Stepless regulated vertical nitrogen compressor

Abstract

The utility model discloses a vertical nitrogen compressor of stepless regulation, this compressor adopts vertical two column two stage structure, including fuselage, movement mechanism, compression system, auxiliary system and stepless air volume regulating system, fuselage adopts integral casting structure, and the inside integrated main bearing seat is to, and movement mechanism drives connecting rod and crosshead linkage piston rod through crank, and compression system is composed of independent casting first stage cylinder and second stage cylinder, and is equipped with stainless steel cylinder sleeve and water cooling structure, and auxiliary system contains seal ware, buffer set and cooler set. The system is compatible with DCS / PLC digitization control, and completes air volume regulation in three piston reciprocating periods, and significantly improves energy efficiency ratio and operation flexibility.

Description

Technical Field

[0001] This utility model relates to the field of compressor technology, specifically a steplessly adjustable vertical nitrogen compressor. Background Technology

[0002] Reciprocating compressors are a common type of chemical machinery widely used in industries such as petroleum and chemicals. They rely on the reciprocating motion of a piston inside a cylinder to compress the gas within the cylinder. With the assistance of valves, they achieve the intake, compression, and discharge of gas, thereby increasing the gas pressure and meeting the requirements of process production.

[0003] Currently, as reciprocating piston compressors are used more and more, the requirements for their use are also becoming more stringent. For the special requirements of some newly built equipment, the newly added reciprocating piston compressors need to be adjusted and flexibly controlled in terms of air volume.

[0004] Therefore, in view of the above problems, this technical solution designs a stepless adjustable vertical nitrogen compressor. Utility Model Content

[0005] The purpose of this invention is to provide a steplessly adjustable vertical nitrogen compressor to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, this utility model provides the following technical solution:

[0007] A stepless adjustable vertical nitrogen compressor includes a body, a moving mechanism, a compression system, an auxiliary system, and a stepless gas volume adjustment system; the body adopts an integral casting structure of the intermediate body and crankcase; the compression system includes independently cast vertical primary cylinder and secondary cylinder; the stepless gas volume adjustment system achieves stepless gas volume adjustment by delaying the closing of the intake valve.

[0008] As a further aspect of this utility model: the stepless air volume regulation system includes:

[0009] The actuator is connected to the hydraulic oil station and drives the intake valve through the hydraulic pipeline;

[0010] Top dead center sensor to detect piston position in real time;

[0011] The intermediate interface unit connects to the actuator via an RS485 bus, receives sensor signals, and calculates the valve's actuation timing.

[0012] The Modbus interface connects to an external DCS / PLC controller to achieve closed-loop control.

[0013] As a further embodiment of this utility model: the crankshaft of the motion mechanism is provided with an oil supply hole, and the lubrication path is sequentially connected to the main bearing, the connecting rod big end bearing, and the connecting rod small end bearing.

[0014] As a further embodiment of this utility model: the inner wall of the cylinder is lined with a 30Cr13 stainless steel cylinder liner.

[0015] As a further aspect of this utility model: the auxiliary system includes:

[0016] Sealers, slow-cooling components, and safety components;

[0017] The seal includes a primary seal and a secondary seal. The primary seal is a combination of a pressure-reducing ring, four main sealing rings, and a leakage sealing ring.

[0018] The secondary seal adopts a combination of one pressure-reducing ring, five main sealing rings, and one leakage sealing ring.

[0019] The slow-cooling component includes a damper and a cooler; the damper includes a first-stage intake damper, a first-stage exhaust damper, a second-stage intake damper, and a second-stage exhaust damper;

[0020] The cooler includes a primary cooler and a secondary cooler;

[0021] Safety components include gas lines;

[0022] Safety valves: installed in each stage of the exhaust pipe;

[0023] Cooling control components include a manual shut-off valve located on the main drain pipe, the opening of which is adjusted to control the drain temperature to ≤40℃.

