.8 MPa, and the direction of the exhaust port flange can be rotated and positioned 360° around the axis, and a 0.5 mm thick Stellite alloy layer is surfacing welded on the flange sealing surface.

[0107] Furthermore, the high-rigidity chassis 5 adopts a welded frame structure of H-shaped steel and channel steel, and a composite transportation interface of a forklift slot and a lifting ear plate is set at the bottom, and the overall natural frequency of the chassis is ≥80 Hz.

[0108] Furthermore, each support unit of the elastic support module 9 is provided with an M30 adjustment bolt at the bottom, the adjustment stroke is ±15 mm, and the pre-compression amount of the disc spring group is 10% - 15% of the total height.

[0109] Furthermore, the power transmission and distribution module 8 includes a vacuum circuit breaker, a current transformer and an overvoltage protector. The opening and closing signals of the vacuum circuit breaker are connected to the relay module of the control module 7 through hard wiring, and the thickness of the silver plating layer on the contacts of the vacuum circuit breaker is 8 - 12 μm.

[0110] Furthermore, the PLC of the control module 7 is configured with the Modbus TCP communication protocol, and integrates the signal acquisition channels of vibration sensors and temperature sensors. The alarm threshold of the vibration sensor is 4.5 mm / s, and the delay time for the PLC to execute the shutdown response to the vibration overrun signal is ≤50 ms.

[0111] Furthermore, the ventilation module 3 includes an axial flow fan and a fairing. The air volume of the axial flow fan is 2000 - 3000 m 3 / h, the outlet direction of the fairing is adjustable and is equipped with a rain-proof louver structure, and the opening and closing angle of the louver is controlled by an electric push rod.

[0112] Furthermore, the side wall of the box body 4 is provided with a double-layer sound insulation board. The inner layer is a 50-mm-thick glass wool layer, and the outer layer is a 1.5-mm galvanized steel sheet punched panel. The noise inside the box body 4 is ≤ 75 dB(A) @ 1 m.

[0113] Furthermore, the system is applicable to the bypass of the pressure reducing valve for oil and gas pipelines and the surplus pressure power generation scenario in chemical plants, and the continuous operation efficiency is ≥ 35% within the inlet pressure difference range of 0.5 - 2.5 MPa.

[0114] Example 1: Power generation by the bypass of the pressure reducing valve for oil and gas pipelines

[0115] 1. System installation

[0116] Lift the high-rigidity chassis 5 to the preset position of the pipeline bypass, and detect the level deviation by a laser level to be +18 mm;

[0117] Adjust the M30 bolts of the elastic support module 9 to make the pre-compression of the disc spring group reach 12%. It takes 25 seconds to level, and finally the level deviation is ≤ ±1.5 mm;

[0118] Use a torque wrench (230 N·m) to fix the connecting bolts between the main engine module and the chassis.

[0119] 2. Pipeline connection and sealing

[0120] Weld the flange of the turbine steam inlet (DN200) to the outlet of the pipeline pressure reducing valve, and build a Stellite alloy layer (0.5 mm) on the sealing surface. TIG welding parameters: current 100 A, argon gas flow rate 18 L / min;

[0121] After rotating the exhaust port flange 270°, dock it with the condensation system, and the leakage rate test is 0.008%.

[0122] 3. Operation test

[0123] When the inlet pressure difference is 1.8 MPa, the turbine speed is stable at 8500 rpm, the power generation power is 1.2 MW, and the system efficiency is 38.5%;

[0124] The highest temperature inside the box body 4 is T1 = 115 °C (winding), T2 = 75 °C (circuit breaker), the air volume of the fan is 2500 m 3 / h, and the heat dissipation efficiency is 220 W / m 2 ·K;

[0125] The monitored vibration speed value v = 3.2 mm / s, and the noise test value is 72 dB(A) @ 1 m.

[0126] Refer to Figure 1As shown, the output shaft of the high-speed steam turbine 1 is connected to the high-speed permanent magnet generator 2. The use of the high-speed turbine improves the hot-spot conversion efficiency and reduces the equipment volume. The use of the high-speed permanent magnet generator 2 enables direct connection between the high-speed turbine and the generator, eliminating the need for a gearbox transfer and reducing the floor space occupied by the equipment.

[0127] Among them, the main engine module is installed on the skid-mounted module, which can be assembled and debugged before leaving the factory, making on-site installation very simple and eliminating the need for complex construction. When the main engine parameters change within a certain range, the same skid-mounted module can be used, which has a certain degree of versatility.

[0128] Further referring to Figure 1 As shown, the main engine module composed of the high-speed steam turbine 1 and the high-speed permanent magnet generator 2 is installed on the skid-mounted module.

[0129] Among them, in order to ensure the good operation of the main engine module in the skid-mounted environment, the skid-mounted module includes a ventilation module 3 and an air inlet module 6 to complete forced ventilation and maintain the temperature inside the box body 4 within a controllable range and have a relatively reasonable temperature field distribution; it includes a control module 7 to complete the operation control and load adjustment of the main engine module; it includes a power transmission and distribution module 8 to complete the wiring and on-off control of the generator outlet.

