Energy-saving and environment-friendly screw type steam compressor testing device

Abstract

The utility model relates to an energy-saving and environment-friendly screw type steam compressor testing device, which comprises an air suction filter, an exhaust separator, a heat recoverer, a lubricating oil tank, a softened water tank and a softened water treatment device, an air suction silencer and an air exhaust silencer are respectively arranged on the compressor air exhaust pipe and the compressor air inlet pipe; the compressor air inlet pipe is connected with the exhaust separator through a circulating water spraying pipeline; the heat recoverer is connected with the softened water tank through a condensate pipe and a balance pipe, the softened water treatment device is connected with the softened water tank, and the softened water tank supplements water to the screw type steam compressor to be tested through a softened water supplementing pipe. The steam generation speed of the air dynamic heat engine is increased through the circulating water spraying pipeline, the dynamic heat engine time is short, and meanwhile the power consumption of the driving motor is reduced; the noise reduction effect is good, the noise reduction cost is greatly reduced, and meanwhile, the field working environment of the test device is greatly improved; through the condensation phase change white smoke elimination technology of the heat recoverer, the heat in the steam can be completely recycled.

Description

Technical Field

[0001] This utility model relates to an energy-saving and environmentally friendly screw-type steam compressor test device, belonging to the field of compressor technology. Background Technology

[0002] Energy conservation means saving existing energy consumption; environmental protection means protecting the environment from pollution. In people's production and daily life, on the one hand, we need to study new methods and processes, adopt new energy-saving measures as much as possible, improve energy utilization, and reduce energy consumption; on the other hand, we need to reduce or even eliminate the emission of energy pollutants, research, develop, and utilize new pollution-free energy sources, and strive to achieve zero pollution and zero emissions. This is energy conservation and environmental protection.

[0003] Current screw steam compressor testing equipment is used to conduct hot operation tests, mechanical operation tests, and performance tests on screw steam compressors before they leave the factory. The purpose of the performance test is to measure the actual volumetric flow rate, shaft power, vibration, and noise of the screw steam compressor under actual or simulated operating conditions. The limitations and feasibility analysis of the energy-saving scheme described in the invention patent application CN113236532A, entitled "Energy-Saving Steam Compressor Testing Equipment and Test Method Thereof," are as follows:

[0004] 1) The exhaust pipe of this test apparatus includes a vertical pipe section with a drain valve and a drain level controller at the bottom. Replacing a storage and separation container with a vertical pipe section reduces the investment cost of the test apparatus and decreases the heat required for the metal container to heat up during the thermal process, thus saving energy. Analysis suggests that if the exhaust temperature is controlled at the saturation temperature during the test, a single vertical exhaust pipe is insufficient for liquid separation. Unseparated water will enter the intake and exhaust pipe system of the test apparatus, hindering accurate measurements by the flow meter and pressure transmitter. Furthermore, the small volume of the vertical exhaust pipe means that a high liquid level will be reached quickly, triggering an alarm. Whether the valve is opened manually or automatically for drainage, it will cause pressure fluctuations in the system. Frequent emergency drainage is unreliable, unsafe, and a waste of thermal energy.

[0005] 2) This experimental setup presents a scheme for recovering and utilizing high-temperature steam after exhaust pressure regulation and venting. The main motor drives the gearbox as the primary power source for the steam compressor, while a thermal power device directly converts thermal energy into mechanical energy as an auxiliary power source to drive the gearbox. Relative to the gearbox, there are two power input ends and one power output end, making the gearbox design quite complex. A steam turbine is a rotary power machine that converts the high-temperature, high-pressure energy of steam into mechanical work. Also known as a steam turbine, it is mainly used as a prime mover for power generation, but can also directly drive various pumps, fans, compressors, and ship propellers. Its thermal-to-mechanical conversion efficiency is only 30-45%, and its total heat utilization efficiency is less than 10%. Therefore, when using a steam turbine for thermal conversion, the gearbox design is difficult, the equipment investment is large, the footprint is large, the thermal-to-mechanical conversion efficiency is low, only a small portion of the steam heat energy is recovered, and the environmental problem of high-temperature steam white smoke emitted on-site cannot be solved.

[0006] 3) This experimental setup presents a second scheme for recovering and utilizing high-temperature steam after exhaust pressure regulation and venting. The steam can be directly driven to generate electricity and then reused in the grid. A screw steam expander can be used to drive an asynchronous generator for grid connection, achieving a thermoelectric conversion efficiency of 75-80% and a total heat utilization efficiency of 10-20%. Since there is no voltage during grid connection, there is a transition period with an inrush current of 5-6 times the rated current. This inrush current typically returns to steady state after a few tenths of a second. When connected to a large grid, the inrush current at the moment of closing has little impact on the safe operation of the generator and the large grid system. However, for small-capacity grid systems, it can cause a significant drop in grid voltage, affecting stability and safety. If grid connection is possible, power factor correction capacitors are typically used for appropriate reactive power compensation. Dynamic reactive power compensation equipment is essential for effectively stabilizing the system voltage. Therefore, the first step in adopting an expansion power generation device is to investigate whether the conditions for power generation and grid connection are met. The device requires a lot of equipment, large investment, and a large area. The low-pressure exhaust gas after expansion is still discharged into the atmosphere. The heat-work conversion efficiency is low, most of the steam heat energy cannot be recovered, and the environmental problem of high-temperature water vapor and white smoke discharged on site cannot be solved.