[0024] As a further embodiment of this utility model: the coolers are all stuffed box type, high-efficiency finned tube coolers, and the shell is made of carbon steel; the gas pipeline is made of carbon steel and the inlet is equipped with an air filter.

[0025] As a further improvement of this utility model: the stepless air volume regulation system completes the air volume regulation within three reciprocating cycles of the piston, and supports parameter setting and monitoring by service software under the Windows environment.

[0026] Compared with the prior art, the beneficial effects of this utility model are: by delaying the closing of the intake valve to achieve zero-power gas recirculation, the energy consumption of part load is greatly reduced, and stepless adjustment and energy saving are achieved.

[0027] The stepless gas volume regulation system 14, combined with the top dead center sensor and Modbus interface, realizes precise digital regulation of gas volume.

[0028] The vertical design reduces the footprint, the integral casting of the fuselage enhances rigidity, and the oil supply holes inside the crankshaft optimize the lubrication path.

[0029] The gas station is equipped with a dual-gear oil pump (one in use and one on standby), and the cooling system is precisely temperature-controlled via a manual shut-off valve. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of a vertical nitrogen compressor with stepless regulation.

[0031] Figure 2 This is a schematic diagram of the process for a vertical nitrogen compressor with stepless regulation.

[0032] Figure 3 This is a logic diagram of a vertical nitrogen compressor with stepless regulation.

[0033] Figure 4 This is a flowchart of the stepless gas volume regulation process in a vertical nitrogen compressor with stepless regulation.

[0034] Figure 5 This is a reference diagram of the control logic for the stepless gas volume regulation system in a vertical nitrogen compressor with stepless regulation.

[0035] The components include: body 1, cylinder 5, first-stage cylinder 50, second-stage cylinder 51, oil station 11, air intake filter 12, electric motor 13, stepless air volume regulation system 14, and manual shut-off valve 23.

[0036] Primary cooler 90, secondary cooler 91;

[0037] First-stage intake damper 100, first-stage exhaust damper 101, second-stage intake damper 102, second-stage exhaust damper 103. Detailed Implementation

[0038] It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0039] In the description of this utility model, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this utility model, unless otherwise stated, "a plurality of" means two or more.

[0040] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0041] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0042] Please see Figure 1 A stepless adjustable vertical nitrogen compressor includes a body 1, a running mechanism, a compression system, an auxiliary system, and a stepless gas volume adjustment system 14;

[0043] The engine body 1 adopts an integral structure that combines the intermediate body and the crankcase. The main bearing housing is installed inside. One end of the crankshaft is connected to the motor 13 by a rigid coupling, and the other end is supported on two main bearings.

[0044] The motion mechanism includes a connecting rod, a cross, and a piston rod; the connecting rod includes a large end bearing and a small end bearing, and the crosshead is connected to the small end bearing of the connecting rod through a crosshead pin. At the same time, the crosshead and the piston rod are rigidly locked together by a hydraulic tightening mechanism.

[0045] The crankshaft is made of ductile iron, with two rows of cranks at 180 degrees to each other. The crankshaft has oil supply holes drilled inside, which connect the main bearing → connecting rod big end bearing → connecting rod small end bearing.

[0046] The connecting rod is forged from medium carbon steel. The upper small end bearing and the lower large end bearing are both made of aluminum-magnesium alloy bushings. The crosshead is cast as a whole from cast steel, and the friction surface is cast with Babbitt alloy.

[0047] The compression system includes cylinder 5 and piston assembly; cylinder 5 adopts a vertical two-row, two-stage structure, including a first-stage cylinder 50 and a second-stage cylinder 51, both of which are independently cast.

[0048] The piston assembly includes a piston body, piston rod, piston rings, guide rings, and an oil scraper; the piston bodies of the first-stage cylinder 50 and the second-stage cylinder 51 are made of cast aluminum and 30Cr13, respectively; at the same time, both the guide rings and piston rings are made of materials with high wear resistance.

