A fault parking control method of air energy storage series compressor unit

Abstract

The application provides a kind of air energy storage series compressor unit fault parking control method, belongs to air energy storage series compressor unit technical field, comprising: in parameter meets alarm condition but has not reached interlock failure before, carry out early warning shutdown protection, as the third parking control logic outside normal parking and interlock parking, form a new control level.When the parameter is abnormal but has not reached the fault interlock value enough to cause equipment damage, actively and in advance intervene the compressor unit, control the compressor unit to execute safe unloading and lossless parking, increase the parking protection logic before the failure interlock of unit operation to control the unit to stop safely in advance, avoid the loss of unit shutdown caused by interlock parking from the root;Since the safe unloading of the unit is completed in the early warning stage, the unit can be stopped without loss, not only eliminating the impact damage to the compressor, gear box and other key mechanical components, but also directly avoiding the significant economic loss caused by equipment damage.

Description

Technical Field

[0001] This application belongs to the technical field of air energy storage series compressor units, specifically relating to a fault shutdown control method for air energy storage series compressor units. Background Technology

[0002] With the development of air energy storage technology, the start-stop control of compressor units connected in series in air energy storage devices is frequent. In addition to normal shutdown control, the reliability requirements for fault shutdown control are extremely high. Improper fault handling will directly lead to huge equipment damage and economic losses.

[0003] In existing technologies, compressor units generally employ a three-tiered safety control framework of "monitoring-alarm-interlocking." Specifically: when the unit's operating parameters are within the normal range, the system continuously monitors them; when parameters exceed the normal range but do not reach dangerous values, the system triggers an alarm and attempts to activate auxiliary equipment for automatic adjustment, which is a minor fault handling phase; if the parameters continue to deteriorate and reach the preset fault interlocking value, the control system will command all units to simultaneously execute an emergency interlock shutdown. However, this interlock shutdown is an emergency protection measure, and its control logic issues the shutdown command and unloading command simultaneously, or even shutdown before unloading, resulting in a sudden shutdown of the unit under load. This destructive shutdown is highly likely to cause compressor surge and can also cause severe impact damage to core mechanical components such as rotors, bearings, and gears, resulting in significant economic losses. Summary of the Invention

[0004] The present invention aims to solve at least one of the technical problems existing in the prior art or related art.

[0005] In view of this, a fault shutdown control method for an air storage series compressor unit is proposed according to an embodiment of this application, including:

[0006] Monitor at least one parameter in the compressor unit that is related to operational safety;

[0007] When the parameters meet the preset alarm conditions but do not reach the fault interlock value, determine the warning protection shutdown value;

[0008] When the parameters reach the warning protection shutdown value, the warning protection shutdown is executed, and the compressor unit is controlled to unload and stop safely.

[0009] In one feasible implementation, parameters related to operational safety include:

[0010] Bearing vibration value, shaft displacement value, bearing temperature value, lubricating oil pressure value, sealing gas differential pressure value, process gas outlet pressure value, and process gas outlet temperature value.

[0011] In one feasible implementation, the fault shutdown control method for an air storage series compressor unit further includes:

[0012] When the monitored parameters reach the fault interlock value, the compressor unit is controlled to perform an interlock shutdown operation;

[0013] This allows the stop command and the unload command to be issued simultaneously, or the stop command to be issued before the unload command.

[0014] In one feasible implementation, the compressor unit includes a low-pressure compressor, a medium-pressure compressor, and a high-pressure compressor connected in series.

[0015] Controlling the compressor unit to perform interlocked shutdown operations includes the following steps:

[0016] The shutdown sequence of the compressor units is controlled based on the position of the compressor that triggers the interlock shutdown in the series sequence of the compressor units.

[0017] In one feasible implementation, when the compressor that triggers the interlock shutdown is a low-pressure compressor, the low-pressure compressor, medium-pressure compressor and high-pressure compressor are controlled to perform interlock shutdown.

[0018] When the compressor that triggers the interlock shutdown is a medium-pressure compressor, the low-pressure compressor is controlled to perform a normal shutdown, and the medium-pressure compressor and the high-pressure compressor are controlled to perform an interlock shutdown.

[0019] When the compressor that triggers the interlock shutdown is the high-pressure compressor, the low-pressure compressor and the medium-pressure compressor are controlled to perform normal shutdown, and the high-pressure compressor is controlled to perform interlock shutdown.

[0020] In one feasible implementation, determining the early warning protection parking value includes the following steps:

[0021] Set the parameter range preceding the fault interlock value to U1;

[0022] The parameter range outside the normal operating range is defined as U2;

[0023] The fault variable interval U is obtained by taking the intersection of parameter interval U1 and parameter interval U2;

[0024] Select the warning protection shutdown value within the fault variable range U.

