往复压缩机管路气流脉动分析与消减优化

doi:10.16085/j.issn.1000-6613.2022-2300

摘要/Abstract

摘要：

往复压缩机周期性吸排气的特性，易导致管路脉动幅值超标，管路安全性降低。因此，本文以撬装式往复压缩机组压力变化较大的二级压缩排气管路为研究对象，采用数值模拟的方法，开展了管路气流脉动特性研究。研究表明：气缸动态压缩过程中，气阀启闭导致二级压缩排气管路压力波动较大，管路压力脉动幅值超过API 618标准。同时，开展了二级排气管路振动测试试验，验证了仿真方法和结果的准确性。针对二级排气管路气流脉动幅值超标的问题，分析了滤波管对管路气流脉动幅值的影响，并基于正交试验，开展了管路气流脉动幅值消减优化研究。结果表明：优化后管路最大压力脉动幅值为37.02kPa，相比于优化前降低了38.36%，管路安全指数提升了80.4%，降低了管路发生破坏的风险，提高了往复压缩机组的安全性和稳定性。

关键词: 撬装往复压缩机, 气流脉动, 管路振动测试, 滤波管, 脉动消减

Abstract:

The safety of the pipeline is decreased by the periodic suction and discharge features of the reciprocating compressor, which are easily responsible for pipeline pulsation amplitudes that are too high. As a result, this research studied the secondary compression discharge line of a skid-mounted reciprocating compressor set with substantial pressure variations, employing numerical simulation methods to investigate pipeline airflow pulsation characteristics. According to research, the cylinder dynamic compression process, valve opening and shutting caused secondary compression exhaust pressure variations, and pipeline pressure pulsation amplitude exceeded the API 618 requirement. The secondary exhaust pipe’s vibration test was conducted concurrently to ensure the validity of the modeling method and findings. In order to solve the issue of the secondary exhaust pipe’s airflow pulsation amplitude exceeding the standard, the influence of the filter pipe on the pipe’s airflow pulsation amplitude was examined, and an optimization study was conducted based on the orthogonal test to reduce the pipe’s airflow pulsation amplitude. According to the results, the maximum pressure pulsation of the optimized pipeline was 37.02kPa, 38.36% less than that prior to optimization, and the pipeline safety index was 80.4% higher, which lowered the risk of pipeline damage and increased the safety and stability of the reciprocating compressor set.

Key words: skid-mounted reciprocating compressor, airflow pulsation, pipeline vibration test, filter tube, pulsation abatement

中图分类号:

TQ055.8

李琴, 母德全, 张克海, 黄志强, 王杰, 王硕. 往复压缩机管路气流脉动分析与消减优化[J]. 化工进展, 2023, 42(11): 5612-5621.

LI Qin, MU Dequan, ZHANG Kehai, HUANG Zhiqiang, WANG Jie, WANG Shuo. Investigation and optimization of airflow pulsation reduction in the pipeline of a reciprocating compressor[J]. Chemical Industry and Engineering Progress, 2023, 42(11): 5612-5621.

图/表 22

图1 往复式压缩机组及现场实际工况参数

表1 往复压缩机参数

活塞行程/m	气阀升程/m	压缩机转速/r·min^-1
0.0889	0.00433	1490

图2 往复压缩机二级排气管路模型

表2 二级压缩排气管路出口压力与压降的网格无关性检验

网格数量	压降/kPa
11643896	9.53
17956443	9.77
24983287	10.51
28322126	10.64
31845267	10.67
最大误差/%	7.6

图3 计算域网格

表3 介质组分表（体积分数）

气体	占比/%
甲烷	98.683
乙烷	0.542
二氧化碳	0.393
氮气	0.348
氦气	0.02
丙烷	0.011
氢气	0.003

图4 二级压缩气缸进气压力随时间变化曲线

图5 往复压缩机气缸动态压缩过程分析

图6 往复压缩机二级排气管路压力云图

表4 往复压缩机二级排气管路最大脉动比值系数K及脉动超标率

监测点	最大气流脉动幅值/kPa	最大脉动比值系数	超标率/%
1	54.68	1.58	57.8
2	49.86	1.25	24.5
3	36.55	1.31	30.6
4	64.39	1.53	52.5
5	62.02	1.47	46.9

图7 最大脉动比值系数和脉动超标率变化曲线

图8 管路振动测试传感器和振动综合状态分析仪

图9 往复压缩机二级压缩排气管路试验布点

表5 振动试验与仿真计算的气流脉动峰值频率对比

测点	振动试验峰值频率/Hz	气流脉动峰值频率/Hz	误差/%
1	49.96	49.84	0.24
2	50	49.84	0.32
3	50	49.84	0.32

图10 二级排气管路测点2振动位移频谱和脉动频谱

图11 缓冲罐内置滤波管安装形式

图12 往复压缩机二级排气缓冲罐某时刻内部压力变化云图

图13 最大压力脉动比值系数和最大压降比值系数变化曲线

表6 往复压缩机二级排气管路气流脉动优化正交试验方案与结果

方案	x₁/m	x₂/m	r	最大压力脉动比值系数	最大压降/kPa
1	0.125	0.175	0.55	0.43	59.246
2	0.125	0.200	0.6	0.61	51.338
3	0.125	0.225	0.65	0.73	45.659
4	0.150	0.175	0.6	0.62	50.86
5	0.150	0.200	0.65	0.74	46.003
6	0.150	0.225	0.55	0.44	60.446
7	0.175	0.175	0.65	0.74	46.086
8	0.175	0.200	0.55	0.43	61.101
9	0.175	0.225	0.6	0.62	53.111

图14 正交试验方案结果

图15 优化前后往复压缩机二级排气管路气流脉动结果对比分析

表7 优化前后往复压缩机二级排气管路压力脉动消减率和安全指数提升率

监测点	优化前压力脉动幅值/kPa	优化前脉动比值系数	优化后压力脉动幅值/kPa	优化后脉动比值系数	脉动消减率/%	安全指数提升率/%
1	54.68	1.58	29.11	0.84	46.8	74
2	49.86	1.25	30.45	0.51	38.9	74
3	43.14	1.31	36.42	0.61	15.6	70
4	64.39	1.53	37.02	0.62	42.5	91
5	62.02	1.47	32.24	0.54	48.02	122

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