[0007] The aforementioned utility model patent application does not comprehensively address energy conservation and environmental protection issues; it only provides partial energy-saving solutions, and these solutions have limitations. For example, the lubricating oil tank is an essential piece of equipment for the operation of a screw steam compressor, and there are still problems with oil leakage from the lubricating oil tank breather valve, the compressor isolation gas outlet, and the compressor shaft extension end. Therefore, the screw steam compressor test device, while meeting the requirements for test operation, urgently needs to address the following energy conservation and environmental protection issues:

[0008] The normal operating temperature for compressed steam in the steam testing apparatus is between 100℃ and 200℃. Before this, the compressed air needs to undergo dynamic warm-up, gradually raising the temperature of the steam compressor from room temperature to approximately 125℃. This dynamic warm-up process typically takes one and a half hours. During the warm-up process, to ensure the safe operation of the compressed air and control its exhaust temperature below 100℃, softened cold water needs to be injected for cooling. At this time, the injected cooling water, after compression, has an exhaust temperature below 100℃ and cannot evaporate, so it can only be stored at the lowest point of the exhaust pipeline system. If the storage volume is small, it will need to be urgently discharged after quickly reaching the alarm level, wasting softened water.

[0009] Fluid dynamic noise refers to the noise generated by fluid vibration caused by fluid flow. With in-depth research on mechanical vibration noise and improvements in machining and assembly precision, mechanical vibration noise has been effectively controlled. However, fluid noise induced by airflow pulsation has become the main noise source of screw steam compressors, which can be divided into intake noise and exhaust noise according to its location and characteristics. During the operation of the test equipment, significant airflow noise was inevitably generated, far exceeding the noise of the variable frequency main motor, reaching over 120 decibels, which is considered very loud noise pollution. The noise damage to hearing forces on-site test personnel to wear earplugs, making verbal communication impossible, and the noise can also induce various diseases.

[0010] During the experiment, to reduce the exhaust temperature of the screw steam compressor and ensure its internal cleanliness, softened cold water was added for cooling. This added softened water was compressed and vaporized into high-temperature, high-pressure steam. After being depressurized by the exhaust pressure regulating valve, it was released into the atmosphere, producing a large amount of white steam, commonly known as white smoke. In addition, during the compression process, high-pressure steam also leaked from the carbon ring seal at both the intake and exhaust ends of the screw steam compressor. This mixture combined with the isolation gas from the compressor body side and was also released into the atmosphere, producing a small amount of high-temperature white steam as well.

[0011] In summary, there is an urgent need for an energy-saving and environmentally friendly screw steam compressor testing device that can solve the problems of long warm-up time, high power consumption, high airflow noise, and large waste of soft water in the operation of existing screw steam compressor testing devices. Utility Model Content

[0012] This invention addresses the shortcomings of existing technologies by providing an energy-saving and environmentally friendly test device for screw-type steam compressors.

[0013] The technical solution of this utility model to solve the above-mentioned technical problems is as follows: An energy-saving and environmentally friendly screw steam compressor test device, including an intake filter, an exhaust separator, an exhaust pressure regulating and venting pipe, a heat recovery unit, a condensate pipe, a lubricating oil tank, a soft water tank, a soft water treatment device, and a drive motor;

[0014] The drive motor is used to drive the screw-type steam compressor under test.

[0015] The exhaust port of the screw steam compressor to be tested is connected to the inlet of the exhaust separator through the compressor exhaust pipe, and the compressor exhaust pipe is equipped with an exhaust silencer;

[0016] The suction port of the screw steam compressor to be tested is connected to the suction filter through the compressor intake pipe, and the compressor intake pipe is equipped with a suction silencer;

[0017] The compressor intake pipe is connected to the liquid outlet of the exhaust separator via a circulating water spray pipe.

[0018] The exhaust end of the exhaust separator is connected to the input end of the exhaust pressure regulating and venting pipeline through an exhaust pipe. The output end of the exhaust pressure regulating and venting pipeline is connected to the upper input end of the shell side of the heat recovery unit. The lower output end of the shell side of the heat recovery unit is connected to the upper first input end of the soft water tank through the condensate pipe. The upper output end of the shell side of the heat recovery unit is connected to the upper second input end of the soft water tank through a balance pipe. The tube side input end of the heat recovery unit is connected to the output end of the hot water pipe. The tube side output end of the heat recovery unit is connected to the input end of the hot water pipe.

[0019] The output end of the soft water treatment device is connected to the soft water tank through a pipeline, and the soft water tank replenishes water to the screw steam compressor under test through a soft water supply pipe.

[0020] The beneficial effects of this utility model are as follows: The main noise source of this test device is the screw steam compressor, and the noise is generated at the intake and exhaust ports. The corresponding intake silencer and exhaust silencer are directly connected to the compressor intake pipe and exhaust pipe through flanges. The modification is simple, the installation is convenient, the size is small, the weight is light, and the effect is good. In practice, the noise level can be reduced to below 90 decibels. There is no need to adopt the noise reduction method of adding an overall soundproof cover or soundproof room, which greatly reduces the noise reduction cost and at the same time greatly improves the working environment of the test device site.

