CN116971974B - Self-adaptive regulation and control method and system for variable-working-condition reciprocating compressor - Google Patents
Self-adaptive regulation and control method and system for variable-working-condition reciprocating compressor Download PDFInfo
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
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- F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
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Abstract
The invention provides a self-adaptive regulation and control method and a system for a variable-working-condition reciprocating compressor, wherein the method comprises the following steps: matching three-dimensional efficient running spaces of the compressor in different capacity intervals; three parameters of the capacity of the compressor, the running power of the compressor and the air inlet pressure of the compressor are matched to a three-dimensional efficient running space through joint control and joint adjustment, and the three-dimensional efficient running space is automatically identified under different working conditions; in the three-dimensional efficient operation space, the air inlet pressure of the compressor is slowly increased in a sine wave mode, so that the purposes of high productivity and low unit consumption are achieved. After the method and the system are modified, no matter what working conditions are used, a set of optimal operation modes can be automatically identified and matched, so that the compressor always operates in a high-efficiency operation space. The user can decide the output according to the actual condition of the gas well and the production requirement, and manual intervention is not needed. The whole system is automatically identified and intelligently operated in the whole process, manual operation is not needed, and the purposes of energy saving and consumption reduction can be realized by switching between new and old modes through one key.
Description
Technical Field
The invention relates to the technical field of natural gas reciprocating compressors, in particular to a variable working condition reciprocating compressor self-adaptive regulation and control method and system.
Background
The natural gas, shale gas, coal bed gas and other resources in China are rich in reserves, but are subject to the complexity of geographical geological conditions, and the exploitation depth is generally larger than that of the foreign countries, so that the exploitation technical requirements are high, and the exploitation cost is high. With the high-speed development of the economy in China, the current self-produced natural gas can not meet the social requirements far, so that a large amount of import is needed. The natural gas exploitation fracturing technology is urgently required to break through, and exploitation cost is also urgently required to be reduced.
The natural gas well naturally decays along with the oil extraction time, the wellhead pressure drops irregularly and continuously, and the reciprocating compressor is needed to be used as a supercharging device for supercharging exploitation in order to ensure the pressure stability of the external pipeline network. However, as the capacity and wellhead pressure further drop, the compressor energy consumption problem becomes increasingly pronounced.
The phenomenon that the productivity is reduced and the power consumption is not reduced is becoming a common phenomenon for natural gas exploitation units. Under the national 'double carbon' strategy, green low carbon development is a trend, and how to reduce the energy consumption of the natural gas reciprocating compressor on the premise of maintaining the productivity not to be reduced, thereby improving the energy efficiency of products and being a new subject faced by natural gas exploitation units.
The traditional technology of low-carbon reformation of the natural gas compressor is a variable-frequency speed regulation technology, and the aim of reducing power consumption is achieved by reducing the frequency and the rotating speed of a motor. However, in the special working condition scene of the natural gas compressor, the working condition presents irregular attenuation, the direct frequency modulation cannot adapt to the continuous and irregular fluctuation current situation of the working condition, the effectiveness of the variable frequency speed regulation technology is greatly reduced, and even the phenomenon of no energy-saving effect occurs. The practice of the natural gas extraction units in China proves that a novel low-cost energy-saving technology is urgently needed in the low-carbon market of the natural gas compressor to fill the current technical blank.
Disclosure of Invention
In view of the above, the invention provides a variable working condition self-adaptive regulation and control method and a system for a reciprocating compressor, so as to realize obvious energy-saving effect under different working conditions.
The technical scheme of the invention is as follows:
the invention provides a self-adaptive regulation and control method of a variable-working-condition reciprocating compressor, which comprises the following steps:
the first step: matching three-dimensional efficient running spaces of the compressor in different capacity intervals;
and a second step of: three parameters of the capacity of the compressor, the running power of the compressor and the air inlet pressure of the compressor are matched to a three-dimensional efficient running space through joint control and joint adjustment, and the three-dimensional efficient running space is automatically identified under different working conditions;
and a third step of: in the three-dimensional efficient operation space, the air inlet pressure of the compressor is slowly increased in a sine wave mode, so that the purposes of high productivity and low unit consumption are achieved.
Further, in the first step: firstly, dividing the current productivity working condition into a plurality of intervals, and collecting wellhead pressure, compressor inlet pressure, compressor productivity, compressor current voltage and ambient temperature in real time;
according to the fluctuation condition of the actual working condition, a mathematical model is built, the three-dimensional efficient operation space of the compressor under the current working condition is calculated in a matching mode, the three-dimensional efficient operation space is a three-dimensional space, and the three-dimensional efficient operation space is formed by combining the capacity of the compressor as an X axis, the operation power of the compressor as a Y axis and the air inlet pressure of the compressor as a Z axis.
