Special equipment for debugging ORC (organic Rankine cycle) generator set

Abstract

The utility model discloses special equipment for debugging an ORC (organic Rankine cycle) generator set. The special equipment comprises a working medium filling system, a vacuumizing system, a lubricating oil filling system and an intelligent monitoring unit, the vacuum-pumping system is used for carrying out vacuum-pumping and negative pressure testing on the ORC generator set; the working medium charging system is used for charging a working medium into the ORC generator set; the lubricating oil filling system is used for filling lubricating oil into the ORC generator set; the working medium charging system, the vacuumizing system and the lubricating oil charging system are arranged around the ORC generator set to jointly form a core part of the special equipment for debugging the ORC generator set; the working medium filling system is connected between the working medium storage tank and the ORC generator set, and the vacuumizing system is connected between the ORC generator set, an oil tank of the ORC generator set and the exhaust main line; and the intelligent monitoring unit is used for monitoring and controlling the operation of each system. Three sets of independent equipment are integrated, so that the management is convenient and the efficiency is improved; the control system monitors the pressure in real time, automatically judges the rising condition, judges whether the unit leaks or not, records debugging data and reduces energy consumption.

Description

A special equipment for commissioning ORC generator sets Technical Field

[0001] This utility model relates to the field of cryogenic power generation technology, and in particular to a special equipment for commissioning ORC generator sets. Background Technology

[0002] Organic Rankine cycle (ORC) generator sets are devices that convert low-grade thermal energy into mechanical energy to drive a generator to produce electricity. Their commissioning process is complex and critical, including pressure testing and leak detection, vacuuming, lubrication, and working fluid filling. Traditional commissioning equipment is often scattered, inefficient, and lacks traceability, making it difficult to effectively guarantee commissioning quality. Summary of the Invention

[0003] The purpose of this invention is to provide a special equipment for commissioning ORC generator sets, thereby solving the aforementioned problems existing in the prior art.

[0004] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0005] A special equipment for commissioning ORC generator sets includes a working fluid charging system, a vacuum system, a lubricating oil charging system, and an intelligent monitoring unit;

[0006] The vacuum system is used for vacuuming and negative pressure testing of ORC generator sets;

[0007] The working fluid charging system is used to charge the ORC generator set with working fluid;

[0008] The lubricating oil filling system is used to fill the ORC generator set with lubricating oil;

[0009] The working fluid charging system, vacuuming system, and lubricating oil charging system are all designed around the ORC generator set and together constitute the core part of the dedicated commissioning equipment for the ORC generator set.

[0010] The working fluid charging system is connected between the working fluid storage tank and the ORC generator set; the vacuum system is connected between the ORC generator set, its oil tank, and the exhaust main line; and the lubricating oil charging system is connected between the oil tank and the ORC generator set oil tank.

[0011] The intelligent monitoring unit is connected to the vacuum system, working fluid filling system, and lubricating oil filling system to monitor and control the operation of each system.

[0012] In some specific embodiments, the vacuum system includes an ORC generator set vacuum exhaust pipeline, an ORC generator set oil tank exhaust pipeline, an exhaust main line, and a seventh automatic valve installed on the exhaust main line, which are connected in sequence.

[0013] The working fluid charging system includes a working fluid inlet, a working fluid charging system front pipeline, a first filter, a first shut-off valve, a working fluid charging system rear pipeline, and an exhaust outlet connected in sequence. A third automatic valve is installed on the working fluid charging system front pipeline, and a fourth automatic valve is installed on the working fluid charging system rear pipeline.

[0014] The lubricating oil filling system includes a lubricating oil inlet, a lubricating oil filling system front pipeline, a second filter, a second shut-off valve, a lubricating oil filling system rear pipeline, and an ORC generator set oil tank connected in sequence. The fifth automatic valve is located on the lubricating oil filling system front pipeline, and the sixth automatic valve is located on the lubricating oil filling system rear pipeline.

[0015] In some specific embodiments, a pressure gauge manual valve and a remote pressure gauge are also included. The pressure gauge manual valve is connected to the corresponding remote pressure gauge to control the on / off state of the remote pressure gauge.

[0016] In some specific embodiments, the first filter and the second filter are dual filters, which are respectively installed on the corresponding pipelines of the working fluid filling system and the lubricating oil filling system to filter impurities in the working fluid and the lubricating oil.

[0017] In some specific embodiments, the intelligent monitoring unit integrates a PLC controller, a touch screen, and a data storage module. It is linked with various sensors through a bus to realize real-time acquisition of process parameters, abnormal alarms, and automatic control of the process flow. The intelligent monitoring unit is electrically connected to the remote pressure gauges, sight glasses, and automatic valves in the vacuum system, working fluid filling system, and lubricating oil filling system, respectively.

