大型往复式压缩机轴系动力学特性研究
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摘要
往复式压缩机是石油化工行业关键的动力设备。曲轴作为往复式压缩机的关键核心部件,在机组运转过程中承受着随时间进行周期性变化的交变载荷。正是这种交变载荷的作用,使得曲轴产生弯曲、扭转以及弯扭组合等各种振动。曲轴高速旋转产生的振动是引发压缩机机组共振的重要因素,轴系动力学特性不仅影响着曲轴的使用寿命,而且直接关系到机组的安全性和稳定性,对压缩机其他零部件的寿命和性能也将产生很大的负面影响,尤其对连杆瓦、主轴瓦以及气阀等零部件的影响最为明显。随着化工流程的不断扩大,往复式压缩机向大型多列方向发展,曲轴列数的增加,轴系扭转固有频率减小,轴系共振现象频繁发生,轴系动力学问题已成为往复式压缩机向多列、高转速方向发展的技术瓶颈,大型往复式压缩机轴系动力学分析与研究已受到广大科技工作者的高度重视。
本文针对6M50型往复式压缩机运转过程中以及后续产品改进过程中出现的断轴、烧连杆瓦问题,对大型往复式压缩机轴系动力学进行分析与研究。利用德国博尔齐格(BORSIG)公司BX系列压缩机专用KOL热-动力分析平台,获得连杆传递到曲柄销上的切向力、法向力、谐波载荷以及电动机转子承受的扭转力矩等外部激励载荷。采用有限单元法对大型往复式压缩机曲轴进行静力学分析,并分别对曲轴进行了静强度和疲劳强度校核。提出了在往复式压缩机轴系中施加活塞、连杆、十字头以及驱动电机转子等惯性质量的基本方法,建立考虑各种惯性质量的轴系动力学分析模型。采用有限单元法对轴系进行模态分析,并对模态分析结果进行对比研究,以确定轴系可能出现扭转共振的阶次及对应的转速。提出了谐频载荷的基本概念,将曲轴各次谐波载荷划分成谐频载荷和稳态载荷,简化了轴系谐响应的分析过程。在轴系模态分析基础上,施加谐频载荷对轴系进行谐响应分析,施加时间历程载荷对轴系进行瞬态响应分析,利用谐响应分析结果判别各谐次载荷对轴系共振的影响效果；利用轴系瞬态响应分析结果分别对轴系进行静强度和疲劳强度校核,结合曲轴静力学分析结果对轴系进行附加应力分析；最后,利用本文提出来的轴系动力学分析方法对存在问题的轴系进行了结构改进和试验研究。
对往复式压缩机轴系动力学特性进行研究的结果发现：原设计轴系断轴是静强度问题,加粗后轴系断轴与烧连杆瓦是轴系扭转共振所致；在大型往复式压缩机轴系各种弯曲、扭转以及弯扭组合等多种振动模态中,只有扭转可能出现共振现象,轴系的各种弯曲、横向共振在轴系动力学分析中不需要考虑；大型往复式压缩机轴系动力学主要考虑—阶扭转共振固有频率,二阶及以上扭转模态可忽略不计；轴系节点振幅和应力出现“拍”是曲轴载荷与惯性载荷共同作用的结果；减小压缩机行程可以改善轴系扭转动力学特性；改进的6M50型往复式压缩机样机运转试验结果与理论分析吻合,进一步验证了该分析方法的可行性。
本文提出的分析方法能够完成大型往复式压缩机轴系静力学分析、模态分析、谐响应分析以及瞬态响应分析。在各种往复式压缩机轴系振动与强度校核中,首先进行曲轴静力学分析,当静力学分析满足强度要求后,才有必要进行轴系动力学分析。按API618轴系共振判断准则,根据轴系模态分析结果确定轴系的共振状态,如果轴系转速脱离共振区,静力学分析结果就能满足设计要求；如果轴系转速处于共振区,需要对轴系进行动态响应分析。该研究成果的应用,不仅可以对现有往复式压缩机轴系进行结构优化、故障诊断及分析处理,还可以为新型多列往复式压缩机的开发与研制提供动力学理论分析依据。
Reciprocating compressor, as power equipment, plays a key role in petrochemical industry. The crankshaft forced by complex alternating load, with its magnitude and orientation, is key component of reciprocating compressor and occurs various vibrations, such as bending, torsioning, and combined bending and torsional vibrations. The crankshaft's vibration caused by high-speed rotation positions a key factor to trigger the vibration of compressors. crankshaft's dynamics characteristics affect not only the lifetime of crankshaft, but also safety and stability of compressor units, all of which has a negative impact on other components'lifetime and performance. The most obvious examples are crank bearing, main shaft bearing and gas valve. With the developing of chemical processes, the reciprocating compressor is now going towards the tendency of large-scale and multi crank. However, the increase of crank of crankshafts causes the decrease of torsional frequency of crankshaft. As a result, torsional resonance of crankshaft happens with increasing frequency. The torsional vibration has been a technical software for reciprocating compressor to develop towards multi crank and highly rotational speed. Also, research on shaft dynamics analysis of large-scale reciprocating compressor has received more and more great attention from scientists and technicians.