[0025] In one feasible implementation, determining the early warning protection parking value further includes the step of:

[0026] Obtain the unloading time T1 required for the compressor unit to perform a safe unloading;

[0027] Get the estimated time T2 for the parameter to reach the fault interlock value from the current value;

[0028] Based on the unloading time T1 and the estimated time T2, the warning protection parking value is determined.

[0029] In one feasible implementation, a time margin ΔT is set, where ΔT≥0;

[0030] When T1≤T2, select a warning protection shutdown value within the fault variable interval U, such that when the warning protection shutdown value triggers the warning protection shutdown, T2≥T1+ΔT.

[0031] In one feasible implementation, the parameters related to operational safety are bearing vibration values, shaft displacement values, bearing temperature values, or lubricating oil pressure values.

[0032] In one feasible implementation, when a main oil pump failure causes T1 to exceed T2, an accumulator is added to the main lubricating oil pipeline;

[0033] The oil pressure is maintained by the accumulator, extending the estimated time T2.

[0034] The warning protection stop value is determined until T1≤T2;

[0035] Among them, the parameter related to operational safety is the lubricating oil pressure.

[0036] The fault shutdown control method for an air energy storage series compressor unit disclosed in this application has the following advantages compared with the prior art:

[0037] The fault shutdown control method for air storage series compressor units provided in this application provides early warning shutdown protection before the parameters meet the alarm conditions but before the interlocking fault is reached. This serves as a third type of shutdown control logic, in addition to normal shutdown and interlocking shutdown, forming a completely new control level. When the parameters are abnormal but have not yet reached the fault interlocking value sufficient to cause equipment damage, the compressor unit is proactively and in advance intervened to control the compressor unit to perform safe unloading and non-destructive shutdown. Shutdown protection logic is added before the unit's fault interlocking to control the unit to shut down safely in advance, realizing a shift from passive emergency shutdown after a fault to proactive safety protection before a fault. This fundamentally avoids damaged shutdowns caused by interlocking shutdowns. Because the safe unloading of the unit is completed at the early warning stage, allowing the unit to stop without damage, it not only eliminates impact damage to key mechanical components such as compressors and gearboxes but also directly avoids significant economic losses caused by equipment damage. Simultaneously, it reduces the workload of professional maintenance personnel after a fault interlocking shutdown, shortens the downtime, and helps improve production efficiency. Attached Figure Description

[0038] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the scope of this application. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings:

[0039] Figure 1 A schematic flowchart illustrating the steps of a fault shutdown control method for an air storage series compressor unit according to an embodiment of this application;

[0040] Figure 2 A schematic flowchart illustrating the steps of a fault shutdown control method for an air storage series compressor unit according to another embodiment of this application. Detailed Implementation

[0041] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0042] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0043] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0044] The preferred embodiments of this application are described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit this application.

[0045] like Figure 1As shown in the embodiments of this application, a fault shutdown control method for an air storage series compressor unit is proposed, comprising:

[0046] Step 100: Monitor at least one parameter related to operational safety in the compressor unit;

[0047] Step 200: When the parameters meet the preset alarm conditions but do not reach the fault interlock value, determine the warning protection shutdown value;

[0048] Step 300: When the parameters reach the warning protection shutdown value, execute the warning protection shutdown, control the compressor unit to unload and stop safely.

[0049] The fault shutdown control method for air storage series compressor units provided in this application provides early warning shutdown protection before the parameters meet the alarm conditions but before the interlocking fault is reached. This serves as a third type of shutdown control logic, in addition to normal shutdown and interlocking shutdown, forming a completely new control level. When the parameters are abnormal but have not yet reached the fault interlocking value sufficient to cause equipment damage, the compressor unit is proactively and in advance intervened to control the compressor unit to perform safe unloading and non-destructive shutdown. Shutdown protection logic is added before the unit's fault interlocking to control the unit to shut down safely in advance, realizing a shift from passive emergency shutdown after a fault to proactive safety protection before a fault. This fundamentally avoids damaged shutdowns caused by interlocking shutdowns. Because the safe unloading of the unit is completed at the early warning stage, allowing the unit to stop without damage, it not only eliminates impact damage to key mechanical components such as compressors and gearboxes but also directly avoids significant economic losses caused by equipment damage. Simultaneously, it reduces the workload of professional maintenance personnel after a fault interlocking shutdown, shortens the downtime, and helps improve production efficiency.