[0130] Further referring to Figure 1 As shown, the skid-mounted module includes a ventilation module 3, a box body 4, a high-rigidity chassis 5, an air inlet module 6, a control module 7, and a power transmission and distribution module 8.

[0131] Among them, the control module 7 and the power transmission and distribution module 8 are arranged at the tail end of the generator. This area is the relatively low-temperature area of the entire box body 4, which is convenient for controlling the operating temperature of electronic and electrical components.

[0132] Further referring to Figure 1 As shown, the control module 7 and the power transmission and distribution module 8 are arranged at the tail end of the generator.

[0133] Among them, the air inlet module 6 is arranged between the high-speed permanent magnet generator 2 and the control module 7 and the power transmission and distribution module 8, and the ventilation module 3 is arranged above the box body 4 on the steam turbine side. This is to better isolate the temperature of the installation area of the control module 7 and the power transmission and distribution module 8 from the temperature of the installation area of the main engine module inside the box body 4, avoiding the influence of high temperature on the operation of electronic and electrical equipment. At the same time, the temperature of the high-speed permanent magnet motor area is lower than the temperature of the high-speed steam turbine 1 area, achieving a reasonable distribution of the temperature field.

[0134] Further referring to Figure 1 As shown, the air inlet module 6 is arranged between the high-speed permanent magnet generator 2 and the control module 7 and the power transmission and distribution module 8; the ventilation module 3 is arranged above the box body 4 on the steam turbine side.

[0135] Three groups of independent elastic support modules 9 are installed under the high-rigidity base frame 5. This can ensure that the high-rigidity base frame 5 of the equipment will not be affected or deformed when the installation foundation is uneven or the foundation changes after installation, and the installation base cannot provide good rigid support. It will not affect the centering and running posture of the host module, thereby ensuring the safe operation of the equipment.

[0136] Further references Figure 1 As shown, the high-rigidity chassis 5 is mounted on an elastic support module 9 .

[0137] This system realizes efficient recovery of industrial waste energy through cascade utilization of pressure difference and mechatronic design, and provides standardized distributed power generation solutions for high-energy-consuming industries such as oil, gas, and chemical industries.

[0138] It should be further explained that the high-pressure steam enters the high-speed steam turbine 1 to generate expansion work therein, so that the high-speed turbine rotor rotates at high speed, driving the high-speed permanent magnet generator 2 to generate electricity, which is output to the outside through the power transmission and distribution module 8. At the same time, the steam is expanded and depressurized in the high-speed steam turbine 1 and then discharged from the outlet for use in the industrial heat network.

[0139] When the pressure difference power generation platform is running, the operation of the high-speed steam turbine 1 and the high-speed permanent magnet generator 2 will increase the temperature inside the box 4. By setting a ventilation module 3 at a position on the top of the box 4 biased towards the high-speed steam turbine 1 and setting an air intake module 6 on the side of the box 4 close to the high-speed permanent magnet generator 2 and the control module 7 and the power transmission and distribution module 8, forced ventilation is provided for the box 4 to adjust the temperature of the space of the box 4 to a reasonable range.

[0140] The pressure difference power generation platform is assembled, wired, and debugged in the factory, and sent to the site after passing the test. On site, it only needs to be arranged in a suitable place; connected to the steam inlet and outlet pipelines; and connected to the main power transmission and distribution cable before it can be used.

[0141] The use of the elastic support module 9 can balance the forces on each supporting part when the site is partially subsided or deformed, and will not cause the high-rigidity chassis 5 to deform due to uneven load, affecting the operation of the equipment. The site adaptability of the pressure difference power generation platform is greatly improved. It only needs to confirm the bearing capacity, and no longer requires a high stability foundation and high flatness.

[0142] When the equipment needs to be moved or the installation site needs to be changed, it can also be achieved quickly.

[0143] Case: A printing and dyeing factory purchases steam from the heating company's pipeline network for use in the printing and dyeing process. The steam consumption is 31T / h. The heating pipeline network is designed with a steam supply parameter of 0.8 Mpa and 227 °C to meet the needs of different users. However, only steam at 0.4 MPa is required for the printing and dyeing process to heat the water tank. Therefore, a desuperheating and pressure-reducing valve is used to reduce the steam at 0.8 Mpa and 227 °C to 0.4 MPa before using it for water tank heating, which causes a large amount of energy waste. At this time, using a traditional back-pressure steam turbine unit for energy-saving transformation requires huge investment in equipment, plant, and civil engineering, and a large construction site is needed, making the energy-saving transformation lose its economic viability.