[0021] Each time the test apparatus is turned on, a dynamic compressed air warm-up is required. The main reason for the long warm-up time is that some of the heat generated by the compressed air is continuously carried away by the room-temperature soft water, resulting in a slow temperature rise of the compressed air. However, during the dynamic compressed air warm-up process, by adding a circulating water spray pipe between the compressor intake pipe and the exhaust separator, due to the pressure difference between the intake and exhaust, the soft water stored in the exhaust separator will automatically circulate and spray water into the compressor intake port. At this time, the soft water can be turned off, allowing some of the heat of the compressed air to continuously accumulate in the circulating water. In a short time, the temperature of the circulating water rises rapidly, generating compressed steam, and quickly entering the stage of compressed water vapor venting. This shortens the warm-up time of the test apparatus by about half an hour, keeping it within one hour, greatly reducing the power consumption of the warm-up and the amount of soft water added during the warm-up. Compared to using the high-temperature steam discharged from the test device for thermal or thermoelectric conversion, the heat in the steam can be completely recovered and utilized simply by using the condensation phase change elimination technology of the heat recovery unit. The equipment is simple, the investment is small, and it achieves energy saving and emission reduction, elimination of whitening and dehumidification, and recycling of cooling soft water, which extends the life of the soft water treatment device filter element. It saves tap water resources and reduces the consumption of industrial salt required for replacement.

[0022] Based on the above technical solution, the present invention can be further improved as follows.

[0023] Furthermore, it also includes an air-sealed cooler, a third exhaust fan, and a liquid-sealed coil. The upper shell-side mixed gas input end of the air-sealed cooler is connected to the mixed gas output end of the screw-type steam compressor under test through a mixed gas outlet pipe. The upper shell-side output end of the air-sealed cooler is connected to the input end of the third exhaust fan, and the output end of the third exhaust fan is connected to a vent pipe. The lower shell-side output end of the air-sealed cooler is connected to the input end of the liquid-sealed coil, and the output end of the liquid-sealed coil is connected to a condensate drain pipe.

[0024] The beneficial effect of adopting the above-mentioned further scheme is that a small portion of the water vapor in the mixed gas is condensed by the gas seal cooler. A small amount of high-temperature water vapor is condensed into liquid and directly enters the liquid seal drainage pipeline system. The isolation gas separated by condensation is discharged into the atmosphere through the third exhaust fan added to the top of the gas seal cooler, always maintaining a slight negative pressure in the shell-side space of the gas seal cooler, so that the mixed gas can passively and continuously flow to the gas seal cooler.

[0025] Furthermore, the height difference between the gas-sealed cooler and the liquid-sealed coil is greater than or equal to 600 mm.

[0026] The beneficial effect of adopting the above-mentioned further scheme is that it ensures that the gravitational potential energy of the condensate in the gas-sealed cooler can overcome the friction loss and local resistance loss of the condensate drain pipe, and will not accumulate in the gas-sealed cooler, so that the mixed gas outlet of the screw steam compressor to be tested flows smoothly.

[0027] Furthermore, the height of the liquid seal coil is greater than or equal to 200 mm.

[0028] The beneficial effect of adopting the above-mentioned further scheme is that it isolates the gas-sealed cooler from the outside atmosphere, forming a liquid seal, preventing air from entering the shell-side micro-negative pressure space of the gas-sealed cooler, and ensuring smooth flow of the mixed gas outlet of the screw steam compressor to be tested.

[0029] Furthermore, the input end of the intake filter is connected to an intake pipe, the input end of the intake pipe is connected to a heat engine air supply pipe, the heat engine air supply pipe is equipped with a heat engine air supply regulating valve, and an intake pressure regulating pipe is also provided between the intake pipe and the exhaust pipe, and an intake pressure regulating valve is provided on the intake pressure regulating pipe.

[0030] The beneficial effects of adopting the above-mentioned further scheme are that, in the initial stage of the hot engine, sufficient compressed air is supplied through the hot engine air supply regulating valve to increase the hot engine load and accelerate the hot engine speed; during the entire operation, the high temperature and high pressure gas on the compressor exhaust side is adjusted to a low temperature and low pressure state through the suction pressure regulating valve, so that a pressure difference is formed in the closed-loop test system, ensuring the normal operation of the compressor and guaranteeing the test conditions of the compressor.

[0031] Furthermore, it also includes a first oil mist separator, a first exhaust fan, and a first flame arrester. The isolation gas input end of the screw steam compressor under test is connected to the isolation gas inlet pipe, the isolation gas output end of the screw steam compressor under test is connected to the input end of the isolation gas outlet pipe, the output end of the isolation gas outlet pipe is connected to the input end of the first oil mist separator, the upper output end of the first oil mist separator is connected to the input end of the first flame arrester through the first exhaust fan, and the output end of the first flame arrester is connected to the vent pipe.

[0032] The beneficial effect of adopting the above-mentioned further solution is that, during the operation of the existing test device, the isolation gas outlet pipe near the bearing and synchronous gear end of the screw steam compressor also carries a small amount of lubricating oil. The current method of handling this is to release it into the air on-site, which not only causes significant oil pollution but also poses a hazard to the surrounding environment, the site environment, and personnel. In the improved test device, the small amount of oil mist contained in the isolation gas outlet is not directly released on-site. Instead, it is completely separated by the filtration device within the first oil mist separator. The separated oil droplets are collected at the bottom periodically for environmental treatment. The separated isolation gas meets environmental standards and is then released on-site. Because the isolation gas pressure is low, there is resistance loss when passing through the filtration device within the first oil mist separator; therefore, a first exhaust fan is used to transport it outwards. The function of the first flame arrester is to prevent the spread of flames from flammable gases. It is a safety device and is generally installed in pipelines transporting flammable gases.

[0033] Furthermore, it also includes a second oil mist separator, a second exhaust fan, and a second flame arrester. The oil tank vent outlet of the lubricating oil tank is connected to the input end of the second oil mist separator. The upper output end of the second oil mist separator is connected to the input end of the second flame arrester through the second exhaust fan. The output end of the second flame arrester is connected to a vent pipe.