Based on frequent fracture of crankshaft and crank bearing scuffing happened during development process of China's first 6M50 type reciprocating compressor and its subsequent products, the article conducts analysis and studies on the dynamics characteristics of large-scale reciprocating compressor crankshaft.The principal excitation loads, such as tangential force, normal force, harmonic load on crank pin from connecting rod and torsional moment borne by motor rotor, are obtained according to KOL heat-power analysis platform introduced from German BORSIG for special use of BX series compressors. Finite element method of statics is employed to make crankshaft statics analysis of large-scale reciprocating compressors and the static and fatigue strength of crankshaft under changing load are examined. Basic method that exerts inertial mass of piston, connecting rod, crosshead and drive motor rotor is forwarded to build dynamics analysis model which considers all inertial mass. Modal analysis of crankshafts is analyzed by dynamic finite element method (FEM). Basic concept of harmonic frequency load is presented so that basic methods to separate harmonic frequency load and steady-state load from harmonic load of crankshaft is proposed, which greatly simplifies the process to analyze harmonic response to shafting. Harmonic Response analysis of crankshafts forced harmonic frequency load is analyzed on basis of modal analysis. Transient dynamic analysis of crankshafts forced time history load is analyzed on basis of modal analysis, and the static and fatigue strength of crankshaft under changing load are examined. Add stress analysis of crankshafts is analyzed on basis the results of statics and transient dynamic analysis. Experimental study and structure optimization for those fracture'crankshafts are carried out by the analysis method, which is provided in this paper.
The results obtained show that:the static strength problem can be identified as a result of checking of static and fatigue strength for the original crankshafts and the torsional resonance problem for the magnified crankshafts; Torsional resonance is only possible form of resonance, which can be clear that various kinds of bending and transverse modal don't have to be considered. The 2nd and more order torsional resonance can be negligible, which provides theoretical foundation to analyze and study only on 1st torsional natural frequency of large reciprocating compressors. After transient response analysis on crankshafts of different rotational speeds, it is further verified the origin of "beat" is an integration of the same vibration forms resulted from crankshaft load and inertial load. Through the research that compressor parameters affect on shafting dynamic performance, it turns out the smaller compressor stroke is, the better dynamic performance it will be. By structure optimization and tests contrast on 6M50 compressors with different main shaft diameters, test results are identical with theoretical analysis, proving the feasibility of that analytical method.