Further, in the second step: in a certain set capacity interval, the self-adaptive analysis is carried out on the output load and the power factor of the motor by analyzing the load profile, the voltage, the inlet and outlet parameter configuration, the control mechanism, the maintenance time, the interelectrode temperature and the machine head temperature rise ratio, and the combination control and the adjustment are carried out on the rotating speed, the torque, the voltage, the current and the magnetic flux of the motor of the compressor, so that the three parameters of the capacity of the compressor, the running power of the compressor and the air inlet pressure of the compressor are automatically matched into the three-dimensional efficient running space.
Further, in the third step: the running power of the compressor is reduced by dynamically adjusting the rotating speed, torque, voltage, current and magnetic flux of the motor of the compressor under different working conditions, and the electric power is the lowest on the premise of ensuring that the productivity is not reduced.
The invention also provides a variable-working-condition self-adaptive regulation and control system of the reciprocating compressor, which comprises a variable-control intelligent regulation and control device, a signal acquisition module, a vector control module, a compressor PLC control system and a PLC control center;
the variable control intelligent regulation and control device comprises a ternary flow simulation calculation module and a logic control module which are electrically connected, wherein a mathematical model is established through the ternary flow simulation calculation module, and a three-dimensional efficient operation space of the compressor under the current working condition is calculated in a matching way, wherein the three-dimensional efficient operation space is a three-dimensional space, and the variable control intelligent regulation and control device is formed by combining the capacity of the compressor with the X axis, the operation power of the compressor with the Y axis and the air inlet pressure of the compressor with the Z axis;
the method comprises the steps of matching three parameters of compressor productivity, compressor running power and compressor air inlet pressure to a three-dimensional efficient running space through a logic control module and compressor joint control joint adjustment;
the signal acquisition module is electrically connected with the three-dimensional flow simulation calculation module to acquire the current, voltage, power, productivity and environmental temperature of the motor of the compressor;
the vector control module is electrically connected with the logic control module to dynamically adjust the rotating speed, torque, voltage, current and magnetic flux of the motor of the compressor under different working conditions, so that the running power of the compressor is reduced, and the electric power is the lowest on the premise of ensuring that the productivity is not reduced;
the PLC control system of the compressor is respectively and electrically connected with the three-dimensional flow simulation calculation module and the PLC control center so as to acquire partial real-time data, and the partial real-time data are transmitted to the three-dimensional flow simulation calculation module to calculate three-dimensional efficient running spaces of the compressor under different capacity working conditions;
the PLC control center is electrically connected with the PLC control system and the vector control module respectively, so that signals of the vector control module are transmitted to the PLC control center.
Further, firstly dividing the working condition of the gas gathering station into a plurality of sections according to the productivity, matching the three-dimensional efficient operation space of the current compressor in each section through a three-dimensional flow simulation calculation module, carrying out fine control and adjustment on parameter combinations of motor voltage, rotating speed, torque and magnetic flux of the compressor through tracking analysis on various parameters of the gas gathering station, a power distribution system and the compressor system, slowly improving the air inlet pressure of the compressor through a logic control module in a sine waveform mode, and finally matching the productivity, the operation power and the air inlet pressure of the compressor to the three-dimensional efficient operation space under the specified working condition;
and then according to the vibration, the oil temperature, the exhaust temperature and the environmental temperature of the compressor, the vector control module is used for further carrying out fine control and adjustment on the parameter combination of the motor voltage, the rotating speed, the torque and the magnetic flux of the compressor in the three-dimensional efficient operation space after comprehensive analysis, so that the operation power of the compressor is reduced, and the electric power is the lowest on the premise that the productivity is not reduced.
Further, the three-dimensional flow simulation calculation module comprises a sensor assembly, a signal conditioning conversion circuit, a conversion element and a microprocessor which are electrically connected in sequence, wherein the sensor assembly comprises a plurality of sensors which are used for respectively measuring the rotating speed, the torque, the rotating angle, the magnetic flux, the flow and the pressure of a compressor motor, data conversion is carried out on the sensing result, meanwhile, the data interaction is carried out with the logic control module, the three-dimensional flow calculation analysis of NASA TN D-7344 is used for analog analysis and calculation, an optimal design program can analyze and verify the calculation result and automatically adjust the rotor position and the rotor torque, the optimal calculation is automatically carried out, a new operation curve is obtained through a large number of loop iterations, and finally, the working condition data of the high-efficiency curve for the actual operation is established.
Further, the signal conditioning conversion circuit is used to divert or amplify the signal from the sensor assembly, making it more suitable for further transmission and processing.
Further, the conversion element is used for carrying out data conversion on the sensing result, takes the output of the sensor assembly as input, converts the input signal into circuit parameters, and the microprocessor is in data interaction with the logic control module and is connected with the NC1 and NO1 joints to the vector control module to form driving adjustment calculation.