[0034] The beneficial effect of adopting the above-mentioned further solution is that, during the operation of the existing test device, there is an oil leakage problem at the breather valve of the lubricating oil tank. A small amount of oil mist discharged from the breather valve is directly released into the air at the test site, posing a hazard to the surrounding environment, the site conditions, and the health of on-site personnel. The improved test device eliminates the breather valve at the lubricating oil tank's breather opening. The small amount of oil mist contained in the breather opening is not directly discharged on-site, but is completely separated by the filtration device within the second oil mist separator. The separated oil droplets return to the lubricating oil tank, and the separated breather air meets environmental standards and is discharged on-site. Due to the low breathing pressure, there is resistance loss in the filtration device within the second oil mist separator; therefore, a second exhaust fan is used to transport the air outwards. The function of the second flame arrester is to prevent the spread of flames from flammable gases; it is a safety device and is generally installed in pipelines transporting flammable gases.

[0035] Furthermore, the lubricating oil tank is connected to the oil supply input end of the screw steam compressor under test via an oil supply pipe; the bearing oil output end and the shaft extension oil end of the screw steam compressor under test are connected to the lubricating oil tank via an oil return pipe.

[0036] The beneficial effect of adopting the above-mentioned further solution is that during the operation of the test device, oil leakage at the male rotor shaft extension lip seal of the screw steam compressor is generally 6 drops / minute. Existing solutions often use an oil collection container, discarding it as waste oil once it is full. However, if this is not observed properly, overflowing oil can pollute the surrounding environment and the site. Furthermore, treating it as waste oil is wasteful. The improved solution allows the leaked oil droplets from the male rotor shaft extension lip seal of the screw steam compressor to be recovered through the return oil pipe to the atmospheric pressure return oil pipe of the lubricating oil tank, reducing lubricating oil loss. This replaces the conventional solution of simply discharging into an oil collection container. The oil return method for the screw steam compressor bearings and synchronous gears is also designed as a gravity return method, which also reduces the power consumption of the oil supply pump. It only requires ensuring that the oil return port of the screw steam compressor is at a certain height from the oil return port of the lubricating oil station to overcome the resistance loss of the return oil pipe.

[0037] Furthermore, an intake / exhaust bypass pipe is provided between the exhaust pipe and the compressor intake pipe.

[0038] The beneficial effect of adopting the above-mentioned further solution is that when the steam compressor experiences an emergency alarm shutdown during test operation, the intake and exhaust bypass pipes are quickly connected, allowing the compressor intake pipe pressure and exhaust pipe pressure to quickly reach a balance, preventing the compressor from reversing and protecting the compressor from damage. Attached Figure Description

[0039] Figure 1 This is a schematic diagram of the structure of this utility model;

[0040] 1. Drive motor; 2. Coupling; 3. Exhaust pipe; 4. Oil drain pipe; 5. Screw-type steam compressor to be tested; 6. Compressor exhaust pipe; 7. Exhaust temperature transmitter; 8. Exhaust pressure transmitter; 9. Exhaust separator; 10. Exhaust flow meter; 11. Exhaust pressure regulating valve; 12. Suction pressure regulating valve; 13. Heat engine make-up gas regulating valve; 14. Suction flow meter; 15. Suction filter; 16. Suction and exhaust bypass pipe; 17. Suction and exhaust bypass switch valve; 18. Compressor inlet pipe; 19. Suction temperature transmitter; 20. Suction pressure transmitter; 21. Isolation gas inlet pipe; 22. Mixed gas outlet pipe; 23. Isolation gas outlet pipe; 24. Oil tank breather; 25. Lubricating oil tank; 26. Lubricating oil pump; 27. Oil cooler; 28. 29. Oil supply pipe; 30. Oil return pipe; 31. Condensate drain pipe; 32. Soft water supply pipe; 33. Soft water flow meter; 34. Soft water supply regulating valve; 35. Soft water supply pump; 36. Soft water tank; 37. Drainage pipe; 38. Soft water treatment device; 39. Suction pressure regulating pipe; 40. Exhaust pressure regulating and venting pipe; 41. Suction silencer; 42. Circulating spray water regulating valve; 43. Circulating spray water pipe; 44. Exhaust silencer; 45. Heat recovery unit; 46. Suction pipe; 47. Condensate pipe; 48. Balance pipe; 49. Air seal cooler; 50. Liquid seal coil; 51. Third exhaust fan; 52. First oil mist separator; 53. First exhaust fan; 54. First flame arrester; 55. Second oil mist separator; 56. Second exhaust fan; 57. Second flame arrester. Detailed Implementation

[0041] The principles and features of this utility model are described below with reference to examples. The examples are only used to explain this utility model and are not intended to limit the scope of this utility model.

[0042] like Figure 1 As shown, an energy-saving and environmentally friendly screw steam compressor test device includes an intake filter 15, an exhaust separator 9, an exhaust pressure regulating and venting pipeline 39, a heat recovery unit 44, a condensate pipe 46, a lubricating oil tank 25, a soft water treatment device 37, and a drive motor 1.

[0043] The drive motor 1 is used to drive the screw steam compressor 5 under test to operate; the output end of the drive motor 1 is connected to the screw steam compressor 5 under test through the coupling 2, and is used to drive the screw steam compressor 5 under test to rotate.

[0044] The exhaust port of the screw steam compressor under test is connected to the inlet of the exhaust separator 9 through the compressor exhaust pipe 6, and the compressor exhaust pipe 6 is equipped with an exhaust silencer 43;

[0045] The suction port of the screw steam compressor to be tested is connected to the suction filter 15 through the compressor intake pipe 18, and the compressor intake pipe 18 is equipped with a suction silencer 40.