[0050] It should be noted that in the application scenarios of centrifugal compressors, such as petrochemical and metallurgical air separation units, the reaction time from the occurrence of an alarm to the cessation of the reaction within the unit, i.e., the catalysis, circulation, and other processes, is longer than the unloading time of the unit. Moreover, the process losses are also higher than the interlocking shutdown losses of the compressor unit. Therefore, in previous application scenarios, it was impossible to unload and disconnect the network before a fault shutdown.

[0051] It should be noted that the early warning shutdown protection is particularly well-suited to the process characteristics of air energy storage devices, which require immediate shutdown and storage. It can provide the highest level of protection for the compressor unit without affecting the energy storage process.

[0052] In one feasible implementation, parameters related to operational safety include: bearing vibration value, shaft displacement value, bearing temperature value, lubricating oil pressure value, sealing gas differential pressure value, process gas outlet pressure value, and process gas outlet temperature value.

[0053] This technical solution clearly defines the specific parameters related to operational safety that are monitored, ensuring that early warning protection covers critical subsystems and core fault modes of the compressor. Bearing vibration and shaft displacement values ​​directly reflect the dynamic health status of the mechanical shaft system; bearing temperature and lubricating oil pressure values ​​reflect the working status of the lubrication system; sealing gas differential pressure values ​​reflect the reliability of the gas seal; and process gas outlet pressure and temperature values ​​directly reflect the gas path system and compression performance. This comprehensive state perception network enables early warning protection shutdown control to accurately capture potential risks from various aspects, including the mechanical body, drive system, lubrication system, sealing system, and process gas path, thereby ensuring the comprehensiveness and effectiveness of early warning and avoiding protection failures due to monitoring blind spots.

[0054] In some examples, parameters of faults in the mechanical body shaft system, drive system, lubrication system, sealing gas system, process gas system, and heat exchange system of the monitoring group are specifically shown in Table 1.

[0055] Table 1. Variables monitored for the fleet

[0056]

[0057] like Figure 2 As shown, in one feasible implementation, the fault shutdown control method for an air storage series compressor unit further includes:

[0058] Step 400: When the monitored parameters reach the fault interlock value, control the compressor unit to perform an interlock shutdown operation;

[0059] Step 500: Issue the stop command and the unload command simultaneously, or issue the stop command before the unload command.

[0060] In this technical solution, when the monitored parameters change abruptly or rapidly deteriorate to a dangerous fault interlock value, the fastest possible forced shutdown is achieved by issuing the shutdown command and the unloading command simultaneously or by issuing the shutdown command before the unloading command. This prevents the accident from escalating into a catastrophic event. Through the dual protection of early warning shutdown and interlock shutdown, the protection gradient of the entire control system is made more complete, thereby providing a guarantee for the safe operation of the unit.

[0061] In one feasible implementation, the compressor unit includes a low-pressure compressor, a medium-pressure compressor, and a high-pressure compressor connected in series.

[0062] Controlling the compressor unit to perform interlocked shutdown operations includes the following steps:

[0063] The shutdown sequence of the compressor units is controlled based on the position of the compressor that triggers the interlock shutdown in the series sequence of the compressor units.

[0064] In this technical solution, the shutdown sequence of the compressor unit is controlled according to the position of the compressor that triggers the interlock shutdown in the series sequence of the compressor unit. This reduces the negative impact range of a single point of failure, avoids damage to healthy units, reduces unnecessary equipment damage and maintenance costs, and prevents long-term production stoppages caused by simultaneous damage to multiple units.

[0065] In one feasible implementation, when the compressor that triggers the interlock shutdown is a low-pressure compressor, the low-pressure compressor, medium-pressure compressor and high-pressure compressor are controlled to perform interlock shutdown.

[0066] When the compressor that triggers the interlock shutdown is a medium-pressure compressor, the low-pressure compressor is controlled to perform a normal shutdown, and the medium-pressure compressor and the high-pressure compressor are controlled to perform an interlock shutdown.

[0067] When the compressor that triggers the interlock shutdown is the high-pressure compressor, the low-pressure compressor and the medium-pressure compressor are controlled to perform normal shutdown, and the high-pressure compressor is controlled to perform interlock shutdown.

[0068] In this technical solution, when only a fault occurs at the end of the unit, the low-pressure and medium-pressure compressors at the front end are allowed to perform normal shutdown, i.e., unloading before shutdown, so that the low-pressure and medium-pressure compressors can be safely and without damage to exit operation, reducing losses. When the medium-pressure compressor fails, the low-pressure compressor at the front end is allowed to perform normal shutdown, so that the low-pressure compressor can be safely and without damage to exit operation. Only when the low-pressure compressor at the front end fails is the low-pressure compressor, medium-pressure compressor, and high-pressure compressor interlocked shut down. By deciding the shutdown method of the unit based on the specific location of the fault, the control logic of single-unit fault and emergency damage shutdown of the whole unit is replaced. The series interlocking of a single unit fault among the three units will not cause other unit faults. After adding protective shutdown control, economic losses are reduced, the workload of professional maintenance personnel after fault interlock shutdown is reduced, and the fault time is shortened, realizing the precision and localization of interlock shutdown loss control.

