Modular compressor performance test device

Abstract

The utility model relates to a kind of modularization compressor performance testing device, including compressor unit, low-pressure intake module and high-pressure cylinder group module, and vent module, pressure reducing valve group module and cooling water system;The water inlet of compressor unit is connected with the water outlet of cooling water system, and its water outlet is connected with the backwater of cooling system;Compressor unit connecting pipeline includes pipeline A, pipeline B and pipeline C;High-pressure cylinder group module is connected to compressor unit after connecting pressure reducing valve group module in pipeline A, pipeline B is connected to vent module by the exhaust port of compressor unit, and low-pressure intake module is directly connected to compressor unit in pipeline C;Vent module 1 way is connected to compressor unit vent line, 2 way and 3 way are connected to the exhaust port of compressor unit, and 4 way is used to avoid the danger caused by high-pressure venting.The utility model reaches the beneficial effect is: meeting the performance test requirement of various working conditions and various model compressors, while operability is strong, reduce experimental cost.

Description

Technical Field

[0001] This utility model relates to the technical field of compressor performance testing devices, and in particular to a modular compressor performance testing device. Background Technology

[0002] Before leaving the factory, the manufacturer generally conducts no-load and air (or nitrogen) load mechanical operation performance tests on process compressors. The purpose of performance acceptance is to verify whether all performance characteristics of the compressor equipment meet the requirements of the technical specifications.

[0003] Even with mature technology, compressor equipment can experience assembly errors during final assembly due to variations in parts or human negligence. If factory operational testing is not performed, or if only no-load atmospheric pressure testing is conducted without load pressure testing, these assembly errors will go undetected. Discovering these errors during equipment use can lead to serious accidents.

[0004] Especially for process compressors, which are custom-made products, the characteristics of process compressors are highly customized. Almost no two process compressors are exactly the same. Their design depends entirely on the specific application conditions. They are diverse in type, complex in form, and cover a wide range of media compositions. It is impossible to use a simple and fixed standard testing device to test all products. Current compressor testing equipment often can only perform some performance tests on a certain type of compressor. Moreover, the adjustment of commonly used testing equipment is very complicated, and the testing efficiency and accuracy are low. This is mainly because there are many types of compressors (such as D-type, M-type, Z-type, V-type, etc., and vertical and horizontal layouts). At the same time, the inlet and outlet pressures and temperatures of each compressor are different, the inlet and outlet pressure ratios are large, and the applicable pressure regulating valves are different. In addition, the media of various compressors are also different. Some gases are highly flammable and explosive, which can easily cause safety accidents. Utility Model Content

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide a modular compressor performance testing device that can meet the factory performance test requirements of various working conditions and various models of compressors, achieve the purpose of one-time investment and repeated use, enhance the operability of test personnel, and reduce the test cost.

[0006] The purpose of this utility model is achieved through the following technical solution: a modular compressor performance testing device, including a compressor unit, a basic platform, a low-pressure intake module and a high-pressure gas cylinder group module, as well as a venting module, a pressure reducing valve group module and a cooling water system; The compressor unit is mounted on a foundation platform, with its inlet connected to the outlet of the cooling water system and its outlet connected to the return outlet of the cooling system. The compressor unit's connecting pipelines include pipeline A, pipeline B, and pipeline C. In pipeline A, the high-pressure gas cylinder module is connected to the pressure reducing valve module and then to the compressor unit. In pipeline B, the compressor unit's exhaust port is connected to the venting module, while in pipeline C, the low-pressure intake module is directly connected to the compressor unit. The venting module includes four vent ports: one connects to the compressor unit's venting pipeline, two and three connect to the compressor unit's exhaust port, and the fourth is used to prevent the danger caused by high-pressure venting.

[0007] As a preferred technical solution of this application, the high-pressure gas cylinder group module is composed of a high-pressure gas cylinder group, which is equipped with a pressure sensor. The high-pressure gas cylinder group module is set up to alleviate the pressure fluctuation of the device's exhaust system, and when the low-pressure intake module is closed, the gas from the high-pressure gas cylinder group is depressurized and enters the compressor intake port, forming a closed loop of the performance testing system.

[0008] As a preferred technical solution of this application, the low-pressure air intake module includes a screw air compressor, a separator, a dryer, a nitrogen generator, an air storage tank, and a nitrogen storage tank; the low-pressure air intake module can provide nitrogen in one path and clean air in another path, the air or nitrogen outlet of the low-pressure air intake module is connected to the air inlet of the compressor unit via a first flow meter, and the exhaust port of the compressor unit is connected to the corresponding inlet of the venting module via a second flow meter.