The analysis methods of this paper can be applied to static, modal, harmonic response and transient response analysis of crankshafts for reciprocating compressors. Crankshaft static analysis has to be performed first during dynamic performance analysis and strength check for various reciprocating compressors. Modal analysis can only be executed once static analysis results meet the requirements. In accordance with standard of resonant vibration of API618, crankshaft resonance conditions can be determined by modal analysis results of crankshafts. Static analysis results can meet the design requirements if shafting speed is deviated from resonant zone. Dynamic response analysis for shafting is needed if shafting speed is within resonant zone. The application of research results can not only optimize the crankshaft structure of current reciprocating compressors, but also diagnose and handle faults for large reciprocating compressors, providing analysis basis on dynamics theory for the research and development of new multi crank reciprocating compressors.
本文针对6M50型往复式压缩机运转过程中以及后续产品改进过程中出现的断轴、烧连杆瓦问题,对大型往复式压缩机轴系动力学进行分析与研究。利用德国博尔齐格(BORSIG)公司BX系列压缩机专用KOL热-动力分析平台,获得连杆传递到曲柄销上的切向力、法向力、谐波载荷以及电动机转子承受的扭转力矩等外部激励载荷。采用有限单元法对大型往复式压缩机曲轴进行静力学分析,并分别对曲轴进行了静强度和疲劳强度校核。提出了在往复式压缩机轴系中施加活塞、连杆、十字头以及驱动电机转子等惯性质量的基本方法,建立考虑各种惯性质量的轴系动力学分析模型。采用有限单元法对轴系进行模态分析,并对模态分析结果进行对比研究,以确定轴系可能出现扭转共振的阶次及对应的转速。提出了谐频载荷的基本概念,将曲轴各次谐波载荷划分成谐频载荷和稳态载荷,简化了轴系谐响应的分析过程。在轴系模态分析基础上,施加谐频载荷对轴系进行谐响应分析,施加时间历程载荷对轴系进行瞬态响应分析,利用谐响应分析结果判别各谐次载荷对轴系共振的影响效果；利用轴系瞬态响应分析结果分别对轴系进行静强度和疲劳强度校核,结合曲轴静力学分析结果对轴系进行附加应力分析；最后,利用本文提出来的轴系动力学分析方法对存在问题的轴系进行了结构改进和试验研究。
对往复式压缩机轴系动力学特性进行研究的结果发现：原设计轴系断轴是静强度问题,加粗后轴系断轴与烧连杆瓦是轴系扭转共振所致；在大型往复式压缩机轴系各种弯曲、扭转以及弯扭组合等多种振动模态中,只有扭转可能出现共振现象,轴系的各种弯曲、横向共振在轴系动力学分析中不需要考虑；大型往复式压缩机轴系动力学主要考虑—阶扭转共振固有频率,二阶及以上扭转模态可忽略不计；轴系节点振幅和应力出现“拍”是曲轴载荷与惯性载荷共同作用的结果；减小压缩机行程可以改善轴系扭转动力学特性；改进的6M50型往复式压缩机样机运转试验结果与理论分析吻合,进一步验证了该分析方法的可行性。
本文提出的分析方法能够完成大型往复式压缩机轴系静力学分析、模态分析、谐响应分析以及瞬态响应分析。在各种往复式压缩机轴系振动与强度校核中,首先进行曲轴静力学分析,当静力学分析满足强度要求后,才有必要进行轴系动力学分析。按API618轴系共振判断准则,根据轴系模态分析结果确定轴系的共振状态,如果轴系转速脱离共振区,静力学分析结果就能满足设计要求；如果轴系转速处于共振区,需要对轴系进行动态响应分析。该研究成果的应用,不仅可以对现有往复式压缩机轴系进行结构优化、故障诊断及分析处理,还可以为新型多列往复式压缩机的开发与研制提供动力学理论分析依据。
Reciprocating compressor, as power equipment, plays a key role in petrochemical industry. The crankshaft forced by complex alternating load, with its magnitude and orientation, is key component of reciprocating compressor and occurs various vibrations, such as bending, torsioning, and combined bending and torsional vibrations. The crankshaft's vibration caused by high-speed rotation positions a key factor to trigger the vibration of compressors. crankshaft's dynamics characteristics affect not only the lifetime of crankshaft, but also safety and stability of compressor units, all of which has a negative impact on other components'lifetime and performance. The most obvious examples are crank bearing, main shaft bearing and gas valve. With the developing of chemical processes, the reciprocating compressor is now going towards the tendency of large-scale and multi crank. However, the increase of crank of crankshafts causes the decrease of torsional frequency of crankshaft. As a result, torsional resonance of crankshaft happens with increasing frequency. The torsional vibration has been a technical software for reciprocating compressor to develop towards multi crank and highly rotational speed. Also, research on shaft dynamics analysis of large-scale reciprocating compressor has received more and more great attention from scientists and technicians.