[0069] In one feasible implementation, determining the early warning protection parking value includes the following steps:

[0070] Set the parameter range preceding the fault interlock value to U1;

[0071] The parameter range outside the normal operating range is defined as U2;

[0072] The fault variable interval U is obtained by taking the intersection of parameter interval U1 and parameter interval U2;

[0073] Select the warning protection shutdown value within the fault variable range U.

[0074] In this technical solution, the warning value must be set outside the normal operating range value U2 to prevent malfunctions caused by normal fluctuations and ensure the stability of unit operation. At the same time, the warning value must be within an interval U1 before the fault interlock value to ensure the timeliness and necessity of warning intervention and avoid the failure of warning shutdown protection due to delayed warning action. The intersection of U1 and U2 is taken to obtain the fault variable interval U, so that the warning protection shutdown can intervene at the appropriate time to protect the unit, thereby balancing the safety of unit operation and production continuity.

[0075] In one feasible implementation, determining the early warning protection parking value further includes the step of:

[0076] Obtain the unloading time T1 required for the compressor unit to perform a safe unloading;

[0077] Get the estimated time T2 for the parameter to reach the fault interlock value from the current value;

[0078] Based on the unloading time T1 and the estimated time T2, the warning protection parking value is determined.

[0079] In this technical solution, the relationship between risk and time is dynamically and quantitatively assessed by calculating the unloading time T1 required for safe unloading and the estimated time T2 for the fault to deteriorate to the interlock point. The warning will only be activated when the control system anticipates that there is enough time to complete the safe shutdown process. This transforms the warning protection shutdown value from a static and fixed threshold judgment to a dynamic and intelligent decision-making process based on real-time operating status prediction, avoiding blind warnings or warning failures. This improves the accuracy and scientific nature of the warning protection shutdown, thereby achieving predictive maintenance and safety control of the unit.

[0080] In one feasible implementation, a time margin ΔT is set, where ΔT≥0;

[0081] When T1≤T2, select a warning protection shutdown value within the fault variable interval U, such that when the warning protection shutdown value triggers the warning protection shutdown, T2≥T1+ΔT.

[0082] In this technical solution, by introducing an adjustable time margin ΔT, operators or the system can adjust the advance amount of the warning based on actual conditions such as equipment aging, process importance, and historical fault data. This allows the setting of the warning point to be based not only on theoretical calculations but also on practical engineering experience, individual differences in equipment, and different safety level requirements, thereby enhancing the adaptability of the warning control. This enables the control method to be flexibly applied to different operating conditions and requirements, ensuring the most economical operation under the premise of safety.

[0083] In one feasible implementation, the parameters related to operational safety are bearing vibration values, shaft displacement values, bearing temperature values, or lubricating oil pressure values.

[0084] In this technical solution, the common feature of the parameters of bearing vibration value, shaft displacement value, bearing temperature value and lubricating oil pressure value is that the deterioration process is relatively slow and easy to monitor. By calculating the estimated time T2 of the above parameters, when the mechanical condition has not deteriorated sharply but has clearly deviated from the healthy track, a safe shutdown can be arranged in advance, creating conditions for preventive maintenance and replacement of mechanical components, avoiding sudden mechanical failures, and thus protecting the core part of the compressor.

[0085] In one feasible implementation, when a main oil pump failure causes T1 to exceed T2, an accumulator is added to the main lubricating oil pipeline;

[0086] The oil pressure is maintained by the accumulator, extending the estimated time T2.

[0087] The warning protection stop value is determined until T1≤T2;

[0088] Among them, the parameter related to operational safety is the lubricating oil pressure.

[0089] In this technical solution, when the main oil pump suddenly ruptures, causing the oil pressure to collapse within a very short time (T2), and the required time for safe unloading (T1) cannot be met, the warning protection shutdown value cannot be determined. By adding an accumulator to the lubricating oil main pipeline and improving the hardware, working in conjunction with the software warning logic, the accumulator can act as a temporary emergency pressure source at the moment of main oil pump failure, briefly maintaining the system oil pressure, thereby artificially extending the estimated fault deterioration time T2, and thus satisfying the condition T1≤T2. This brings the originally unpredictable sudden extreme faults into the controllable safe shutdown range, achieving comprehensive protection of the lubricating oil system from slow leakage to sudden rupture fault modes, and improving the safety of the entire unit in dealing with extreme operating conditions.