[0018] In some specific embodiments, the vacuum system further includes a first remote pressure gauge, which is installed on the exhaust line to monitor pressure changes during the vacuuming process.

[0019] In some specific embodiments, the working fluid charging system also includes sight glasses. A first sight glass is disposed on the pipeline between the first filter and the first shut-off valve, and a second sight glass is disposed on the pipeline between the first shut-off valve and the exhaust outlet, for real-time observation of the gas-liquid mixing state during the working fluid charging process.

[0020] In some specific embodiments, the lubricating oil filling system further includes a third sight glass and a fourth sight glass. The third sight glass is installed on the pipeline between the second filter and the second shut-off valve, and the fourth sight glass is installed on the pipeline between the second shut-off valve and the ORC generator set oil tank, for real-time observation of the gas-liquid mixing state during the lubricating oil filling process.

[0021] In some specific embodiments, the third, fourth, fifth, sixth, and seventh automatic valves are all solenoid valves, which are respectively installed on the corresponding pipelines of the working fluid charging system, the lubricating oil charging system, and the vacuum system to control the opening and closing of the pipelines.

[0022] In some specific embodiments, the first shut-off valve, the second shut-off valve, and the ball valve are respectively installed on the corresponding pipelines of the working fluid charging system and the lubricating oil charging system to control the charging flow rate of the working fluid and the lubricating oil.

[0023] The beneficial effects of this utility model are as follows: This utility model discloses a special equipment for commissioning ORC generator sets, including a working fluid charging system, a vacuum system, a lubricating oil charging system, and an intelligent monitoring unit. The vacuum system is used to perform vacuum and negative pressure tests on the ORC generator set; the working fluid charging system is used to charge the ORC generator set with working fluid; the lubricating oil charging system is used to charge the ORC generator set with lubricating oil. The working fluid charging system, vacuum system, and lubricating oil charging system are all arranged around the ORC generator set, together forming the core part of the special equipment for commissioning ORC generator sets. The working fluid charging system is connected between the working fluid storage tank and the ORC generator set; the vacuum system is connected between the ORC generator set, its oil tank, and the exhaust main line; and the lubricating oil charging system is connected between the oil tank and the ORC generator set's oil tank. The intelligent monitoring unit is connected to the vacuum system, working fluid charging system, and lubricating oil charging system, and is used to monitor and control the operation of each system. This utility model integrates three independent sets of equipment, which facilitates management and improves efficiency. The control system monitors pressure in real time, automatically assesses pressure recovery, detects potential leaks, and records commissioning data to reduce energy consumption. It monitors pressure and flow during the working fluid charging process to eliminate the risk of cavitation and overpressure, ensuring reliable charging and accurate quantity. It also monitors pressure and flow during the lubricating oil charging process to ensure reliable filling and accurate quantity. Attached Figure Description

[0024] Figure 1 is a structural schematic diagram of a special equipment for commissioning ORC generator sets according to this utility model;

[0025] Figure 2 is a structural schematic diagram of another embodiment of this utility model.

[0026] In the attached diagram, 1. First pressure gauge manual valve; 2. Second pressure gauge manual valve; 3. Third pressure gauge manual valve; 4. Fourth pressure gauge manual valve; 5. Fifth pressure gauge manual valve; 6. First remote pressure gauge; 7. Second remote pressure gauge; 8. Third remote pressure gauge; 9. Fourth remote pressure gauge; 10. Fifth remote pressure gauge.

[0027] 11. First automatic valve; 12. Second automatic valve; 13. Third automatic valve;

[0028] 14. Fourth automatic valve; 15. Fifth automatic valve; 16. Sixth automatic valve;

[0029] 17. Seventh automatic valve; 18. First filter; 19. First sight glass; 20. First shut-off valve;

[0030] 21. Second sight glass; 22. Second filter; 23. Third sight glass; 24. Second shut-off valve;

[0031] 25. Fourth sight glass; 26. ORC generator set; 27. ORC generator set fuel tank;

[0032] 28. ORC generator set vacuum exhaust line; 29. ​​ORC generator set fuel tank exhaust line;

[0033] 30. Exhaust main line; 31. Pre-fill pipeline of working fluid charging system; 32. Post-fill pipeline of working fluid charging system;

[0034] 33. Pre-lubricating oil filling system pipeline; 34. Post-lubricating oil filling system pipeline;

[0035] 35. Working fluid filling system; 36. Vacuum system; 37. Lubricating oil filling system; 38. Working fluid inlet; 39. Exhaust outlet; 40. Lubricating oil inlet. Detailed Implementation

[0036] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are merely illustrative of the present utility model and are not intended to limit the scope of the present utility model.

[0037] Referring to Figures 1 and 2, a special equipment for commissioning an ORC generator set includes a working fluid charging system 35, a vacuum system 36, a lubricating oil charging system 37, and an intelligent monitoring unit.