[0046] The compressor intake pipe 18 is connected to the liquid outlet of the exhaust separator 9 through the circulating water spray pipe 42; the circulating water spray pipe 42 is equipped with a circulating water spray regulating valve 41;

[0047] The exhaust end of the exhaust separator 9 is connected to the input end of the exhaust pressure regulating and venting pipe 39 through the exhaust pipe 3. The output end of the exhaust pressure regulating and venting pipe 39 is connected to the upper input end of the shell side of the heat recovery unit 44. The lower output end of the shell side of the heat recovery unit 44 is connected to the upper first input end of the soft water tank 35 through the condensate pipe 46. The upper output end of the shell side of the heat recovery unit 44 is connected to the upper second input end of the soft water tank 35 through the balance pipe 47. The tube side input end of the heat recovery unit 44 is connected to the output end of the hot water pipe. The tube side output end of the heat recovery unit 44 is connected to the input end of the hot water pipe.

[0048] The output of the soft water treatment device 37 is connected to the soft water tank 35 via a pipeline. The soft water tank 35 supplies water to the screw steam compressor under test through the soft water supply pipe 31. The soft water supply pipe 31 is equipped with a water supply flow meter 32, a soft water supply regulating valve 33, and a soft water supply pump 34. The soft water in the soft water tank 35 can enter the screw steam compressor under test through the soft water supply pipe 31 and the compressor inlet pipe 18 to supply water.

[0049] The compressor inlet pipe 18 is equipped with an intake temperature transmitter 19 and an intake pressure transmitter 20. The intake temperature transmitter 19 monitors the gas temperature in the compressor inlet pipe 18 in real time to ensure that the temperature is within a suitable range; the intake pressure transmitter 20 monitors the gas pressure in the compressor inlet pipe 18 in real time to ensure that the pressure is within a suitable range. The compressor exhaust pipe 6 is equipped with an exhaust temperature transmitter 7 and an exhaust pressure transmitter 8. The exhaust temperature transmitter 7 monitors the gas temperature in the compressor exhaust pipe 6 in real time to ensure that the temperature is maintained within a safe and efficient range; the exhaust pressure transmitter 8 monitors the gas pressure in the compressor exhaust pipe 6 in real time to ensure that the pressure is maintained within a set range. The temperature and pressure transmitters play an important role in monitoring and controlling the compressor's operating status and ensuring production safety and efficiency.

[0050] An exhaust flow meter 10 is installed on the exhaust pipe 3. An exhaust pressure regulating valve 11 is installed on the exhaust pressure regulating and venting pipe 39.

[0051] It also includes a gas-sealed cooler 48, a third exhaust fan 50, and a liquid-sealed coil 49. The upper input end of the shell side of the gas-sealed cooler 48 is connected to the mixer output end of the screw-type steam compressor under test through a mixed gas outlet pipe 22. The upper output end of the shell side of the gas-sealed cooler 48 is connected to the input end of the third exhaust fan 50, and the output end of the third exhaust fan 50 is connected to a vent pipe. The lower output end of the shell side of the gas-sealed cooler 48 is connected to the input end of the liquid-sealed coil 49, and the output end of the liquid-sealed coil 49 is connected to a condensate drain pipe. A small portion of the water vapor in the mixed gas is condensed by the gas-sealed cooler 48. After a small amount of high-temperature water vapor condenses into liquid, it directly enters the liquid-sealed drain pipeline system. The isolation gas separated by condensation is discharged into the atmosphere through the third exhaust fan 50 added to the top of the gas-sealed cooler 48, always maintaining a slight negative pressure in the shell side space of the gas-sealed cooler 48, allowing the mixed gas to passively and continuously flow into the gas-sealed cooler 48.

[0052] The height difference between the gas-sealed cooler 48 and the liquid-sealed coil 49 is greater than or equal to 600 mm. This ensures that the gravitational potential energy of the condensate in the gas-sealed cooler 48 can overcome the friction loss and local resistance loss of the condensate drain pipe, preventing it from accumulating in the gas-sealed cooler 48 and ensuring smooth flow of the mixed gas at the outlet of the screw steam compressor 5 under test.

[0053] The height of the liquid-sealed coil 49 is greater than or equal to 200mm. This isolates the gas-sealed cooler 48 from the outside atmosphere, forming a liquid seal. Air does not enter the slightly negative pressure space in the shell side of the gas-sealed cooler 48, ensuring smooth flow of the mixed gas at the outlet of the screw-type steam compressor 5 to be tested.

[0054] The intake filter 15 is connected to an intake pipe 45 at its input end. An intake flow meter 14 is installed on the intake pipe 45. The intake pipe 45 is also connected to a heat engine replenishment pipe, which is equipped with a heat engine replenishment regulating valve 13. An intake pressure regulating pipe 38 is also provided between the intake pipe 45 and the exhaust pipe 3, and an intake pressure regulating valve 12 is installed on the intake pressure regulating pipe 38. During the initial warm-up phase, sufficient compressed air is supplied through the heat engine replenishment regulating valve 13 to increase the heat engine load and accelerate the warm-up speed. Throughout the entire operation, the intake pressure regulating valve 12 adjusts the high-temperature, high-pressure gas on the compressor exhaust side to a low-temperature, low-pressure state, creating a pressure difference in the closed-loop test system to ensure the compressor operates normally and meets the test conditions.