[0049] The oil scraper structures of the two piston rods are identical, consisting of an oil scraper body, an oil scraper ring, and an oil baffle ring. The oil scraper ring is made of phosphor bronze, while the oil baffle ring is made of polytetrafluoroethylene. The function of the oil scraper is to prevent the accumulated oil mist from being introduced into the seal as the piston rod moves.

[0050] The auxiliary system includes seals, slow-cooling components, and safety components;

[0051] The seal includes a primary seal and a secondary seal. The primary seal is a combination of a pressure-reducing ring, four main sealing rings, and a leakage sealing ring.

[0052] The secondary seal adopts a combination of one pressure-reducing ring, five main sealing rings, and one leakage sealing ring.

[0053] The sealing ring is made of wear-resistant material.

[0054] The slow cooling component includes a damper and a cooler; the damper includes a primary intake damper 100, a primary exhaust damper 101, a secondary intake damper 102, and a secondary exhaust damper 103.

[0055] The cooler includes a primary cooler 90 and a secondary cooler 91, both of which are stuffed-gland type, high-efficiency finned tube coolers with shells made of carbon steel.

[0056] The cylinder 5 is lined with 30Cr13 stainless steel cylinder liners and is cooled by water, with the water circuit connected in parallel with the primary cooler 90 and the secondary cooler 91.

[0057] The safety components include a gas pipeline 21 made of carbon steel, with an intake filter 12 at the inlet to prevent mechanical impurities from entering the cylinder 5;

[0058] Safety valve 22: installed in each stage of the exhaust pipe;

[0059] The cooling control unit includes a manual shut-off valve 23 located on the main drain pipe, the opening of which is adjusted to control the drain temperature to ≤40℃.

[0060] 14 includes an actuator, an intermediate interface unit, a top dead center sensor, a hydraulic power unit, and a Modbus interface; the actuator is connected to the hydraulic power unit via hydraulic lines and is used to control the opening and closing of the intake valve.

[0061] The intermediate interface unit is connected to the actuator via an RS485 bus and serves as a signal conversion hub.

[0062] The top dead center sensor is input to the intermediate interface unit via a signal to detect the piston position in real time;

[0063] The hydraulic power station is equipped with an independent oil supply line to provide hydraulic power;

[0064] The Modbus interface connects to an external controller and is compatible with DCS / PLC control systems.

[0065] Air volume regulation mechanism: When it is necessary to reduce the exhaust volume, the actuator delays closing the intake valve. At the beginning of the compression stroke, some gas returns to the intake chamber to achieve zero-power recirculation.

[0066] Control closed-loop process: The top dead center sensor detects the piston position, the intermediate interface unit calculates the valve closing timing, and the bus connects to the actuator for signal conversion.

[0067] The top dead center sensor sends commands to the actuator, which is then driven by hydraulic oil. The intake valve is delayed in closing to regulate the air volume, and the DCS monitors the pressure data for feedback and adjustment.

[0068] In one example of the present invention, such as Figures 4-5 As shown, the function of the stepless air volume regulation system 14 is as follows:

[0069] (1) All intake valves are equipped with actuators. When performing actual control tasks, i.e. under partial load, the closing of the intake valves is delayed. The hydraulic power unit supplies the power required by the actuators through hydraulic lines.

[0070] (2) The signal transmission between the actuator and the intermediate interface unit is realized through the RS485 bus. The intermediate interface unit provides control signals to the actuator and serves as the link between the DCS / PLC and the stepless air volume regulation system, thereby completing the closed-loop control.

[0071] (3) The signals between the DCS / PLC or other loop controller and the stepless gas volume regulation system are analog and binary switching signals.

[0072] (4) While the top dead center sensor measures the compressor speed, it also provides the real-time position of the piston in cylinder 5 to the intermediate interface unit. The actuator uses this information to control the opening and closing time of the intake valve. This simplifies the regulation of the compressor's air volume to simply inputting the required parameter values ​​in the control room.

[0073] The stepless air volume regulation system 14, which uses digital control technology, can change the air volume output of the compressor within three reciprocating cycles of the piston.