Further, the logic control module is used for matching the capacity, the operation power and the air inlet pressure of the compressor into the three-dimensional efficient operation space in a specified mode when the capacity working condition is fixed to a certain specified range, and can automatically identify the three-dimensional efficient operation space under different working conditions.
The invention has the beneficial effects that:
compared with the prior art, the variable-working-condition self-adaptive regulation and control method of the reciprocating compressor is implemented on a gas gathering station platform of a shale gas exploration and development company. The shale gas gathering station platform is provided with 2 110kW reciprocating compressors, the average total capacity is 7.5 kilowatts/day, and the total capacity is designed to be 10 kilowatts/day. After the invention is implemented, the energy consumption standard (universal gas power consumption) before transformation is 501.76 kwh/universal m 3 The energy consumption data (universal gas power consumption) after transformation is 372.87 kwh/universal m 3 The energy saving rate reaches 25.69%, and the effect is very obvious.
According to the variable working condition self-adaptive regulation and control system of the reciprocating compressor, working conditions of a gas collecting station are divided into a plurality of sections according to productivity, and three-dimensional efficient operation space of the current compressor is matched in each section through a three-dimensional flow simulation calculation module. By tracking and analyzing various parameters of the gas gathering station, the power distribution system and the compressor system, the combination of parameters such as the voltage, the rotating speed, the torque, the magnetic flux and the like of the motor of the compressor is finely controlled and regulated, the air inlet pressure of the compressor is slowly increased in a sine waveform mode through the logic control module, and finally, the parameters such as the capacity of the compressor, the running power of the compressor, the air inlet pressure of the compressor and the like are matched to a three-dimensional efficient running space under a specified working condition.
And then according to factors such as vibration, oil temperature, exhaust temperature, ambient temperature and the like of the compressor, after comprehensive analysis, the vector control module is used for further carrying out fine control and adjustment on parameter combinations such as voltage, rotating speed, torque, magnetic flux and the like of a motor of the compressor in a three-dimensional efficient operation space, so that the operation power of the compressor is reduced, and the electric power is the lowest on the premise that the productivity is not reduced, namely, the unit consumption is the lowest (unit consumption=power consumption/productivity), and finally the effects of saving energy and reducing consumption are achieved.
After the system is modified, no matter what working conditions are operated, the system can automatically identify and match a set of optimal operation modes, so that the compressor is always operated in a high-efficiency operation space. The user can decide the output according to the actual condition of the gas well and the production requirement, and manual intervention is not needed. The whole system is automatically identified and intelligently operated in the whole process, manual operation is not needed, and the purposes of energy saving and consumption reduction can be realized by switching between new and old modes through one key.
The preferred embodiments of the present invention and their advantageous effects will be described in further detail with reference to specific embodiments.
Drawings
The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification, illustrate the invention and together with the description serve to explain the invention. In the drawings of which there are shown,
FIG. 1 is a three-dimensional efficient operating space of a natural gas gathering station under 75% capacity conditions;
FIG. 2 is a schematic diagram of the adaptive regulation system of the variable-duty reciprocating compressor of the present invention;
FIG. 3 is a schematic diagram of a three-dimensional flow simulation calculation module of the adaptive regulation system of the variable-working-condition reciprocating compressor;
FIG. 4 is a schematic diagram of the logic control module of the adaptive regulation system of the variable-working-condition reciprocating compressor;
FIG. 5 is a schematic diagram of the vector control module of the adaptive regulation system of the variable-duty reciprocating compressor of the present invention.
Reference numerals illustrate: the variable control intelligent regulation device 10, the signal acquisition module 20, the vector control module 30, the compressor PLC control system 40, the PLC control center 50, the three-way flow simulation calculation module 101, the logic control module 102, the sensor assembly 1011, the signal conditioning conversion circuit 1012, the conversion element 1013, the microprocessor 1014, the compressor motor 100 and the communication module 60.
Detailed Description
The following describes specific embodiments of the present invention in detail with reference to the drawings. It should be understood that the detailed description and specific examples, while indicating and illustrating the invention, are not intended to limit the invention.
Referring to fig. 1, the invention provides a variable-working-condition self-adaptive regulation and control method of a reciprocating compressor, which comprises the following steps:
the first step: and matching three-dimensional efficient running spaces of the compressor in different capacity intervals.
The current productivity working condition is divided into four sections of 6-7 square/day, 7-8 square/day, 8-9 square/day and 9-10 square/day. Parameters such as wellhead pressure, compressor inlet pressure, compressor capacity, compressor current voltage and ambient temperature are collected in real time.
According to the fluctuation condition of the actual working condition, a mathematical model is built, and the three-dimensional efficient operation space of the compressor under the current working condition is calculated in a matching mode, wherein the three-dimensional efficient operation space is a three-dimensional space, and the three-dimensional efficient operation space is formed by combining the capacity of the compressor as an X axis, the operation power of the compressor as a Y axis and the air inlet pressure of the compressor as a Z axis.