[0009] As a preferred technical solution of this application, the pressure reducing valve group module includes a set of gas pressure reducing orifice plates and two sets of pressure reducing valve groups; the pressure reducing orifice plates are set in the front section of the pressure reducing valves to reduce pressure and avoid corrosion of the valves; each set of pressure reducing valve groups is equipped with two paths, one with a pneumatic valve and the other with a pressure regulating valve; the two sets of pressure reducing valves can work simultaneously or independently according to the pressure regulation requirements of the actual working conditions.

[0010] As a preferred technical solution of this application, the cooling water system includes a cooling water tower, a water pump, a pressure gauge, and inlet and outlet valves; the inlet and outlet of the compressor unit are respectively connected to the hoses at the outlet and return outlet of the cooling water system, and pressure gauges and flow meters are installed on the pipeline for data collection and detection.

[0011] As a preferred technical solution of this application, the venting module includes a storage tank, a silencer, a valve, and a valve frame; each venting line in the device is connected to the valve frame; two of the venting lines in the venting module are emergency manual venting lines, three are emergency pneumatic venting valve venting lines, and four are used for overpressure venting on one hand, and for allowing high-pressure gas to be regulated and its pressure reduced to low pressure before venting on the other hand.

[0012] As a preferred technical solution of this application, it also includes a sewage discharge module; the sewage discharge module includes a sewage tank and a sewage valve frame, and the sewage generated in this device is connected to the sewage valve frame in the sewage discharge module.

[0013] As a preferred technical solution of this application, it also includes a protection module; the protection module includes an explosion-proof wall; an explosion-proof wall is set around the basic platform, and an electrostatic eliminator is installed at the edge of the wall, and an explosion-proof power control cabinet, a frequency converter cabinet and an industrial control computer are installed inside the explosion-proof wall.

[0014] This utility model has the following advantages: (1) This solution modularizes devices with different functions, which can meet the testing requirements of customized compressors under different working conditions (pressure, temperature, medium, air intake), and comprehensively cover the entire performance testing process; moreover, with this modular structure, during testing, only the module that matches the equipment being tested needs to be placed in the testing site and connected to the corresponding flange on the equipment, reducing the setup time and achieving the goal of increasing efficiency; after testing, it can also be better stored in inventory; each module realizes a specific sub-function, and all modules can be quickly assembled into a whole device according to a specific method, achieving the goal of rapid assembly; (2) This scheme also includes a safety protection module to effectively improve the safety of the test; and a sewage discharge module and an venting module to effectively recycle the pollution caused by the test process, thereby achieving the goal of civilized production; in addition, the modular test device can achieve the goal of one-time investment and repeated use, thereby reducing the test cost. The modular setting enhances operability and simplifies the steps of relearning for each test; the modular device is not limited by the site, the movable module can be quickly transported to the test site, and the device can be quickly assembled and connected. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the overall process of this utility model; Figure 2 This is a schematic diagram of the testing process for this utility model; Figure 3 This is a schematic diagram of the high-pressure gas cylinder assembly module of this utility model; Figure 4 This is a schematic diagram of the compressor under test according to this utility model; Figure 5 This is a schematic diagram of the low-pressure intake module of this utility model; Figure 6 This is a schematic diagram of the pressure reducing valve assembly module of this utility model; Figure 7 This is a schematic diagram of the cooling water system of this utility model; Figure 8 This is a schematic diagram of the venting module of this utility model; Detailed Implementation The present invention will be further described below with reference to the accompanying drawings, but the scope of protection of the present invention is not limited to the following description.

[0016] It should be noted that the orientation or positional relationship indicated by terms such as "left" and "right" is based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship that the product of this invention is usually placed in during use, or the orientation or positional relationship that is commonly understood by those skilled in the art. Such terms are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0017] It should be noted that, unless otherwise specified, the embodiments and features and technical solutions in the present invention can be combined with each other.

[0018] Therefore, based on the above issues, please refer to Figure 1 This utility model proposes a modular compressor performance testing device to solve the problem.