[0074] The aforementioned system uses service software within a Windows environment for system configuration. This service software also serves as a comprehensive tool for data display and continuously variable air volume regulation system services.

[0075] In this embodiment of the invention, the lubrication of the motion mechanism is forced by an oil station 11 installed at one end of the motion mechanism. The station is equipped with two oil pumps. During operation, one gear oil pump is working and the other auxiliary oil pump is used as a backup oil pump. The lubricating oil is drawn in from the crankcase through the intake filter 12 by the gear oil pump. After being cooled by the oil cooler, the pressurized oil is divided into two paths. One path enters the crankshaft to lubricate the main bearing and the connecting rod big end bearing, and also enters the connecting rod small end bushing. The other path goes to lubricate the crosshead guide rail, and can also enter the connecting rod small end bushing.

[0076] The working principle of this utility model is as follows: In the idle position of this device, all the aforementioned driving components (representing power elements, electrical devices, and compatible power supplies) are connected via wires. The electrical connections are completed in sequence between the working components. The detailed connection methods are well-known in the field. The following mainly describes the working principle and process, without further explanation of the electrical control.

[0077] like Figure 2 Process and Figure 3 As shown in the logic, the normal startup operation of this machine is as follows:

[0078] (1) Turn the crankshaft a few times to check if there are any obstacles in the operation of the machine.

[0079] (2) Open the cooling water valve and adjust the flow rate of each water circuit.

[0080] (3) Start the auxiliary oil pump motor and pre-fill each lubrication point with oil. If the oil temperature is below 5℃, heat the lubricating oil by turning on the electric heater. When the oil temperature is above 20℃, the electric heater will automatically disconnect.

[0081] (4) Open the reflux valve V906 and the vent valve V905.

[0082] (5) Start the motor 13. After the motor starts, the suction valve V901 and the discharge valve V904 will open automatically 20 seconds after starting. After 50 seconds after starting, the gas inside the compressor and the pipeline will be discharged. The vent valve V905 will close automatically. Check whether the stepless gas volume regulation system 14 is operating normally.

[0083] If the stepless air volume regulation system is operating normally, the return valve V906 will be automatically closed. At the same time, the stepless air volume regulation system will be manually adjusted. When the first-stage inlet pressure PICAS911 ≥ 0.7MPa, the stepless air volume regulation system 14 will switch to automatic adjustment.

[0084] If the stepless gas volume regulation system malfunctions, the return valve V906 will adjust as needed. Once the terminal exhaust pressure reaches the rated value or the pressure required by the pipeline network, the compressor will enter normal operation. After the motor 13 starts, its space heater will automatically shut off immediately, and the auxiliary oil pump will automatically shut off 60 seconds after startup.

[0085] One important point to note is the operating procedure when the machine is running normally:

[0086] (1) The main parameters of the compressor during normal operation are as follows: Figure 5 As shown in the logic.

[0087] (2) Record the actual readings of the instruments in operation every hour.

[0088] (3) If the instrument panel issues an alarm signal, the cause must be investigated immediately and the problem adjusted in a timely manner.

[0089] (4) Normal shutdown of the compressor Figure 5 When the normal stop button HS911 is pressed as shown in the logic, the first-stage intake pressure PICAS911 interlock stop is automatically released, the vent valve V905 slowly and automatically opens, the intake valve V901 automatically closes, the return valve V906 automatically adjusts the intake pressure, and the stepless air volume regulation system 14 automatically opens fully (0% load).

[0090] The motor stops when the final exhaust pressure PICAS901 ≤ 50 kPa. After the motor stops, the discharge valve V904 and the vent valve V905 automatically close, the auxiliary oil pump starts, and the first-stage intake pressure PICAS911 automatically resumes operation after the stop. After 1 minute, the return valve V906 automatically closes, and after 5 minutes, the auxiliary oil pump automatically shuts off. Finally, the main inlet and outlet valves are closed to drain all the cooling water from the cylinder block and cooler.