[0038] The vacuum system 36 is used for vacuuming and negative pressure testing of ORC generator sets;

[0039] The working fluid charging system 35 is used to charge the ORC generator set with working fluid;

[0040] Lubricating oil filling system 37 is used to fill the ORC generator set with lubricating oil;

[0041] The working fluid charging system 35, the vacuuming system 36, and the lubricating oil charging system 37 are all set around the ORC generator set 26, and together they constitute the core part of the special equipment for commissioning the ORC generator set.

[0042] The working fluid charging system 35 is connected between the working fluid storage tank and the ORC generator set; the vacuum system 36 is connected between the ORC generator set 26, its oil tank, and the exhaust main line; and the lubricating oil charging system 37 is connected between the oil tank and the ORC generator set oil tank.

[0043] The intelligent monitoring unit is connected to the vacuum system 36, the working fluid filling system 35, and the lubricating oil filling system 37 to monitor and control the operation of each system.

[0044] Intelligent monitoring unit: integrates PLC controller, touch screen and data storage module, and is linked with various sensors through bus. It is electrically connected to the remote pressure gauge, sight glass and automatic valve in vacuum system 36, working fluid filling system 35 and lubricating oil filling system 37 respectively.

[0045] Function: Used for monitoring and controlling the operation of various systems, enabling real-time acquisition of process parameters, abnormal alarms, and automatic control of the process flow. For example, it monitors pressure changes in the vacuum system, the gas-liquid mixing state in the working fluid charging system and lubricating oil charging system in real time, automatically determines whether there are leaks in the unit, and whether the working fluid charging and lubricating oil charging are normal, and records the commissioning data to facilitate subsequent data analysis and equipment maintenance, reduce energy consumption, improve commissioning efficiency and quality, and ensure the stable operation of the ORC generator set.

[0046] It should be noted here that the intelligent monitoring unit works as follows:

[0047] Initialization and parameter settings of the intelligent monitoring unit

[0048] System startup

[0049] When the power to the intelligent monitoring unit is turned on, the PLC controller begins a self-test, checking whether each component, such as the touch screen, data storage module, and communication bus, is working properly, ensuring that the entire monitoring system is in good operating condition.

[0050] Parameter settings

[0051] Input the relevant parameters required for this commissioning via the touchscreen, including but not limited to the target pressure value, flow range, vacuuming time, working fluid charge, and lubricating oil charge settings. These parameters will serve as the benchmark for subsequent monitoring and control, and the system will automatically adjust the control strategy according to actual needs.

[0052] Parameter monitoring and acquisition

[0053] Sensor connectivity and data acquisition

[0054] The intelligent monitoring unit maintains real-time communication with various sensors, such as remote pressure gauges and sight glasses, via a bus. It periodically collects process parameters such as pressure, flow rate, and liquid level transmitted from each sensor, and records the corresponding timestamps to ensure the accuracy and traceability of the data.

[0055] Data processing and storage

[0056] The PLC controller performs preliminary processing on the acquired raw data, including filtering and unit conversion, to improve the accuracy and usability of the data. The processed data is displayed in real-time on the touchscreen for operators to view intuitively; simultaneously, it is transmitted to the data storage module for storage, forming a complete debugging data record to provide a basis for subsequent analysis and traceability.

[0057] State judgment and decision making

[0058] Logical analysis and comparison

[0059] The PLC controller, based on preset control logic and algorithms, compares and analyzes the parameters collected in real time with previously set target values ​​or allowable ranges. For example, during the vacuuming process, it monitors the data from the remote pressure gauge on the exhaust line to determine whether the pressure drops as expected and whether the set negative pressure value has been reached; during the working fluid charging and lubricating oil charging stages, it monitors whether the pressure and flow rate in the charging system are within the normal range, and whether the gas-liquid mixing state displayed in the sight glass meets the requirements, etc.

[0060] Abnormal situation judgment

[0061] When monitored parameters exceed the set normal range, the PLC controller quickly determines the possible abnormality. For example, an abnormally high pressure may indicate pipeline blockage or valve malfunction, while an excessively low flow rate may indicate filter blockage or pump problems. Depending on the type of abnormality, the system will trigger the corresponding alarm mechanism to promptly remind operators to check and handle the situation.

[0062] Automatic control and execution

[0063] Control command generation

[0064] Based on the status judgment, the PLC controller generates corresponding control commands to achieve precise control of each system. For example, during the vacuuming stage, if the pressure drops too slowly, the power or opening degree of the vacuuming system can be adjusted appropriately; during the working fluid and lubricating oil filling process, the opening degree of the automatic valve is automatically adjusted according to the flow rate and liquid level to control the filling speed, ensuring the accuracy of the filling amount and the stability of the filling process.