And a second step of: three parameters of the capacity of the compressor, the running power of the compressor and the air inlet pressure of the compressor are matched to a three-dimensional efficient running space through joint control and joint adjustment, and the three-dimensional efficient running space is automatically identified under different working conditions.
In a certain set capacity interval (such as 6-7 square/day), by analyzing a load profile, the parameters of voltage (commonly 380V, 6KV, 10KV and the like), inlet and outlet parameter configuration (including inlet and outlet temperature, inlet and outlet pressure, outlet flow, cooling oil temperature and the like), control mechanism, maintenance time, interelectrode temperature, machine head temperature rise ratio, self output load, power factor and the like are adaptively analyzed, and parameters of motor rotation speed, torque, voltage, current, magnetic flux and the like of the compressor are combined, controlled and regulated, so that the three parameters of the capacity of the compressor, the running power of the compressor and the inlet pressure of the compressor are automatically matched into a three-dimensional efficient running space.
And a third step of: in the three-dimensional efficient operation space, the air inlet pressure of the compressor is slowly increased in a sine wave mode, so that the purposes of high productivity and low unit consumption are achieved.
By dynamically adjusting parameters such as the rotation speed, torque, voltage, current, magnetic flux and the like of the motor of the compressor under different working conditions, the running power of the compressor is reduced, and the electric power is the lowest, namely the unit consumption is the lowest (unit consumption=power consumption/capacity) on the premise of ensuring that the capacity is not reduced. Finally, the effects of energy saving and consumption reduction are achieved.
The variable-working-condition self-adaptive regulation and control method of the reciprocating compressor is implemented on a gas gathering station platform of a shale gas exploration and development company. The shale gas gathering station platform is provided with 2 110kW reciprocating compressors, the average total capacity is 7.5 kilowatts/day, and the total capacity is designed to be 10 kilowatts/day. After the invention is implemented, the energy consumption standard (universal gas power consumption) before transformation is 501.76 kwh/universal m 3 The energy consumption data (universal gas power consumption) after transformation is 372.87 kwh/universal m 3 The energy saving rate reaches 25.69%, and the effect is very obvious.
Referring to fig. 2, the present invention is necessary to provide a variable-working-condition self-adaptive control system for a reciprocating compressor, which includes a variable-control intelligent control device 10, a signal acquisition module 20, a vector control module 30, a compressor PLC control system 40 and a PLC control center 50. The variable control intelligent regulation device 10 comprises a ternary flow simulation calculation module 101 and a logic control module 102 which are electrically connected. And a mathematical model is established through the three-dimensional flow simulation calculation module 101, and the three-dimensional efficient operation space of the compressor under the current working condition is calculated in a matching way, wherein the three-dimensional efficient operation space is a three-dimensional space, and the three-dimensional efficient operation space is formed by combining the capacity of the compressor as an X axis, the operation power of the compressor as a Y axis and the air inlet pressure of the compressor as a Z axis. Three parameters of the capacity of the compressor, the running power of the compressor and the air inlet pressure of the compressor are matched to a three-dimensional efficient running space through a logic control module 102 and a compressor joint control joint debugging. The signal acquisition module 20 is electrically connected with the three-way flow simulation calculation module 101 to acquire real-time data such as current, voltage, power, capacity, ambient temperature and the like of the compressor motor. The vector control module 30 is electrically connected with the logic control module 102 to dynamically adjust parameters such as the rotation speed, torque, voltage, current, magnetic flux and the like of the compressor motor under different working conditions, reduce the running power of the compressor, and ensure that the electric power is the lowest under the premise of not reducing the productivity. The compressor PLC control system 40 is electrically connected with the three-dimensional flow simulation calculation module 101 and the PLC control center 50, respectively, so as to collect part of real-time data such as inlet and outlet temperatures, inlet and outlet pressures, outlet cooling oil temperatures, interelectrode temperatures, machine head temperatures, etc., and transmit the data to the three-dimensional flow simulation calculation module 101, so as to calculate three-dimensional efficient operation space of the compressor under different capacity working conditions. The PLC control center 50 is electrically connected to the PLC control system 40 and the vector control module 30, respectively, so that signals of the vector control module 30 are transmitted to the PLC control center 50.
Firstly, dividing the working condition of the gas gathering station into a plurality of sections according to the productivity, and matching the three-dimensional efficient running space of the current compressor (the X axis is the productivity of the compressor, the Y axis is the running power of the compressor, and the Z axis is the air inlet pressure of the compressor) in each section through the three-dimensional flow simulation calculation module 101. By tracking and analyzing various parameters of the gas gathering station, the power distribution system and the compressor system, the combination of parameters such as the voltage, the rotating speed, the torque, the magnetic flux and the like of the motor of the compressor is finely controlled and regulated, the air inlet pressure of the compressor is slowly increased in a sine waveform mode through the logic control module 102, and finally, the parameters such as the capacity of the compressor, the running power of the compressor, the air inlet pressure of the compressor and the like are matched to a three-dimensional efficient running space under a specified working condition.