[0055] The system also includes a first oil mist separator 51, a first exhaust fan 52, and a first flame arrester 53. The isolation gas input end of the screw-type steam compressor under test is connected to the isolation gas inlet pipe 21, and the isolation gas output end of the screw-type steam compressor under test is connected to the input end of the isolation gas outlet pipe 23. The output end of the isolation gas outlet pipe 23 is connected to the input end of the first oil mist separator 51. The upper output end of the first oil mist separator 51 is connected to the input end of the first flame arrester 53 through the first exhaust fan 52, and the output end of the first flame arrester 53 is connected to a vent pipe. The small amount of oil mist contained in the isolation gas outlet is not directly discharged on-site, but is completely separated by the filtration device inside the first oil mist separator 51. The separated oil droplets are collected at the bottom and treated periodically for environmental protection. The separated isolation gas meets environmental standards and is discharged on-site. Because the isolation gas pressure is low, there is resistance loss after passing through the filtration device inside the first oil mist separator 51, so the first exhaust fan 52 is used to transport it outward. The function of the first flame arrester 53 is to prevent the spread of flames from flammable gases. It is a safety device and is generally installed in pipelines that transport flammable gases.

[0056] It also includes a second oil mist separator 54, a second exhaust fan 55, and a second flame arrester 56. The output end of the oil tank vent 24 of the lubricating oil tank 25 is connected to the input end of the second oil mist separator 54. The upper output end of the second oil mist separator 54 is connected to the input end of the second flame arrester 56 through the second exhaust fan 55. The output end of the second flame arrester 56 is connected to a vent pipe. The oil tank vent valve of the lubricating oil tank 25 is removed. The small amount of oil mist contained in the oil tank vent 24 is not directly discharged on-site, but is completely separated by the filter device inside the second oil mist separator 54. The separated oil droplets return to the lubricating oil tank 25. The separated breather gas meets environmental protection standards and is discharged on-site. Due to the low breathing pressure, there is resistance loss after passing through the filter device inside the second oil mist separator 54. Therefore, the second exhaust fan 55 is used to transport it outward. The function of the second flame arrester 56 is to prevent the spread of flames of flammable gases. It is a safety device and is generally installed in pipelines that transport flammable gases.

[0057] The lubricating oil tank 25 is connected to the oil supply input end of the screw-type steam compressor under test via an oil supply pipe 28. An oil pump 26 is installed on the oil supply pipe 28. An oil cooler 27 is also installed on the oil supply pipe 28. The oil cooler 27 is used to cool the lubricating oil in the oil supply pipe 28. The bearing oil outlet end and shaft oil extension end of the screw-type steam compressor under test are connected to the lubricating oil tank 25 via an oil return pipe 29. The bearing oil outlet end and shaft oil extension end of the screw-type steam compressor under test are connected to the oil return pipe 29 via an oil drain pipe 4. The atmospheric pressure oil droplets leaking from the male rotor shaft extension lip seal of the screw steam compressor can be recovered through the return oil pipe 29 to the atmospheric pressure return oil pipe 29 of the lubricating oil tank 25, reducing lubricating oil loss. This replaces the conventional solution of only discharging into the oil collection container. The oil return method of the screw steam compressor bearings and synchronous gears is optimized from the traditional pressurized oil return to a gravity oil return method, which also has the advantage of reducing the power consumption of the oil supply pump. However, it is necessary to ensure that the oil return port of the screw steam compressor is at a certain height from the oil return port of the lubricating oil station to overcome the resistance loss of the return oil pipe 29. For the oil mist leaking from the isolation gas outlet pipe 23 near the bearings and synchronous gears of the screw steam compressor and the breather valve on the lubricating oil tank 25, oil mist separators are installed to separate and purify the lubricating oil and air or isolation gas. The separated lubricating oil can be returned to the lubricating oil station tank or collected periodically as waste oil. The separated pure air or isolation gas is discharged into the atmosphere after passing through a flame arrester, completely eliminating the safety hazards of oil mist.

[0058] An exhaust bypass pipe 16 is also provided between the exhaust pipe 3 and the compressor intake pipe 18. An exhaust bypass switch valve 17 is provided on the exhaust bypass pipe 16. When the steam compressor experiences an emergency alarm shutdown during test operation, the exhaust bypass pipe 16 is quickly connected, so that the pressure in the compressor intake pipe 18 and the exhaust pipe pressure quickly reach equilibrium, preventing the compressor from reversing and protecting the compressor from damage.

[0059] The liquid outlet of the screw steam compressor under test is connected to the condensate drain pipe via the condensate drain pipe 30.

[0060] The soft water tank 35 is connected to the main drain pipe via a drain pipe 36. The exhaust separator 9 is connected to the main drain pipe via a pipeline.

[0061] The experimental procedure of the experimental apparatus:

[0062] 1. Start-up process: Sequentially close the device drain valve, supply air to the isolation gas inlet, turn on the first exhaust fan 52, turn on the second exhaust fan 55, turn on the third exhaust fan 50, turn on the soft water treatment device 37, turn on the lubricating oil pump 26 to supply oil to the compressor, turn on the cooling water circulation, turn on the hot water circulation, turn on the heat engine gas supply regulating valve 13, turn on the suction pressure regulating valve 12, turn on the soft water supply regulating valve 33, turn on the soft water supply pump 34, and turn on the drive motor 1.