[0091] (5) When the compressor is shut down by emergency interlock, the motor stops first, the auxiliary oil pump starts automatically, the vent valve V905 opens automatically, the suction valve V901 and the discharge valve V904 close automatically, the return valve V906 continues to adjust the pressure as needed, and the stepless gas volume regulating system 14 opens fully automatically (0% load). When the terminal exhaust pressure PICAS901 < 50 kPa, the vent valve V905 closes automatically. The auxiliary oil pump shuts down automatically after 5 minutes.

[0092] (6) If the compressor is to be shut down for several weeks or more, to prevent internal rusting, close all valves after normal shutdown. Close the main inlet and outlet valves for cooling water and drain all accumulated water from the unit. During the shutdown period, start the auxiliary oil pump once a week for 30 minutes, while simultaneously rotating the flywheel several times.

[0093] It should be understood that in this application, all rotating, sliding, meshing, belt-driven and other moving parts are well lubricated and not prone to slippage or wear, and each part is provided with a corresponding protective shell. However, in the accompanying drawings of this application, the connection state of each moving part is not shown. It should also be understood that all parts in this application are made of metal or plastic materials with suitable strength in the relevant field to ensure that their structural rigidity meets the actual requirements.

[0094] The preferred embodiments of the present invention have been described in detail above. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.

Claims

1. A vertical nitrogen compressor with stepless adjustment, characterized in that, It includes a body (1), a motion mechanism, a compression system, an auxiliary system and a stepless air volume regulation system (14); the body (1) adopts an integral casting structure of intermediate body and crankcase; the compression system includes independently cast vertical first-stage cylinder (50) and second-stage cylinder (51); the stepless air volume regulation system (14) realizes stepless air volume regulation by delaying the closing of the intake valve.

2. The steplessly adjustable vertical nitrogen compressor according to claim 1, characterized in that, The continuously variable air volume regulation system (14) includes: The actuator is connected to the hydraulic oil station and drives the intake valve through the hydraulic pipeline; Top dead center sensor to detect piston position in real time; The intermediate interface unit connects to the actuator via an RS485 bus, receives sensor signals, and calculates the valve's actuation timing. The Modbus interface connects to an external DCS / PLC controller to achieve closed-loop control.

3. The steplessly adjustable vertical nitrogen compressor according to claim 1, characterized in that, The crankshaft of the motion mechanism is provided with an oil supply hole, and the lubrication path connects the main bearing, the connecting rod big end bearing, and the connecting rod small end bearing in sequence.

4. The steplessly adjustable vertical nitrogen compressor according to claim 1, characterized in that, The inner wall of the cylinder (5) is lined with a 30Cr13 stainless steel cylinder liner.

5. The steplessly adjustable vertical nitrogen compressor according to claim 1, characterized in that, The auxiliary system includes: Sealers, slow-cooling components, and safety components; The seal includes a primary seal and a secondary seal. The primary seal is a combination of a pressure-reducing ring, four main sealing rings, and a leakage sealing ring. The secondary seal adopts a combination of one pressure-reducing ring, five main sealing rings, and one leakage sealing ring. The slow cooling component includes a damper and a cooler; the damper includes a first-stage intake damper (100), a first-stage exhaust damper (101), a second-stage intake damper (102), and a second-stage exhaust damper (103). The cooler includes a primary cooler (90) and a secondary cooler (91). The safety components include a gas line (21); Safety valve (22): installed in each stage of the exhaust pipe; The cooling control includes a manual shut-off valve (23) located on the main drain pipe, the opening of which is adjusted to control the drain temperature to ≤40°C.

6. The steplessly adjustable vertical nitrogen compressor according to claim 5, characterized in that, All coolers are stuffed box type, high-efficiency finned tube coolers, and the shell is made of carbon steel. The gas pipeline (21) is made of carbon steel and has an inlet filter (12).

7. The steplessly adjustable vertical nitrogen compressor according to any one of claims 1-6, characterized in that, The continuously variable air volume regulation system (14) completes the air volume regulation within three reciprocating cycles of the piston.

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