And then according to factors such as compressor vibration, oil temperature, exhaust temperature, environmental temperature and the like, after comprehensive analysis, the vector control module 30 is used for further carrying out fine control and adjustment on parameter combinations such as compressor motor voltage, rotating speed, torque, magnetic flux and the like in a three-dimensional efficient operation space, so that the operation power of the compressor is reduced, the electric power is the lowest on the premise that the productivity is not reduced, namely, the unit consumption is the lowest (unit consumption=power consumption/productivity), and finally the effects of saving energy and reducing consumption are achieved.
After the system is modified, no matter what working conditions are operated, the system can automatically identify and match a set of optimal operation modes, so that the compressor is always operated in a high-efficiency operation space. The user can decide the output according to the actual condition of the gas well and the production requirement, and manual intervention is not needed. The whole system is automatically identified and intelligently operated in the whole process, manual operation is not needed, and the purposes of energy saving and consumption reduction can be realized by switching between new and old modes through one key.
Referring to fig. 3, a three-dimensional flow simulation calculation module 101 is configured to calculate a three-dimensional dynamic efficient operation space under different capacity conditions.
By adopting a technical route combining the ternary flow theory with CFD computational fluid dynamics and chip processing, the optimal combination of different flow and geometric parameters is searched from the point of considering the minimum pressure loss, the highest efficiency and the maximum flow. Through analysis of all working points in the volume, a complete and real mathematical model of fluid flow in the volume is established, the operation working condition of the device driven by the three-way flow simulation curve can completely adapt to the real flow state of the fluid, the speed distribution of fluid particles can be controlled, and the NC1 and NO1 joints of the three-way flow simulation calculation module 101 are connected to the vector control module 30 to form driving adjustment calculation. Therefore, the application ternary flow operation efficiency is significantly improved.
The three-way flow simulation calculation module 101 includes a sensor assembly 1011, a signal conditioning conversion circuit 1012, a conversion element 1013, and a microprocessor 1014 electrically connected in sequence, and further requires an additional auxiliary power supply to provide conversion energy. The sensor assembly 1011 includes a plurality of sensors for measuring the rotation speed, torque, rotation angle, magnetic flux, flow, pressure, etc. of the compressor motor 100, converting the sensed result, interacting with the logic control module 102, performing analog analysis and calculation using the ternary flow calculation analysis of NASA TN D-7344, and the optimization design program can analyze and verify the calculated result and automatically adjust the geometric parameters such as rotor position and rotor torque, etc., automatically perform "best-in-best" calculation, and obtain a new operation curve through a large number of loop iterations. And finally, establishing working condition data of the energy storage for an actual running high-efficiency curve.
The signal conditioning and conversion circuit 1012 transfers or amplifies the signal from the sensor assembly 1011 to make it more suitable for further transmission and processing, and in most cases converts various electrical signals into a few electrical signals that are convenient for measurement, such as voltage, current, frequency, etc. I.e. filtering, modulating or demodulating, attenuating, calculating, digitizing, etc. the converted signal. Common signal conditioning conversion circuits include an amplifier, a bridge, an oscillator, a charge amplifier, a phase sensitive detector circuit, and the like, and the conversion element 1013 is configured to perform data conversion on a sensing result, and convert an input signal into a circuit parameter by taking an output of the sensor assembly 1011 as an input. The microprocessor 1014 is in data communication with the logic control module 102 and is coupled to the vector control module 30 at the NC1, NO1 junction to form a drive adjustment calculation.
The natural gas compressor operating power W is calculated as follows:
wherein:
w is the work consumed by the compressor in unit time, namely the running power, and the unit is kW;
n is the rotational speed of the compressor motor in (revolutions per minute);
P suction pipe Is the cylinder suction pressure in units of (kgf/cm) 2 )；
P Row of rows Is the cylinder exhaust pressure in units of (kgf/cm) 2 )；
V h Is the cylinder volume, the unit is (m 3 )；
λ v Is the volume coefficient of the cylinder;
k is natural gas adiabatic index;
α is the percent in-cylinder pressure loss, (%).