[0144] Use the present invention for energy-saving transformation to replace the desuperheating and pressure-reducing valve in the original process. After the equipment is installed in the open space on-site, the steam at 0.8 Mpa and 227 °C is directly connected to the inlet of the high-speed steam turbine 1 on the power generation platform. After doing work, the exhaust port of the high-speed steam turbine 1 discharges steam at 0.4 MPa for use in heating the water tank. At the same time, the high-speed steam turbine 1 can drive the high-speed permanent magnet generator 2 to generate electricity, and the power generation power is 780 KW. Calculate that the power generation cost per KWh is about 0.3 yuan. According to the electricity price of 0.7 yuan / KWh, calculate that the annual power generation income is about 2.18 million yuan.

[0145] The most significant advantage is that it can be arranged outdoors without the need to build a new plant; the equipment has a compact structure, small floor area, high degree of integration, and is convenient for installation; the overall power generation efficiency is high; it can be easily disassembled, assembled, or relocated.

[0146] It should be noted that in this article, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the term "comprising", "including" or any other variant thereof is intended to cover non-exclusive inclusion, so that a process, method, article or device comprising a series of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article or device.

[0147] Although the embodiments of the present invention have been shown and described, it will be understood by those of ordinary skill in the art that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the present invention, and the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A quick-install mobile pressure difference power generation system, characterized in that: include: The main engine module is composed of a high-speed steam turbine (1) and a high-speed permanent magnet generator (2) connected coaxially, wherein the high-speed steam turbine (1) is a reaction turbine structure, with a design speed range of 6000 to 10000 rpm, and the turbine blades are integrally formed of 15CrMoV high-temperature resistant alloy; The skid-mounted module comprises a welded high-rigidity chassis (5), a box (4) covering the high-rigidity chassis (5), a ventilation module (3) arranged on the top of the box (4), an air intake module (6) located at the front end of the box (4), and a control module (7) and a power transmission and distribution module (8) arranged in the box (4); The elastic support module (9) comprises three independently leveled elastic support units; each elastic support unit has a built-in double-layer disc spring group, the spring group stiffness coefficient is 500-800N / mm, and the leveling response time is ≤30 seconds; The host module is rigidly fixed to the high-rigidity chassis (5) of the skid-mounted module by bolts, the power transmission and distribution module (8) is directly connected to the output end of the high-speed permanent magnet generator (2) by a copper bar, the control module (7) and the power transmission and distribution module (8) are arranged in parallel at the tail end of the high-speed permanent magnet generator (2), and the air intake module (6) and the ventilation module (3) form a forced convection heat dissipation path in the box (4) through a serpentine guide air duct, and the heat dissipation efficiency is ≥200W / m 2 ·K.

2. The power generation system according to claim 1, characterized in that: The steam inlet flange of the high-speed steam turbine (1) is adapted to the DN150-DN300 pipeline interface, the exhaust pressure range is 0.3-0.8 MPa, and the exhaust flange direction can be rotated 360° around the axis, and the flange sealing surface is welded with a 0.5 mm thick Stellite alloy layer.

3. The power generation system according to claim 1, characterized in that: The high-rigidity chassis (5) adopts an H-shaped steel and channel steel welded frame structure, a composite transportation interface of a forklift slot and a lifting lug is arranged at the bottom, and the overall natural frequency of the chassis is ≥80 Hz.

4. The power generation system according to claim 1, characterized in that: Each support unit of the elastic support module (9) is provided with an M30 adjustment bolt at the bottom, the adjustment stroke is ±15 mm, and the pre-compression amount of the disc spring group is 10% to 15% of the total height.

5. The power generation system according to claim 1, characterized in that: The power transmission and distribution module (8) comprises a vacuum circuit breaker, a current transformer and an overvoltage protector. The opening and closing signals of the vacuum circuit breaker are connected to the relay module of the control module (7) through hard wiring. The thickness of the silver plating layer of the vacuum circuit breaker contact is 8 to 12 μm.

6. The power generation system according to claim 1, characterized in that: The PLC of the control module (7) is configured with the ModbusTCP communication protocol and integrates the signal acquisition channels of the vibration sensor and the temperature sensor. The alarm threshold of the vibration sensor is 4.5 mm / s, and the delay time of the PLC executing the shutdown response to the vibration over-limit signal is ≤50 ms.

7. The power generation system according to claim 1, characterized in that: The ventilation module (3) comprises an axial flow fan and a guide cover, and the air volume of the axial flow fan is 2000-3000m 3 / h, the air outlet direction of the air deflector is adjustable and equipped with a rainproof louver structure, and the opening and closing angle of the louver is controlled by an electric push rod.

8. The power generation system according to claim 1, characterized in that: The side wall of the box (4) is provided with a double-layer sound insulation board, the inner layer is a 50mm thick glass wool layer, and the outer layer is a 1.5mm thick galvanized steel plate punching panel, and the noise inside the box is ≤75dB(A)@1m.

9. The power generation system according to claim 1, characterized in that: The system is suitable for bypass of pressure reducing valves in oil and gas pipelines and residual pressure power generation in chemical plants, with a continuous operating efficiency of ≥35% within the inlet pressure difference range of 0.5 to 2.5 MPa.

Images