[0019] See Figures 1 to 8 The present implementation scheme proposes a modular compressor performance testing device, which includes a compressor unit to be tested and a basic platform for placing the compressor unit, a high-pressure gas cylinder module, a low-pressure air intake module and a venting module, a pressure reducing valve module and a cooling water system. Among them, see Figure 2 The basic platform is equipped with a compressor unit for testing. The air pipeline of the compressor unit is divided into pipeline A, pipeline B and pipeline C. In pipeline A, the high-pressure gas cylinder group module - pressure reducing (regulating) valve group module - compressor unit air inlet; in pipeline B, the compressor unit exhaust port - venting module; and in pipeline C, the low-pressure air inlet module is directly connected to the compressor unit. Among them, see Figure 1 and Figure 2 The inlet pipe of the compressor unit is connected to the outlet pipe of the cooling water system, while the return pipe of the cooling water system is connected to the outlet pipe of the compressor unit, thus forming a cooling water system circulation. Pressure gauges and flow meters are connected to the pipelines to facilitate the detection and data collection. Among them, participants Figure 1 and Figure 2 The venting module includes four venting ports. One port is connected to the compressor unit's venting pipeline, while the fourth port shares the same pipeline as the first port and is connected to a venting check valve and a pneumatic valve to prevent the danger caused by high-pressure venting. The second and third ports are connected to the compressor unit's exhaust port.

[0020] Current testing equipment is not very efficient because compressors are generally custom-made to meet different user needs, resulting in a wide variety of types, complex designs, and diverse media compositions. Current testing equipment often only allows for performance testing of a specific type of compressor, which is inconvenient in practical applications, requiring multiple adjustments. Furthermore, the media used in different compressors vary, with some gases being flammable and explosive, posing a safety hazard. Therefore, this solution designs a modular compressor performance testing device. The compressor unit under test is placed on a testing platform, and the various modules (high-pressure gas cylinder module, low-pressure intake module, venting module, pressure reducing valve module, cooling water system, etc.) are connected via piping to form a complete testing system. This system can meet the testing needs of more customized compressors with different media and pressure levels.

[0021] In this embodiment, the base platform includes T-shaped guide rails and drainage troughs. The platform can withstand a 50t force, ensuring the safe installation of heavy equipment and providing a stable, robust, and precise reference plane for the entire testing system. Secondary grouting on the T-shaped guide rails ensures extremely high installation accuracy. Drainage troughs are installed around the platform to effectively discharge wastewater, facilitating cleaning and handling accidental leaks, keeping the testing area clean and safe. Furthermore, a protective module is installed around the base platform to ensure the safety of personnel and equipment during testing. This module includes an explosion-proof wall; an explosion-proof wall is installed around the base platform, and an electrostatic eliminator is installed on the wall to prevent the risk of igniting flammable gases due to static electricity. An explosion-proof power control cabinet, frequency converter, and industrial computer are installed inside the explosion-proof wall, facilitating operation, ensuring safety, and meeting the power requirements of the testing process.

[0022] It should be noted that by isolating the main testing area from the operating area through the explosion-proof wall, the impact of an explosion can be effectively controlled in the event of an accident.

[0023] In this embodiment, see Figures 3-5 For the low-pressure air intake module and the high-pressure gas cylinder group module; the low-pressure air intake group module is a skid-mounted device consisting of a screw air compressor, separator, dryer, nitrogen generator, air storage tank, and nitrogen storage tank. The device can provide one nitrogen supply (nitrogen is often used for sealing, purging, or testing the performance of compressors in inert environments) and one clean air supply to meet different requirements for low-pressure air intake pressure, temperature, and medium. It is integrated on a single skid, making it compact and easy to move and install. The high-pressure gas cylinder group module is equipped with a pressure sensor with a display, providing a high-pressure gas source for simulating the high-pressure operating conditions of the compressor or conducting high-pressure sealing tests.

[0024] In this embodiment, see Figure 1 and Figure 2 Regarding the pipelines of this performance testing device, the system is divided into: a main air circuit system, a cooling water system, a sewage system, and a venting system. The main air circuit system is mainly used to provide the compressor under test with intake air of different pressures and media, and to process its exhaust gas. It typically consists of a high-pressure gas cylinder module, a low-pressure intake module, a pressure reducing valve module, and a venting module working together. Pipeline C is the low-pressure intake module (used to provide clean air or nitrogen) → first flow meter → compressor unit inlet. This path is the commonly used compressor test mode, simulating the normal working state of the compressor drawing air from the atmospheric environment or a specific air source. The first flow meter is used to accurately measure the intake flow rate, which is the benchmark for calculating the compressor volumetric flow rate and efficiency.

[0025] Pipeline A consists of a high-pressure gas cylinder module → a pressure reducing valve module (pressure regulating valve module) → the compressor inlet. The high-pressure gas cylinder module serves two purposes: firstly, it acts as a buffer and stabilizer, absorbing and buffering fluctuations in the compressor's exhaust pressure to ensure smooth operation of the entire gas system; secondly, after a period of testing, when the low-pressure inlet is closed, the gas discharged by the compressor itself and stored in the high-pressure gas cylinder is depressurized and resupplyed to the compressor inlet, thus forming a closed loop. This is particularly suitable for testing special gases (such as process gases) or long-term continuous operation, saving gas and ensuring safety.