According to the calculation formula of the operating power of the natural gas compressor, the cylinder volume V is obtained under the condition that the compressor is not subjected to large-scale equipment transformation h Volume coefficient lambda of cylinder v The natural gas heat insulation index K and the in-cylinder pressure loss percentage alpha are all unchanged, and the cylinder exhaust pressure P Row of rows The pressure of the gas pipeline is stable and is also a constant value. The main factors determining the operating power of the compressor are the rotational speed n of the compressor motor and the pressure difference P Row of rows -P Suction pipe . The rotation speed n of the compressor motor decreases, the running power W decreases, and the cylinder suction pressure P Suction pipe The operating power W increases. According to the characteristics of the compressor, the rotation speed n of the compressor motor and the suction pressure P of the cylinder Suction pipe In inverse proportion, therefore, to obtain the lowest operating power Wlowest, the speed n of the compressor motor is related to the cylinder suction pressure P Suction pipe There is a best match range. According to the field data test, the productivity is 7 to the maximum
When 8 square meters per day (average 7.5 square meters per day), 1.8-2.1 MPa is the optimal air inlet pressure value range, and the corresponding running power range is 102-115 kW.
Similarly, when the average capacity values are 7.1, 7.2, 7.3, 7.4, 7.6, 7.8 and 7.9 square/day, the corresponding optimal air inlet pressure range and operation power range can be obtained. When the energy production data is sufficiently high, the optimal air inlet pressure and the operating power range are more and more accurate, and finally the three-dimensional efficient operating space of the compressor is obtained when the energy production of the compressor is 6-8 trillion/day. According to the test data, the three-dimensional efficient operation space of productivity, operation power and air inlet pressure can be drawn.
Referring to fig. 4, the logic control module 102 is configured to match parameters such as capacity, operation power, and intake pressure of the compressor into the three-dimensional efficient operation space in a specified manner when the capacity working condition is fixed to a certain specified range, and automatically identify the three-dimensional efficient operation space under different working conditions.
Through carrying out self-adaptive analysis to voltage, exhaust temperature, outlet flow, cooling oil temperature, interelectrode temperature, aircraft nose temperature rise, motor etc., through down-conversion to parameters such as motor rotational speed control and regulation, slowly adjust to 75% lower limit value from rated rotational speed, in this process, control inlet pressure and slowly rise, simultaneously to two compressors joint control joint regulation, ensure that whole productivity is basically stable not to drop. And finally, three parameters of control productivity, operation power and air inlet pressure are matched into a three-dimensional efficient operation space.
When the productivity working condition changes, three parameters of productivity, running power and air inlet pressure are matched into a three-dimensional efficient running space according to the same principle.
Referring to fig. 5, the vector control module 30 functions to minimize the running power, i.e., the unit consumption of the compressor (unit consumption=power consumption/capacity), by adjusting parameters such as the rotation speed, torque, voltage, magnetic flux of the motor of the compressor, while ensuring that the capacity is not reduced.
Parameters such as the rotating speed, torque, voltage, magnetic flux and the like of the motor of the compressor are adjusted through the lifting frequency. The integrated judgment of the vibration of the compressors, the shaft temperature of the motor and the temperature of the winding is realized, so that the joint control and joint adjustment of two compressors are realized, one compressor is used as a regulator, and the other compressor is used as a host, thereby ensuring that the overall productivity is not reduced. Meanwhile, the air inlet pressure of the compressor is controlled to change in a sinusoidal waveform, the wavelength is a time axis, the wave peak value is 2.3MPa, the wave trough value is 1.5MPa, the operation power of the compressor is controlled to be increased and then decreased, the operation power is balanced finally until the average value of the operation power is the lowest, and then the lowest unit consumption (unit consumption=power consumption/capacity) is achieved, and signals are transmitted to the PLC control center 50.
The main power supply of the vector control module 30 is three-phase power supplies L1, L2 and L3, and the breaker QF is used for switching off and switching on a load circuit and switching off a fault circuit, so that safe operation is ensured. Under the condition of overload or abnormal operation of the electric appliance, if the electric appliance fails, the switch can be automatically disconnected, and the electric appliance and the circuit are protected. The fuse FU mainly plays a short-circuit protection role and also plays an overload protection role. TA is a current transformer, which is mainly used for measuring main loop current, measuring power consumption and protecting circuits. The working principle of the device is the same as that of a transformer, the device is a primary loop circuit, a secondary relay and other metering display and driving elements, and the device can also realize on-site current observation.
The vector control module 30 modulates the signal with 4-20mA for a minimum current of 4mA and a maximum current of 20mA, i.e., given a frequency of 0-50Hz, then 4mA is 0Hz and 20mA is 50Hz operating frequency. The analog quantity is in one-to-one correspondence with an external given voltage or current signal, logic control and three-way flow simulation calculation.
The KA1 and KA2 dual-start control trigger point can realize start-stop and speed control of the vector control module 30 through a profibusDP network. The control mode has low cost, and the bus control is stable and not easy to be disturbed, but the terminal control can be automatically switched. The feedback signals NC1, NO1 to the three-way flow simulation calculation module 101 form a closed loop control adjustment.
Referring to fig. 2, the adaptive regulation and control system for a variable-working-condition reciprocating compressor of the present invention further includes a communication module 60 electrically connected to the three-way flow simulation calculation module 101. The communication module 60 is mainly used for realizing the following functions:
1. and (3) data exchange: the communication module can exchange and share the data in the system with the data in other control devices, so that a data communication channel is established between the two devices. Data information such as temperature, humidity, flow and the like can be transmitted to other devices, and the data information of other devices can also be transmitted to the PLC.