[0065] Executive action

[0066] Control commands are transmitted via bus to corresponding actuators such as solenoid valves and ball valves, driving them to perform corresponding actions. For example, opening or closing automatic valves, starting or stopping vacuum equipment, working fluid filling equipment, lubricating oil filling equipment, etc., to achieve automated control of the entire commissioning process.

[0067] Alarms and prompts

[0068] Alarm triggered

[0069] When an anomaly occurs or the system detects a potential risk, the intelligent monitoring unit immediately triggers the alarm device, emitting an audible and visual alarm signal. Simultaneously, an alarm message pops up on the touchscreen, displaying detailed information such as the type of anomaly, the time of occurrence, and its location, enabling operators to quickly and accurately pinpoint the problem.

[0070] Alarm handling and recording

[0071] After taking appropriate measures based on the alarm prompts, operators can confirm the alarm via the touchscreen. The system records the occurrence and handling process of the alarm, generating an alarm log. These records help in the subsequent analysis and summarization of equipment failure causes, providing a reference for optimizing the commissioning process and improving equipment reliability.

[0072] Data Recording and Analysis

[0073] Data Records

[0074] Throughout the commissioning process, the intelligent monitoring unit continuously records various data, including normal operation data and abnormal data, in the data storage module. This data covers comprehensive information such as the operating status of each system, parameter change trends, operator input commands, and alarm events, forming a complete commissioning archive.

[0075] Data Analysis and Report Generation

[0076] After commissioning, the intelligent monitoring unit can perform in-depth analysis of the stored data and generate a detailed commissioning report. The report includes parameter statistics for each stage, graphs and charts, system performance evaluation, fault analysis, and recommendations. Operators and engineers can review the report to gain a comprehensive understanding of the quality and effectiveness of the commissioning work, providing strong support for equipment acceptance, operation and maintenance, and subsequent technical improvements.

[0077] Through the above working methods, the intelligent monitoring unit realizes comprehensive and intelligent monitoring and control of the ORC generator set commissioning process, effectively improving commissioning efficiency and quality, reducing the risk of human error, ensuring the safe and stable operation of the equipment, and laying a solid data foundation for the long-term management and optimization of the equipment.

[0078] In some specific embodiments, the vacuum system 36 includes an ORC generator set vacuum exhaust line 28, an ORC generator set oil tank exhaust line 29, an exhaust main line 30 connected in sequence, and a seventh automatic valve 17 disposed on the exhaust main line 30.

[0079] Function: Used for vacuuming and negative pressure testing of ORC generator sets to remove air and impurities from the unit, creating a favorable environment for subsequent working fluid charging and other operations, ensuring the unit's sealing and operational performance. Simultaneously, the first remote pressure gauge 6 in the vacuuming system is installed on the exhaust main line 30 to monitor pressure changes during the vacuuming process, allowing the intelligent monitoring unit to monitor the progress and effectiveness of the vacuuming in real time and automatically determine if there are any leaks in the unit.

[0080] The working fluid charging system 35 includes a working fluid inlet 38, a working fluid charging system front pipeline 31, a first filter 18, a first shut-off valve 20, a working fluid charging system rear pipeline 32, and an exhaust outlet 39 connected in sequence. A third automatic valve 13 is installed on the working fluid charging system front pipeline 31, and a fourth automatic valve 14 is installed on the working fluid charging system rear pipeline 32.

[0081] The working fluid charging system 35 is used to charge the ORC generator set with working fluid. The first filter 18 filters impurities from the working fluid, ensuring its purity and improving the stability and efficiency of the equipment. The working status of the working fluid charging system is monitored by an intelligent monitoring unit to ensure the smooth progress of the charging process and accurate control of the charging volume.

[0082] The lubricating oil filling system 37 includes a lubricating oil inlet 40, a lubricating oil filling system front pipeline 33, a second filter 22, a second shut-off valve 24, a lubricating oil filling system rear pipeline 34, and an ORC generator set oil tank 27 connected in sequence. The fifth automatic valve 15 is installed on the lubricating oil filling system front pipeline 33, and the sixth automatic valve 16 is installed on the lubricating oil filling system rear pipeline 34.

[0083] Function: Used to fill ORC generator sets with lubricating oil. The second filter 22 filters impurities in the lubricating oil, ensuring the quality of the lubricating oil entering the tank. This allows the lubricating oil to better perform its lubrication, cooling, and sealing functions, extending the service life of the equipment. The intelligent monitoring unit monitors the lubricating oil filling process, ensuring accurate control of the filling flow rate and amount, and preventing insufficient or excessive lubricating oil from affecting the normal operation of the unit.