[0026] Pipeline B is the exhaust and venting pipeline, which goes through the compressor unit exhaust port → second flow meter → venting module (connected to the 2nd or 3rd venting port in the venting module; by comparing the readings of the first flow meter and the second flow meter, the internal leakage and volumetric efficiency of the compressor unit can be accurately determined, thereby verifying its sealing performance and design level, while the exhaust goes to the venting module for safe release.

[0027] Further, see Figure 6 The pressure reducing valve assembly module, also known as the pressure regulating module, is located between the high-pressure gas cylinder assembly module and the compressed air inlet. It includes a gas pressure reducing orifice plate and a pressure reducing valve assembly. The orifice plate reduces pipeline pressure by 50%-70% and handles large pressure drops, protecting downstream precision pressure reducing valves from erosion by high-pressure differential fluids. The orifice plate's dimensions can be precisely customized through calculation to achieve accurate primary pressure reduction. The pressure reducing valve assembly has two sets, each with dual-path regulation: one pneumatic valve and one pressure regulating valve. Each set is equipped with a pressure sensor with a display, allowing for local and remote monitoring of pressure values ​​before and after regulation. The two sets of valves can work in parallel to meet high flow rate requirements or work independently, providing flexible pressure regulation capabilities covering various operating conditions such as high and medium pressure.

[0028] Furthermore, see Figure 7For the cooling water system, the cooling water system includes a cooling water tower, water pumps, pressure gauges, inlet and outlet valves, etc. The outlet and return water in the cooling water system are connected to the inlet and outlet of the compressor unit, respectively. Pressure gauges and flow meters are installed on the pipeline. The cooling water system provides the necessary circulating cooling for the compressor unit and its auxiliary equipment to ensure stable operation at the rated temperature. The pressure gauge monitors whether the cooling water pressure is normal, and the flow meter monitors the cooling water flow rate.

[0029] In this embodiment, see Figure 8 For the venting module, it includes a storage tank, a silencer, valves, and valve supports. All venting lines in the unit are connected to the valve supports. The venting module has four venting ports: one connects to the compressor venting line to release any gas or pressure that may accumulate inside the compressor; ports two and three are emergency venting ports. Port two is a manual emergency venting port, which can be manually opened quickly to release pressure directly when the automatic system malfunctions or requires human intervention; port three is an emergency pneumatic venting valve that automatically opens when overpressure is detected, achieving rapid automatic pressure release and ensuring that the system pressure can be quickly reduced to a safe level under abnormal operating conditions. The fourth venting line serves two purposes: firstly, to release overpressure; secondly, in the shutdown state, to avoid the dangers caused by high-pressure venting, the system design allows high-pressure gas to be regulated and reduced to a low pressure before venting, achieving the goal of safe production.

[0030] In this embodiment, see Figure 4 For the sewage discharge module, it includes a sewage tank and a sewage valve rack. The sewage discharge module connects to the base platform drainage ditch through the compressor unit's drain outlet, then to the sewage valve rack, and finally into the sewage tank. This sewage discharge module can centrally collect industrial wastewater such as oil-water mixtures generated during the testing process, achieving civilized and environmentally friendly production and preventing direct discharge of oil and pollution of the environment.

[0031] It should be noted that the device in this scheme uses flow meters installed at both the inlet and outlet of the main gas path of the test unit, supported by brackets to form a metering module. The dual flow meter setup is used to verify the flow loss of the compressor unit and whether there is internal leakage. At the same time, this scheme is designed with an intelligent detection module. By using an intelligent detection and control system with a PC as the core, it collects PLC signals from the skid-mounted compressor unit and analog signals set by each module to collect, monitor and analyze data on the compressor's testing and performance.