2. And (3) control: the communication module can be used for controlling and interacting between the PLCs. And networking a plurality of PLCs to respond to external sensor feedback, realize logic judgment and cooperative control among devices and realize a complex automatic control system.
3. And (3) monitoring: the communication module may be used to monitor the status of the device or system to which it is connected, for example, it may receive and display data and information from external meters, and send reminders and error messages to the user.
4. And (3) collecting: the communication module can be used for data acquisition. The method can transmit the collected data to a computer or an upper computer, store the data in a local or cloud server and provide support for production decision and data analysis.
The wireless communication distance is 5KM, the Lora spread spectrum maximum transmitting power is 20dbm, the receiving sensitivity is-136 dbm, and the multistage relay networking can be realized by adopting high receiving sensitivity (RSSI) and strong signal-to-noise ratio (SNR) optimization. The device has the functions of address and encryption, and is used for directional communication among modules, so that the device is safe and reliable, and data leakage is prevented. The frequency modulation technology is supported, and the firmware upgrading function is supported.
In the description of the present invention, it should be noted that the azimuth or positional relationship indicated by the terms "upper", "lower", etc. are based on the azimuth or positional relationship shown in the drawings, and are merely for convenience of describing the present invention and simplifying the description, and are not indicative or implying that the apparatus or element in question must have a specified azimuth, be constructed and operated in a specified azimuth, and thus should not be construed as limiting the present invention. Furthermore, the terms "first," "second," and the like, are used for descriptive purposes only and are not to be construed as indicating or implying importance; the words "bottom" and "top", "inner" and "outer" refer to directions toward or away from, respectively, a given component geometry.
In the description of the present invention, it should be noted that, unless explicitly specified and limited otherwise, the terms "mounted," "connected," and "connected" are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; the communication may be direct or indirect through an intermediate medium, or may be internal to two elements. The specific meaning of the above terms in the present invention will be understood in specific cases by those of ordinary skill in the art. Furthermore, in the description of the present invention, unless otherwise indicated, the meaning of "a plurality" is two or more.
The foregoing is only illustrative of the present invention and is not to be construed as limiting thereof, but rather as various modifications, equivalent arrangements, improvements, etc., within the spirit and principles of the present invention.
Claims (9)
1. The self-adaptive regulation and control method for the variable-working-condition reciprocating compressor is characterized by comprising the following steps of:
the first step: matching three-dimensional efficient running spaces of the compressor in different capacity intervals;
in the first step: firstly, dividing the current productivity working condition into a plurality of intervals, and collecting wellhead pressure, compressor inlet pressure, compressor productivity, compressor current voltage and ambient temperature in real time;
according to the fluctuation condition of the actual working condition, a mathematical model is established, and the three-dimensional efficient operation space of the compressor under the current working condition is calculated in a matching way, wherein the three-dimensional efficient operation space is a three-dimensional space, and the three-dimensional efficient operation space is formed by combining the capacity of the compressor as an X axis, the operation power of the compressor as a Y axis and the air inlet pressure of the compressor as a Z axis;
and a second step of: three parameters of the capacity of the compressor, the running power of the compressor and the air inlet pressure of the compressor are matched to a three-dimensional efficient running space through joint control and joint adjustment, and the three-dimensional efficient running space is automatically identified under different working conditions;
and a third step of: in the three-dimensional efficient operation space, the air inlet pressure of the compressor is slowly increased in a sine wave mode, so that the purposes of high productivity and low unit consumption are achieved.
2. The adaptive modulation method of a variable duty reciprocating compressor of claim 1, wherein in the second step: in a certain set capacity interval, the self-adaptive analysis is carried out on the output load and the power factor of the self-adaptive analysis on the voltage, the inlet and outlet parameter configuration, the control mechanism, the maintenance time, the interstage temperature and the machine head temperature rise ratio by analyzing the load profile, and the combination control and the adjustment are carried out on the rotating speed, the torque, the voltage, the current and the magnetic flux of the motor of the compressor, so that the three parameters of the capacity of the compressor, the running power of the compressor and the air inlet pressure of the compressor are automatically matched into the three-dimensional efficient running space.
3. The variable working condition reciprocating compressor self-adaptive adjusting and controlling method according to claim 2, wherein in the third step: the running power of the compressor is reduced by dynamically adjusting the rotating speed, torque, voltage, current and magnetic flux of the motor of the compressor under different working conditions, and the electric power is the lowest on the premise of ensuring that the productivity is not reduced.