[0084] In some specific embodiments, the system also includes pressure gauge manual valves and remote pressure gauges. The pressure gauge manual valves are connected to the corresponding remote pressure gauges to control the on / off state of the remote pressure gauges. These manual valves are distributed at corresponding locations in the vacuum system, working fluid charging system, and lubricating oil charging system to assist the intelligent monitoring unit in monitoring and controlling the pressure of each system.

[0085] It should be noted here that the pressure gauge manual valves include: first pressure gauge manual valve 1; second pressure gauge manual valve 2; third pressure gauge manual valve 3; fourth pressure gauge manual valve 4; and fifth pressure gauge manual valve 5.

[0086] The remote pressure gauges include: a first remote pressure gauge 6; a second remote pressure gauge 7; a third remote pressure gauge 8; a fourth remote pressure gauge 9; and a fifth remote pressure gauge 10.

[0087] In some specific embodiments, the first filter 18 and the second filter 22 are dual filters, which are respectively installed on the corresponding pipelines of the working fluid filling system 35 and the lubricating oil filling system 37, and are used to filter impurities in the working fluid and lubricating oil.

[0088] In some specific embodiments, the intelligent monitoring unit integrates a PLC controller, a touch screen, and a data storage module. It is linked with various sensors through a bus to realize real-time acquisition of process parameters, abnormal alarms, and automatic control of the process flow. The intelligent monitoring unit is electrically connected to the remote pressure gauge, sight glass, and automatic valve in the vacuum system 36, the working fluid filling system 35, and the lubricating oil filling system 37, respectively.

[0089] In some specific embodiments, the vacuum system 36 further includes a first remote pressure gauge 6, which is installed on the exhaust trunk line 30 to monitor pressure changes during the vacuuming process.

[0090] In some specific embodiments, the working fluid charging system 35 also includes sight glasses. A first sight glass 19 is disposed on the pipeline between the first filter 18 and the first shut-off valve 20, and a second sight glass 21 is disposed on the pipeline between the first shut-off valve 20 and the exhaust outlet 39, for real-time observation of the gas-liquid mixing state during the working fluid charging process. A fourth sight glass 25 is disposed on the pipeline between the second shut-off valve 24 and the ORC generator set oil tank 27, for real-time observation of the gas-liquid mixing state during the lubricating oil charging process, providing operators with intuitive visual information to assist in judging whether the charging process is normal.

[0091] In some specific embodiments, the lubricating oil filling system 37 further includes a third sight glass 23 and a fourth sight glass 25. The third sight glass 23 is disposed on the pipeline between the second filter 22 and the second shut-off valve 24, and the fourth sight glass 25 is disposed on the pipeline between the second shut-off valve 24 and the ORC generator set oil tank 27, for real-time observation of the gas-liquid mixing state during the lubricating oil filling process.

[0092] In some specific embodiments, the third automatic valve 13, the fourth automatic valve 14, the fifth automatic valve 15, the sixth automatic valve 16, and the seventh automatic valve 17 are all solenoid valves, which are respectively installed on the corresponding pipelines of the working fluid charging system 35, the lubricating oil charging system 37, and the vacuum system 36 to control the opening and closing of the pipelines. Under the control of the intelligent monitoring unit, the automatic switching and precise control of the operation of each system are realized.

[0093] In some specific embodiments, the first shut-off valve 20 and the second shut-off valve 24 are both ball valves, which are respectively installed on the corresponding pipelines of the working fluid charging system 35 and the lubricating oil charging system 37 to control the charging flow of the working fluid and lubricating oil, so that they can be manually adjusted and controlled as needed.

[0094] In some specific embodiments, the device also includes an alarm device connected to the intelligent monitoring unit for issuing an alarm when an anomaly occurs during the commissioning process.

[0095] The working method of this utility model:

[0096] 1. Debugging and preparation phase

[0097] Equipment inspection

[0098] Before starting commissioning, a comprehensive inspection of the entire commissioning equipment was conducted to ensure that all components of the working fluid charging system, vacuum system, lubricating oil charging system, and intelligent monitoring unit were intact and free from leaks or blockages. The automatic valves were checked to ensure they could open and close normally, and that pressure gauges, remote pressure gauges, sight glasses, etc., were functioning correctly. The PLC controller, touch screen, and data storage module of the intelligent monitoring unit were also checked to ensure they were operating normally.

[0099] Pipe connection

[0100] According to the connection relationship in the patent document, the working fluid charging system is connected between the working fluid storage tank and the ORC generator set, ensuring that the working fluid inlet, the front pipeline of the working fluid charging system, the first filter, the first shut-off valve, the rear pipeline of the working fluid charging system and the exhaust outlet are connected correctly in sequence, and the third automatic valve is set on the front pipeline of the working fluid charging system and the fourth automatic valve is set on the rear pipeline of the working fluid charging system.