[0063] 2. Warm-up process: Gradually increase the frequency of drive motor 1 to start the compressed air warm-up. After a certain amount of soft water is added to the exhaust separator 9, open the circulating water spray regulating valve 41, close the soft water replenishment regulating valve 33, and close the warm-up air replenishment valve. When water vapor is generated, gradually open the soft water replenishment valve, close the circulating water regulating valve, and open the exhaust pressure regulating valve 11 to gradually ventilate the system until the warm-up is complete.

[0064] 3. Testing process: According to the test conditions and exhaust temperature required by the test, adjust the intake pressure regulating valve 12, exhaust pressure regulating valve 11, and soft water supply regulating valve 33. After the test conditions are stabilized, record the intake pressure, intake temperature, exhaust pressure, exhaust temperature, soft water supply pressure, soft water supply temperature, intake flow meter 14 data, exhaust flow meter 10 data, soft water supply flow meter 32 data, noise data, etc.

[0065] 4. Shutdown process: Gradually reduce the frequency of drive motor 1, gradually increase the opening of exhaust pressure regulating valve 11 to reduce exhaust pressure, open the hot air replenishment regulating valve 13 and gradually increase its opening to reduce suction pressure, gradually decrease the opening of soft water replenishment regulating valve 33. When the suction and exhaust pressures are close to atmospheric pressure and the frequency of drive motor 1 drops to 5Hz, turn off drive motor 1 in sequence, turn off soft water replenishment, turn off lubricating oil pump 26, turn off first exhaust fan 52, turn off second exhaust fan 55, turn off third exhaust fan 50, turn off soft water treatment device 37, turn off isolation gas supply, turn off cooling water circulation, turn off hot water circulation, turn off hot air replenishment regulating valve 13, turn off suction pressure regulating valve 12, turn off exhaust pressure regulating valve 11, and open the test device drain valve.

[0066] According to the law of conservation of mass, the softened chilled water injected into the screw steam compressor is discharged in three parts. A large amount is high-temperature steam (white smoke) discharged through the exhaust pressure regulating valve 11; a small amount is white smoke leaking from the carbon ring vapor side of the screw steam compressor and discharged along with the isolation gas outlet; and a trace amount is condensate naturally condensed at the carbon ring, which is discharged directly into the drain pipe 36. Therefore, the main purpose is to eliminate the two streams of high-temperature steam (white smoke). The large amount of steam discharged through the exhaust pressure regulating valve 11 is condensed by the heat recovery unit 44. The fully recovered heat is provided indirectly or directly to the required applications, such as process heat, domestic hot water, and winter heating, through hot water circulation. The high-temperature steam cooled to room temperature liquid state is automatically returned to the atmospheric pressure soft water tank 35 by gravity, allowing this portion of the softened chilled water to be recycled. Note that the cooler and the top of the soft water tank 35 need to be connected through the balance pipe 47 to ensure normal automatic return. Lubricating oil leakage occurs in the form of oil droplets and oil mist. Oil droplets result in significant waste, while oil mist poses a greater hazard. Because the atmospheric pressure oil droplets leaking from the male rotor shaft extension lip seal of the screw steam compressor cannot return to the pressurized return oil pipe 29, the oil return method for the screw steam compressor bearings and synchronous gears has been optimized from the traditional pressurized return oil method to a gravity return oil method. It is necessary to ensure that the oil return port of the screw steam compressor is at a certain height from the oil return port of the lubricating oil station to overcome the resistance loss of the return oil pipe 29. In this way, the pressure inside the return oil pipe 29 is equal to the atmospheric pressure, and then the atmospheric pressure oil droplets at the lip seal can be introduced into the atmospheric pressure return oil pipe 29 through the pipeline. For oil mist leaking from the isolation gas outlet pipe near the bearing and synchronous gear end of the screw steam compressor and the breather valve on the oil tank of the lubricating oil station, oil mist separators are installed separately to separate and purify the lubricating oil and air or isolation gas. The separated lubricating oil can be returned to the oil tank of the lubricating oil station or collected periodically as waste oil. The separated pure air or isolation gas is discharged into the atmosphere after passing through a flame arrester, completely eliminating the safety hazard of oil mist.

[0067] This utility model addresses the energy-saving and environmental protection issues of existing screw-type steam compressor test devices, solving problems such as high heat engine power consumption, loud airflow noise, significant soft water waste, and heavy oil pollution during operation. Its advantages are mainly reflected in the following three aspects: 1. Analysis shows that the main noise source of the test device is the screw-type steam compressor, with noise generated at the intake and exhaust ports. Corresponding silencers can be directly connected to the intake and exhaust pipes via flanges, simplifying the modification and facilitating installation. The silencers are small, lightweight, and effective, reducing noise levels to below 90 decibels, eliminating the need for an overall soundproof enclosure or soundproof room, significantly reducing noise reduction costs, and greatly improving the working environment of the test device. 2. Through the condensation phase change whitening technology of the heat recovery unit 44, the heat in the steam is completely recovered and utilized. The equipment is simple, requires low investment, achieves energy saving and emission reduction, whitening and dehumidification, and also recycles cooling soft water, extending the life of the soft water treatment device 37 filter element. This saves tap water and reduces the consumption of industrial salt required for replacement. 3. By optimizing the oil return method of the screw steam compressor, the discharged oil droplets are automatically recycled, saving the amount of lubricating oil consumed during the operation of the test device. Through the separation and safe handling of the discharged oil mist, the ground is free of oil stains and the air is free of oil mist, further improving the surrounding and on-site working environment. This utility model of an energy-saving and environmentally friendly screw steam compressor test device can comprehensively and rationally treat the noise, exhaust gas, and waste liquid pollution generated at the test device's operating site, meeting the environmental protection requirements of energy conservation, occupational health, and personal safety.