4. The self-adaptive regulation and control system of the variable-working-condition reciprocating compressor is characterized by comprising a variable-control intelligent regulation and control device (10), a signal acquisition module (20), a vector control module (30), a compressor PLC control system (40) and a PLC control center (50);
the variable control intelligent regulation device (10) comprises a ternary flow simulation calculation module (101) and a logic control module (102) which are electrically connected, a mathematical model is built through the ternary flow simulation calculation module (101), and a three-dimensional efficient operation space of the compressor under the current working condition is calculated in a matching mode, wherein the three-dimensional efficient operation space is a three-dimensional space, and the variable control intelligent regulation device is formed by combining the capacity of the compressor as an X axis, the operation power of the compressor as a Y axis and the air inlet pressure of the compressor as a Z axis;
three parameters of the capacity of the compressor, the running power of the compressor and the air inlet pressure of the compressor are matched to a three-dimensional efficient running space through a logic control module (102) and compressor joint control joint adjustment;
the signal acquisition module (20) is electrically connected with the three-way flow simulation calculation module (101) so as to acquire the current, voltage, power, productivity and environmental temperature of the compressor motor;
the vector control module (30) is electrically connected with the logic control module (102) to dynamically adjust the rotating speed, torque, voltage, current and magnetic flux of the compressor motor under different working conditions, so that the running power of the compressor is reduced, and the electric power is the lowest on the premise of ensuring that the productivity is not reduced;
the compressor PLC control system (40) is respectively and electrically connected with the three-dimensional flow simulation calculation module (101) and the PLC control center (50) so as to acquire partial real-time data, and the partial real-time data are transmitted to the three-dimensional flow simulation calculation module (101) to calculate three-dimensional efficient operation space of the compressor under different capacity working conditions;
the PLC control center (50) is electrically connected with the PLC control system (40) and the vector control module (30) respectively, so that signals of the vector control module (30) are transmitted to the PLC control center (50).
5. The variable working condition self-adaptive regulation and control system of the reciprocating compressor according to claim 4 is characterized in that the working condition of a gas gathering station is divided into a plurality of sections according to the productivity, a three-dimensional efficient operation space of a current compressor is matched in each section through a three-dimensional flow simulation calculation module (101), the parameter combination of the voltage, the rotating speed, the torque and the magnetic flux of a motor of the compressor is finely controlled and regulated through tracking analysis of various parameters of the gas gathering station, a power distribution system and the compressor system, the compressor inlet pressure is slowly lifted through a logic control module (102) in a sine waveform mode, and finally the productivity, the operation power and the inlet pressure of the compressor are matched to the three-dimensional efficient operation space under the specified working condition;
and then according to the vibration, the oil temperature, the exhaust temperature and the environmental temperature of the compressor, the vector control module (30) is used for further carrying out fine control and adjustment on the parameter combination of the voltage, the rotating speed, the torque and the magnetic flux of the motor of the compressor in the three-dimensional efficient operation space after comprehensive analysis, so that the operation power of the compressor is reduced, and the electric power is the lowest on the premise of not reducing the productivity.
6. The adaptive regulation and control system of a variable-duty reciprocating compressor according to claim 4, wherein the three-dimensional flow simulation calculation module (101) comprises a sensor assembly (1011), a signal conditioning conversion circuit (1012), a conversion element (1013) and a microprocessor (1014) which are electrically connected in sequence, the sensor assembly (1011) comprises a plurality of sensors for respectively measuring the rotation speed, torque, rotation angle, magnetic flux, flow and pressure of the compressor motor (100), the sensor assembly is used for respectively measuring the corresponding sensors, converting the data of the sensing result, and simultaneously interacting with the logic control module (102), the three-dimensional flow calculation analysis of the NASA TN D-7344 is used for analog analysis calculation, the optimal design program can analyze and verify the calculation result and automatically adjust the rotor position and the rotor torque, the calculation of' good optimization is automatically performed, a new operation curve is obtained through a large number of loop iterations, and finally, the working condition data for the actual operation high-efficiency curve is established.
7. The variable duty reciprocating compressor adaptive modulation system of claim 6, wherein the signal conditioning switching circuit (1012) is configured to divert or amplify signals from the sensor assembly (1011) to make them more suitable for further transmission and processing.
8. The adaptive modulation and control system of a variable duty reciprocating compressor according to claim 6, wherein the conversion element (1013) is configured to perform data conversion on the sensing result, take the output of the sensor assembly (1011) as an input, convert the input signal into a circuit parameter, and the microprocessor (1014) is in data interaction with the logic control module (102), and is connected to the vector control module (30) with the NC1 and NO1 junctions to form a driving adjustment calculation.
9. The variable working condition reciprocating compressor self-adaptive regulation and control system according to claim 4, wherein the logic control module (102) is used for matching the capacity, the running power and the air inlet pressure of the compressor into a three-dimensional efficient running space in a specified mode when the capacity working condition is fixed to a specified range, and can automatically identify the three-dimensional efficient running space under different working conditions.
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