[0101] Connect the vacuum system between the ORC generator set, its oil tank, and the exhaust main line. Connect the ORC generator set vacuum exhaust line, the ORC generator set oil tank exhaust line, and the exhaust main line in sequence, and install the seventh automatic valve on the exhaust main line.

[0102] The lubricating oil filling system is connected between the oil tank and the ORC generator set oil tank. It is sequentially connected to the lubricating oil inlet, the lubricating oil filling system front pipeline, the second filter, the second shut-off valve, the lubricating oil filling system rear pipeline, and the ORC generator set oil tank. The fifth automatic valve is located on the lubricating oil filling system front pipeline, and the sixth automatic valve is located on the lubricating oil filling system rear pipeline.

[0103] 2. Vacuuming and negative pressure testing phase

[0104] Start the vacuum system

[0105] Open the seventh automatic valve 17, start the vacuum system 36, and connect the ORC generator set vacuum exhaust line 28 and the ORC generator set oil tank exhaust line 29 to the exhaust main line 30 in sequence, and start the vacuum operation of the ORC generator set 26 and its oil tank.

[0106] Monitor pressure changes

[0107] The pressure changes during the vacuuming process are monitored in real time by the first remote pressure gauge 6 installed on the exhaust main line 30. At the same time, the intelligent monitoring unit collects the data of the first remote pressure gauge 6 and displays the pressure curve on the touch screen so that the operator can intuitively understand the vacuuming progress.

[0108] negative pressure test

[0109] Once the vacuum reaches the set negative pressure value, close the seventh automatic valve 17 to stop the vacuuming operation and observe the pressure change over a certain period of time. If the pressure rises within the allowable range, it indicates that the ORC generator set has no leakage; if the pressure rises too quickly, there may be a leak, and further investigation and handling are required.

[0110] 3. Working propellant charging stage

[0111] Start the working fluid filling system

[0112] Open the third automatic valve 13 and the fourth automatic valve 14 to allow the working medium to be charged into the ORC generator set 26 from the working medium inlet 38 through the working medium charging system front pipeline 31, the first filter 18, the first shut-off valve 20, the working medium charging system rear pipeline 32 and the exhaust outlet 39.

[0113] Real-time observation and monitoring

[0114] The gas-liquid mixing state during the working fluid charging process is observed in real time through the first sight glass 19 and the second sight glass 21 to ensure uniform and stable charging. At the same time, the intelligent monitoring unit collects parameters such as pressure and flow rate in the working fluid charging system in real time, automatically judges whether the charging process is normal, and immediately issues an alarm and takes corresponding measures such as suspending charging and adjusting valve opening if abnormalities are found, such as excessively high pressure or excessively low flow rate.

[0115] 4. Lubricating oil filling stage

[0116] Start the lubricating oil charging system

[0117] Open the fifth automatic valve 15 and the sixth automatic valve 16 to allow lubricating oil to flow from the lubricating oil inlet 40 through the lubricating oil charging system front pipeline 33, the second filter 22, the second shut-off valve 24, and the lubricating oil charging system rear pipeline 34 into the ORC generator set oil tank 27.

[0118] Observation and monitoring

[0119] The gas-liquid mixing state during the lubricating oil filling process is observed in real time using the third sight glass 23 and the fourth sight glass 25 to ensure smooth lubricating oil filling. The intelligent monitoring unit also monitors the pressure, flow rate and other parameters of the lubricating oil filling system in real time and compares them with the set values. If the values ​​exceed the allowable range, an alarm is issued in time and corresponding adjustments are made to ensure the accuracy and reliability of the lubricating oil filling volume.

[0120] 5. Debugging Completion and Data Recording Phase

[0121] Shut down the system

[0122] After completing the charging of the working fluid and lubricating oil, close all automatic valves, including the third, fourth, fifth, and sixth automatic valves, and stop the operation of each system to ensure that the entire commissioning equipment is in a safe state.

[0123] Data Recording and Analysis

[0124] The intelligent monitoring unit stores various data points throughout the commissioning process, such as pressure, flow rate, and time, and generates a commissioning report. Operators can view and analyze this data via a touchscreen to evaluate the commissioning results, summarize lessons learned, and provide a basis for subsequent equipment maintenance and optimization.

[0125] Example: Application of ORC generator set commissioning equipment in small ORC power plants

[0126] Scene Description

[0127] In a small ORC power plant, the newly installed ORC generator set needs to be commissioned. This generator set is designed to convert industrial waste heat into electricity and has high energy efficiency and stability requirements. The commissioning process requires completing key steps such as vacuuming, negative pressure testing, working fluid charging, and lubricating oil charging.

[0128] Equipment Configuration

[0129] According to the description in the patent document, the dedicated debugging equipment includes the following core systems:

[0130] Working fluid filling system 35

[0131] Vacuum system 36

[0132] Lubricating oil filling system 37

[0133] Intelligent monitoring unit

[0134] The various systems are connected through pipelines and automatic valves to form an integrated commissioning platform.