[0090] In some examples, the calculated and measured start-up time of the electric auxiliary lubricating oil pump is 0.5s~1s, and the time to rise to the set pressure is 0.5s~1s, totaling 1s~2s; by adding an accumulator with a duration of more than 2s in the lubricating oil main pipe, the condition of T1≤T2 for determining the early warning protection shutdown value is met.

[0091] It will be readily understood by those skilled in the art that the above embodiments can be freely combined and superimposed without conflict.

[0092] The above are merely preferred embodiments of this application and are not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application. The above are merely preferred embodiments of this application. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of this application, and these improvements and modifications should also be considered within the protection scope of this application.

Claims

1. A fault shutdown control method for an air-storage series compressor unit, characterized in that, The fault shutdown control method for the air energy storage series compressor unit includes: Monitor at least one parameter in the compressor unit that is related to operational safety; When the parameters meet the preset alarm conditions but do not reach the fault interlock value, the warning protection shutdown value is determined; When the parameter reaches the warning protection shutdown value, the warning protection shutdown is executed, and the compressor unit is controlled to unload and stop safely; The compressor unit is controlled to perform an interlocked shutdown operation, and the shutdown sequence of the compressor unit is controlled according to the position of the compressor that triggered the interlocked shutdown in the series sequence of the compressor unit; The compressor unit includes a low-pressure compressor, a medium-pressure compressor, and a high-pressure compressor connected in series. When the compressor that triggers the interlock shutdown is the low-pressure compressor, the low-pressure compressor, the medium-pressure compressor, and the high-pressure compressor are controlled to perform interlock shutdown. When the compressor that triggers the interlock shutdown is the medium-pressure compressor, the low-pressure compressor is controlled to perform a normal shutdown, and the medium-pressure compressor and the high-pressure compressor are controlled to perform an interlock shutdown. When the compressor that triggers the interlock shutdown is the high-pressure compressor, the low-pressure compressor and the medium-pressure compressor are controlled to perform normal shutdown, and the high-pressure compressor is controlled to perform interlock shutdown.

2. The fault shutdown control method for an air-storage series compressor unit according to claim 1, characterized in that, The parameters related to operational safety include: Bearing vibration value, shaft displacement value, bearing temperature value, lubricating oil pressure value, sealing gas differential pressure value, process gas outlet pressure value, and process gas outlet temperature value.

3. The fault shutdown control method for an air-storage series compressor unit according to claim 2, characterized in that, The fault shutdown control method for the air energy storage series compressor unit also includes: When the parameter is detected to reach the fault interlock value, the compressor unit is controlled to perform an interlock shutdown operation; The stop command and the unload command are issued simultaneously, or the stop command is issued before the unload command.

4. The fault shutdown control method for an air-storage series compressor unit according to claim 1, characterized in that, The process of determining the early warning protection parking value includes the following steps: The parameter range preceding the fault interlock value is defined as U1; The parameter range outside the normal operating range is defined as U2; The fault variable interval U is obtained by taking the intersection of parameter interval U1 and parameter interval U2; Select the warning protection shutdown value within the fault variable range U.

5. The fault shutdown control method for an air-storage series compressor unit according to claim 4, characterized in that, The determination of the early warning protection parking value also includes the following steps: Obtain the unloading time T1 required for the compressor unit to perform safe unloading; Obtain the estimated time T2 for the parameter to reach the fault interlock value from its current value; The warning protection parking value is determined based on the unloading time T1 and the estimated time T2.

6. The fault shutdown control method for an air-storage series compressor unit according to claim 5, characterized in that, Set a time margin ΔT, where ΔT ≥ 0; When T1≤T2, the warning protection shutdown value is selected within the fault variable interval U, such that when the warning protection shutdown value triggers the warning protection shutdown, T2≥T1+ΔT.

7. The fault shutdown control method for an air-storage series compressor unit according to claim 6, characterized in that, The parameters related to operational safety are bearing vibration value, shaft displacement value, bearing temperature value, or lubricating oil pressure value.

8. A fault shutdown control method for an air-storage series compressor unit according to claim 5, characterized in that, When a main oil pump failure causes T1 to exceed T2, an accumulator is added to the main lubricating oil pipeline. The accumulator maintains the oil pressure, thereby extending the estimated time T2. The warning protection parking value is determined until T1 ≤ T2; Among them, the parameter related to operational safety is the lubricating oil pressure.

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