[0068] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. An energy-saving and environmentally friendly screw-type steam compressor test device, characterized in that, It includes an intake filter (15), an exhaust separator (9), an exhaust pressure regulating and venting pipe, a heat recovery unit (44), a condensate pipe (46), a lubricating oil tank (25), a soft water tank (35), a soft water treatment device (37), and a drive motor (1); The drive motor (1) is used to drive the screw steam compressor (5) under test to operate; The exhaust port of the screw steam compressor to be tested is connected to the inlet of the exhaust separator (9) through the compressor exhaust pipe (6), and the compressor exhaust pipe (6) is provided with an exhaust silencer (43); The suction port of the screw steam compressor to be tested is connected to the suction filter (15) through the compressor intake pipe (18), and the compressor intake pipe (18) is provided with a suction silencer (40); The compressor intake pipe (18) is connected to the exhaust separator (9) through the circulating water spray pipe (42); The exhaust end of the exhaust separator (9) is connected to the input end of the exhaust pressure regulating and venting pipeline (39) through the exhaust pipeline (3). The output end of the exhaust pressure regulating and venting pipeline (39) is connected to the upper input end of the shell side of the heat recovery unit (44). The lower output end of the shell side of the heat recovery unit (44) is connected to the upper first input end of the soft water tank (35) through the condensate pipe (46). The upper output end of the shell side of the heat recovery unit (44) is connected to the upper second input end of the soft water tank (35) through the balance pipe (47). The tube side input end of the heat recovery unit (44) is connected to the output end of the hot water pipe. The tube side output end of the heat recovery unit (44) is connected to the input end of the hot water pipe. The output end of the soft water treatment device (37) is connected to the soft water tank (35) through a pipeline, and the soft water tank (35) replenishes water to the screw steam compressor to be tested through the soft water replenishment pipe (31).

2. The energy-saving and environmentally friendly screw-type steam compressor test device according to claim 1, characterized in that, It also includes an air-sealed cooler (48), a third exhaust fan (50), and a liquid-sealed coil (49). The upper mixed gas input end of the shell side of the air-sealed cooler (48) is connected to the mixed gas output end of the screw steam compressor under test through a mixed gas outlet pipe (22). The upper output end of the shell side of the air-sealed cooler (48) is connected to the input end of the third exhaust fan (50). The output end of the third exhaust fan (50) is connected to a vent pipe. The lower output end of the shell side of the air-sealed cooler (48) is connected to the input end of the liquid-sealed coil (49). The output end of the liquid-sealed coil (49) is connected to a condensate drain pipe.

3. The energy-saving and environmentally friendly screw-type steam compressor test device according to claim 2, characterized in that, The height difference between the gas-sealed cooler (48) and the liquid-sealed coil (49) is greater than or equal to 600 mm.

4. The energy-saving and environmentally friendly screw-type steam compressor test device according to claim 2, characterized in that, The height of the liquid seal coil (49) is greater than or equal to 200 mm.

5. The energy-saving and environmentally friendly screw-type steam compressor test apparatus according to any one of claims 1-4, characterized in that, The intake filter (15) is connected to an intake pipe (45) at its input end. The intake pipe (45) is connected to a heat engine air supply pipe at its input end. A heat engine air supply regulating valve (13) is provided on the heat engine air supply pipe. An intake pressure regulating pipe (38) is also provided between the intake pipe (45) and the exhaust pipe (3). An intake pressure regulating valve (12) is provided on the intake pressure regulating pipe (38).

6. The energy-saving and environmentally friendly screw-type steam compressor test apparatus according to any one of claims 1-4, characterized in that, It also includes a first oil mist separator (51), a first exhaust fan (52) and a first flame arrester (53). The isolation gas input end of the screw steam compressor to be tested is connected to the isolation gas inlet pipe (21). The isolation gas output end of the screw steam compressor to be tested is connected to the input end of the isolation gas outlet pipe (23). The output end of the isolation gas outlet pipe (23) is connected to the input end of the first oil mist separator (51). The upper output end of the first oil mist separator (51) is connected to the input end of the first flame arrester (53) through the first exhaust fan (52). The output end of the first flame arrester (53) is connected to the vent pipe.

7. The energy-saving and environmentally friendly screw-type steam compressor test apparatus according to any one of claims 1-4, characterized in that, It also includes a second oil mist separator (54), a second exhaust fan (55) and a second flame arrester (56). The output end of the oil tank vent (24) of the lubricating oil tank (25) is connected to the input end of the second oil mist separator (54). The upper output end of the second oil mist separator (54) is connected to the input end of the second flame arrester (56) through the second exhaust fan (55). The output end of the second flame arrester (56) is connected to the vent pipe.

8. The energy-saving and environmentally friendly screw-type steam compressor test device according to claim 7, characterized in that, The lubricating oil tank (25) is connected to the oil supply input end of the screw steam compressor to be tested via the oil supply pipe (28); the bearing oil output end and the shaft extension oil end of the screw steam compressor to be tested are connected to the lubricating oil tank (25) via the oil return pipe (29).

9. The energy-saving and environmentally friendly screw-type steam compressor test apparatus according to any one of claims 1-4, characterized in that, An intake and exhaust bypass pipe (16) is also provided between the exhaust pipe (3) and the compressor intake pipe (18).

10. The energy-saving and environmentally friendly screw-type steam compressor test device according to claim 9, characterized in that, The intake and exhaust bypass pipe (16) is equipped with an intake and exhaust bypass switch valve (17).

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