Based on frequent fracture of crankshaft and crank bearing scuffing happened during development process of China's first 6M50 type reciprocating compressor and its subsequent products, the article conducts analysis and studies on the dynamics characteristics of large-scale reciprocating compressor crankshaft.The principal excitation loads, such as tangential force, normal force, harmonic load on crank pin from connecting rod and torsional moment borne by motor rotor, are obtained according to KOL heat-power analysis platform introduced from German BORSIG for special use of BX series compressors. Finite element method of statics is employed to make crankshaft statics analysis of large-scale reciprocating compressors and the static and fatigue strength of crankshaft under changing load are examined. Basic method that exerts inertial mass of piston, connecting rod, crosshead and drive motor rotor is forwarded to build dynamics analysis model which considers all inertial mass. Modal analysis of crankshafts is analyzed by dynamic finite element method (FEM). Basic concept of harmonic frequency load is presented so that basic methods to separate harmonic frequency load and steady-state load from harmonic load of crankshaft is proposed, which greatly simplifies the process to analyze harmonic response to shafting. Harmonic Response analysis of crankshafts forced harmonic frequency load is analyzed on basis of modal analysis. Transient dynamic analysis of crankshafts forced time history load is analyzed on basis of modal analysis, and the static and fatigue strength of crankshaft under changing load are examined. Add stress analysis of crankshafts is analyzed on basis the results of statics and transient dynamic analysis. Experimental study and structure optimization for those fracture'crankshafts are carried out by the analysis method, which is provided in this paper.
The results obtained show that:the static strength problem can be identified as a result of checking of static and fatigue strength for the original crankshafts and the torsional resonance problem for the magnified crankshafts; Torsional resonance is only possible form of resonance, which can be clear that various kinds of bending and transverse modal don't have to be considered. The 2nd and more order torsional resonance can be negligible, which provides theoretical foundation to analyze and study only on 1st torsional natural frequency of large reciprocating compressors. After transient response analysis on crankshafts of different rotational speeds, it is further verified the origin of "beat" is an integration of the same vibration forms resulted from crankshaft load and inertial load. Through the research that compressor parameters affect on shafting dynamic performance, it turns out the smaller compressor stroke is, the better dynamic performance it will be. By structure optimization and tests contrast on 6M50 compressors with different main shaft diameters, test results are identical with theoretical analysis, proving the feasibility of that analytical method.
The analysis methods of this paper can be applied to static, modal, harmonic response and transient response analysis of crankshafts for reciprocating compressors. Crankshaft static analysis has to be performed first during dynamic performance analysis and strength check for various reciprocating compressors. Modal analysis can only be executed once static analysis results meet the requirements. In accordance with standard of resonant vibration of API618, crankshaft resonance conditions can be determined by modal analysis results of crankshafts. Static analysis results can meet the design requirements if shafting speed is deviated from resonant zone. Dynamic response analysis for shafting is needed if shafting speed is within resonant zone. The application of research results can not only optimize the crankshaft structure of current reciprocating compressors, but also diagnose and handle faults for large reciprocating compressors, providing analysis basis on dynamics theory for the research and development of new multi crank reciprocating compressors.
引文
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