[0135] Debugging process

[0136] Vacuum and negative pressure test

[0137] Operating steps:

[0138] Open the seventh automatic valve 17 and start the vacuum system 36.

[0139] The air in the ORC generator set 26 and its fuel tank is extracted through the ORC generator set vacuum exhaust line 28 and the ORC generator set fuel tank exhaust line 29.

[0140] Pressure changes during the exhaust process are monitored in real time by the first remote pressure gauge 6, and the data is transmitted to the intelligent monitoring unit.

[0141] effect:

[0142] Remove air and impurities from inside the unit to ensure the purity of the working fluid and lubricating oil used in subsequent charging.

[0143] The intelligent monitoring unit automatically determines whether there is a leak in the unit based on pressure changes, ensuring the equipment's sealing performance.

[0144] working fluid charging

[0145] Operating steps:

[0146] Open the third automatic valve 13 and the fourth automatic valve 14 to start the working fluid charging system 35.

[0147] The working medium enters from the working medium inlet 38, passes through the working medium charging system front pipeline 31, the first filter 18, the first shut-off valve 20, and the working medium charging system rear pipeline 32 in sequence, and finally enters the ORC generator set 26 through the exhaust outlet 39.

[0148] The first sight glass 19 and the second sight glass 21 display the gas-liquid mixing state of the working fluid in real time, ensuring the stability of the filling process.

[0149] effect:

[0150] The ORC generator set is charged with pure working fluid to ensure the high efficiency and stability of the equipment operation.

[0151] The intelligent monitoring unit monitors pressure and flow in real time to avoid the risks of overpressure and cavitation, ensuring the safety and accuracy of the filling process.

[0152] Lubricating oil filling

[0153] Operating steps:

[0154] Open the fifth automatic valve 15 and the sixth automatic valve 16 to start the lubricating oil charging system 37.

[0155] Lubricating oil enters from lubricating oil inlet 40, passes sequentially through the lubricating oil filling system front pipeline 33, the second filter 22, the second shut-off valve 24, and the lubricating oil filling system rear pipeline 34, and finally fills the ORC generator set oil tank 27.

[0156] The third sight glass 23 and the fourth sight glass 25 display the gas-liquid mixing state of the lubricating oil in real time, ensuring the stability of the filling process.

[0157] effect:

[0158] Fill the ORC generator set's oil tank with pure lubricating oil to ensure effective lubrication and cooling during equipment operation.

[0159] The intelligent monitoring unit monitors pressure and flow in real time to avoid the risks of overpressure and underfilling, ensuring the safety and accuracy of the filling process.

[0160] Intelligent monitoring and data logging

[0161] Operating steps:

[0162] The intelligent monitoring unit collects and displays the operating parameters of each system in real time, including pressure, flow rate, and temperature, through a PLC controller, touch screen, and data storage module.

[0163] During the commissioning process, if any abnormalities are detected, such as abnormally high pressure or insufficient flow, the intelligent monitoring unit will immediately issue an alarm and record the relevant data.

[0164] After debugging is completed, the intelligent monitoring unit automatically generates a debugging report, including the recording and analysis results of various parameters.

[0165] effect:

[0166] This enables comprehensive monitoring and automated management of the debugging process, improving debugging efficiency and quality.

[0167] Data logging and analysis capabilities help with subsequent equipment maintenance and troubleshooting, reducing operating costs.

[0168] Implementation effect

[0169] By using the ORC generator set commissioning equipment of this invention, the commissioning process of this small ORC power station is significantly shortened, and the commissioning efficiency is improved by approximately 40%. The integrated design of the equipment makes operation simpler and reduces human error. The real-time monitoring and data recording functions of the intelligent monitoring unit ensure the accuracy and traceability of the commissioning process, effectively improving the operational stability and energy efficiency of the equipment.

[0170] By adopting the above-disclosed technical solution of this utility model, the following beneficial effects are obtained:

[0171] The various structures in this invention cooperate and work together to form a complete set of special equipment for ORC generator set commissioning. This enables efficient, accurate and intelligent control of the ORC generator set commissioning process, improves commissioning quality and equipment operation reliability, and reduces energy consumption and manual operation intensity.

[0172] The above are merely preferred embodiments of this utility model. It should be noted that, for those skilled in the art, several improvements and modifications can be made without departing from the principle of this utility model, and these improvements and modifications should also be considered within the protection scope of this utility model.