[0032] The mechanical equipment used in this solution, such as high-pressure gas cylinders, pressure reducing valves, flow meters, cooling towers, water pumps, PLCs, and industrial control computers, are all mature and commercially available general-purpose products in the industrial field. Their structures, principles, and functions are all existing technologies. In this solution, each piece of equipment is modularly designed, and the testing functions are decomposed into independent and clearly defined modules (basic platform, low-pressure air intake, high-pressure gas cylinders, pressure reducing valve group, cooling, venting, sewage discharge, metering, intelligent control, etc.). This design offers high flexibility and can be used according to the specific model of the compressor under test and the testing requirements (such as pressure range, gas medium, and flow rate). For example, testing a low-pressure compressor may only require activating the low-pressure intake module; testing a high-pressure compressor requires activating both the high-pressure cylinder module and the pressure reducing valve module. This solution, through its design of a pressure reducing orifice plate working in conjunction with the pressure reducing valve assembly, and its four-way venting design for different situations (normal exhaust, emergency overpressure, and shutdown pressure relief), not only achieves specific functions but also ensures system safety and a longer system lifespan. Furthermore, this system is easy to maintain; a single module failure does not affect the entire system's operation, and repair and replacement are convenient. Compared to existing technologies, this solution not only meets the factory performance testing requirements for various operating conditions and compressor models but also allows for one-time investment and cyclical use, making it highly operable for testing personnel and reducing testing costs.

[0033] Finally, it should be noted that the above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A modular compressor performance testing device, characterized in that: It includes a compressor unit, a basic platform, a low-pressure air intake module and a high-pressure gas cylinder group module, as well as a venting module, a pressure reducing valve group module and a cooling water system; The compressor unit is mounted on a foundation platform, and its inlet is connected to the outlet of the cooling water system, while its outlet is connected to the return outlet of the cooling system. The compressor unit's connecting pipelines include pipeline A, pipeline B, and pipeline C. In pipeline A, the high-pressure gas cylinder module is connected to the pressure reducing valve module and then to the compressor unit. In pipeline B, the compressor unit's exhaust port is connected to the venting module, while in pipeline C, the low-pressure intake module is directly connected to the compressor unit. The venting module includes four venting ports, of which one port is connected to the compressor unit's venting pipeline, ports two and three are connected to the compressor unit's exhaust port, and port four is used to prevent the danger caused by high-pressure venting.

2. The modular compressor performance testing device according to claim 1, characterized in that: The high-pressure gas cylinder group module consists of a high-pressure gas cylinder group equipped with a pressure sensor. The high-pressure gas cylinder group module serves two purposes: firstly, to alleviate pressure fluctuations in the device's exhaust system, and secondly, to allow the gas from the high-pressure gas cylinder group to be depressurized and enter the compressor's inlet when the low-pressure intake module is closed, thus forming a closed loop in the performance testing system.

3. The modular compressor performance testing device according to claim 2, characterized in that: The low-pressure air intake module includes a screw air compressor, a separator, a dryer, a nitrogen generator, an air storage tank, and a nitrogen storage tank. The low-pressure air intake module can provide nitrogen in one channel and clean air in another channel. The air or nitrogen outlet of the low-pressure air intake module is connected to the air inlet of the compressor unit via a first flow meter, and the exhaust port of the compressor unit is connected to the corresponding inlet of the venting module via a second flow meter.

4. The modular compressor performance testing device according to claim 1, characterized in that: The pressure reducing valve assembly module includes a gas pressure reducing orifice plate and two pressure reducing valve assemblies. The pressure reducing orifice plate is located at the front of the pressure reducing valve to reduce pressure and prevent corrosion of the valve. Each pressure reducing valve assembly has two channels equipped with a pneumatic valve and a pressure regulating valve. The two pressure reducing valves can work simultaneously or independently according to the pressure regulation requirements of the actual working conditions.

5. The modular compressor performance testing device according to claim 1, characterized in that: The cooling water system includes a cooling tower, a water pump, a pressure gauge, and inlet and outlet valves. The compressor unit's inlet and outlet are connected to hoses at the outlet and return points of the cooling water system, respectively. Pressure gauges and flow meters are installed on the pipeline for data collection and monitoring.

6. The modular compressor performance testing device according to claim 3, characterized in that: The venting module includes a storage tank, a silencer, valves, and valve supports; all venting lines in the device are connected to the valve supports; two of the venting lines in the venting module are emergency manual venting lines, three are emergency pneumatic venting valve venting lines, and four are used for both overpressure venting and allowing high-pressure gas to be regulated and its pressure reduced to low pressure before venting.

7. The modular compressor performance testing device according to claim 1, characterized in that: It also includes a sewage discharge module; the sewage discharge module includes a sewage tank and a sewage valve frame, and the sewage generated in this device is connected to the sewage valve frame in the sewage discharge module.

8. The modular compressor performance testing device according to claim 1, characterized in that: It also includes a protection module; the protection module includes an explosion-proof wall; an explosion-proof wall is set up around the basic platform, and an electrostatic eliminator is installed at the edge of the wall. An explosion-proof power control cabinet, a frequency converter cabinet and an industrial control computer are installed inside the explosion-proof wall.

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