Claims

1. A special equipment for commissioning ORC generator sets, characterized in that: It includes a working fluid charging system (35), a vacuum system (36), a lubricating oil charging system (37), and an intelligent monitoring unit; the vacuum system (36) is used to perform vacuum and negative pressure tests on the ORC generator set (26); the working fluid charging system (35) is used to charge the ORC generator set (26) with working fluid; the lubricating oil charging system (37) is used to charge the ORC generator set (26) with lubricating oil; the working fluid charging system (35), the vacuum system (36), and the lubricating oil charging system (37) are all centered around the ORC generator set (26). The generator set setup together constitutes the core part of the commissioning equipment for the ORC generator set (26); the working fluid charging system (35) is connected between the working fluid storage tank and the ORC generator set, the vacuum system (36) is connected between the ORC generator set and its oil tank and the exhaust main line, and the lubricating oil charging system (37) is connected between the oil tank and the oil tank of the ORC generator set; the intelligent monitoring unit is connected to the vacuum system (36), the working fluid charging system (35), and the lubricating oil charging system (37) and is used to monitor and control the operation of each system.

2. The ORC generator set commissioning equipment according to claim 1, characterized in that, The vacuum system (36) includes an ORC generator set vacuum exhaust pipeline (28), an ORC generator set oil tank exhaust pipeline (29), an exhaust main line (30) connected in sequence, and a seventh automatic valve (17) installed on the exhaust main line (30); the working fluid charging system (35) includes a working fluid inlet (38), a working fluid charging system front pipeline (31), a first filter (18), a first shut-off valve (20), a working fluid charging system rear pipeline (32), and an exhaust outlet (39) connected in sequence, and a third automatic valve (13) installed on the working fluid charging system. On the system front pipeline (31), the fourth automatic valve (14) is installed on the working fluid charging system rear pipeline (32); the lubricating oil charging system (37) includes a lubricating oil inlet (40), a lubricating oil charging system front pipeline (33), a second filter (22), a second shut-off valve (24), a lubricating oil charging system rear pipeline (34) and an ORC generator set oil tank (27) connected in sequence; the fifth automatic valve (15) is installed on the lubricating oil charging system front pipeline (33) and the sixth automatic valve (16) is installed on the lubricating oil charging system rear pipeline (34).

3. The ORC unit commissioning equipment according to claim 2, characterized in that: It also includes a pressure gauge hand valve and a remote pressure gauge, wherein the pressure gauge hand valve is connected to the corresponding remote pressure gauge and is used to control the on / off state of the remote pressure gauge.

4. The ORC generator set commissioning equipment according to claim 3, characterized in that: The first filter (18) and the second filter (22) are dual filters, which are respectively installed on the corresponding pipelines of the working fluid filling system (35) and the lubricating oil filling system (37) to filter impurities in the working fluid and lubricating oil.

5. The ORC generator set commissioning equipment according to claim 4, characterized in that: The intelligent monitoring unit integrates a PLC controller, a touch screen, and a data storage module. It is linked with various sensors via a bus to realize real-time acquisition of process parameters, abnormal alarms, and automatic control of the process flow. The intelligent monitoring unit is electrically connected to the remote pressure gauge, sight glass, and automatic valve in the vacuum system (36), working fluid filling system (35), and lubricating oil filling system (37).

6. The ORC generator set commissioning equipment according to claim 5, characterized in that: The vacuum system (36) also includes a first remote pressure gauge (6), which is installed on the exhaust line (30) to monitor pressure changes during the vacuuming process.

7. The ORC generator set commissioning equipment according to claim 6, characterized in that: The working fluid filling system (35) also includes a sight glass. The first sight glass (19) is installed on the pipeline between the first filter (18) and the first shut-off valve (20), and the second sight glass (21) is installed on the pipeline between the first shut-off valve (20) and the exhaust outlet (39) for real-time observation of the gas-liquid mixing state during the working fluid filling process.

8. The ORC generator set commissioning equipment according to claim 7, characterized in that: The lubricating oil filling system (37) also includes a third sight glass (23) and a fourth sight glass (25). The third sight glass (23) is installed on the pipeline between the second filter (22) and the second shut-off valve (24), and the fourth sight glass (25) is installed on the pipeline between the second shut-off valve (24) and the ORC generator set oil tank (27) for real-time observation of the gas-liquid mixing state during the lubricating oil filling process.

9. The special equipment for commissioning ORC generator sets according to claim 8, characterized in that: The third automatic valve (13), the fourth automatic valve (14), the fifth automatic valve (15), the sixth automatic valve (16), and the seventh automatic valve (17) are all solenoid valves, which are respectively installed on the corresponding pipelines of the working fluid filling system (35), the lubricating oil filling system (37), and the vacuum system (36) to control the opening and closing of the pipelines.

10. The special equipment for commissioning ORC generator sets according to claim 1, characterized in that: The first shut-off valve (20), the second shut-off valve (24), and the ball valve are respectively installed on the corresponding pipelines of the working fluid charging system (35) and the lubricating oil charging system (37) to control the charging flow of the working fluid and the lubricating oil.

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