Process and device for monitoring vibrational excitation of an axial compressor

• US 5,541,857 A
• Filed: 05/20/1994
• Issued: 07/30/1996
• Est. Priority Date: 08/10/1992
• Status: Expired due to Fees

• Current Assignee: Dow Deutschland Inc (Dow, Inc.)
• Original Assignee: Dow Deutschland Inc (Dow, Inc.)
• Inventors: Honen, Herwart, Walter, Hilger A., Gallus, Heinz E.
• Primary Examiner(s): Voeltz, Emanuel T.
• Assistant Examiner(s): Stamber, Eric W.
• Application Number:
  US08/246,886
• Time in Patent Office: 802 Days
• Field of Search: 364/558, 364/431.02, 364/505, 364/508, 364/494, 73/116, 73/660, 417/20, 417/43, 415/26, 60/39, 60/29
• US Class Current: 700/280
• CPC Class Codes: F04D 27/02 Surge control surge detection F04D27/001
• CPC Class Codes: G01H 1/006 of the rotor of turbo machines

Abstract

A process and a computer implemented system for monitoring vibration in the blades of the rotor and stator of an axial compressor through measurement of pressure fluctuations of the dynamic pressure field in the region of the compressor housing in at least one stage of the compressor by means of at least one pressure sensing device sensitive to differential pressure fluctations affecting the blades at the characteristic frequency of the stage. The process and computer implemented system also assist in the control of the compressor by forwarding a status respecting rotor and stator mechanical vibration to the control unit.

Claims

1. Process for controlling mechanical vibrations of rotor blades and stator blades in an axial compressor, said axial compressor comprising:

a rotor,

a housing,

an inlet where, in operation, gas enters at a first pressure, and

an outlet where, in operation, gas exits at a second pressure higher than said first pressure,

said rotor being rotatably mounted within said housing for rotation about a rotational axis,

said axial compressor further comprising a plurality of axial compressor stages, each said axial compressor stage comprising;

a row of said rotor blades mounted on said rotor and being arranged one following the other in a circumferential direction with respect to said rotational axis, and

a row of said stator blades mounted on said housing and being arranged one following the other in a circumferential direction with respect to said rotational axis,

each said axial compressor stage having, in operation, a dynamic pressure field surrounding each said rotor in the region of said housing,

each said axial compressor stage further having, in operation, a characteristic frequency defined as the product of the number of rotor blades mounted in said row of rotor blades and the rotational speed of said rotor,

each said axial compressor stage further having, in operation, a primary rotor stage set of a plurality of primary pressure fluctuation frequencies defined at the rotational speed of said rotor wherein each primary pressure fluctuation frequency is respectively associated with the dynamic pressure influence of each said row of rotor blades in said axial compressor upon the dynamic pressure field of said axial compressor stage,

each said axial compressor stage further having, in operation, a secondary beat set of secondary beat fluctuation frequencies and associated respective secondary threshold values defined at the rotational speed of said rotor wherein each secondary beat fluctuation frequency in the secondary beat set is respectively associated with the difference value of a unique combination of two said primary pressure fluctuation frequencies in the primary rotor stage set,

each said axial compressor stage further having, in operation, a critical frequency set of at least one critical frequency wherein each critical frequency has an associated respective critical frequency threshold value and predetermined frequency range,

said process comprising the following steps;

setting the rotational speed of said rotor to a known value;

selecting a useful primary set of critical frequencies from the critical frequency set and selecting a useful secondary set of secondary beat fluctuation frequencies from the secondary beat set;

measuring the pressure fluctuations of at least one said dynamic pressure field with a pressure sensing means responsive at the characteristic frequency for the known value of rotational speed and generating thereby at least one sensor signal;

deriving a first plurality of frequency components from each sensor signal, wherein each frequency component has an associated frequency attribute and amplitude attribute and wherein each frequency component is derived at frequencies within a critical frequency range so that the first plurality of frequency components has at least one value respective to each critical frequency range in said useful primary set;

further deriving a secondary plurality of frequency components from each sensor signal, wherein each frequency component has a associated frequency attribute and amplitude attribute and wherein each frequency component is derived at one of the secondary beat fluctuation frequencies so that the second plurality of frequency components has a value respective to each secondary beat fluctuation frequency in said useful secondary set;

defining the status respecting mechanical vibrations of said rotor blades and said stator blades by comparing each amplitude attribute from each frequency component respective to each critical frequency in said useful primary set with said associated critical frequency threshold value respective to the same critical frequency and comparing each amplitude attribute from each frequency component respective to each secondary beat fluctuation frequency in said useful secondary set with said associated secondary threshold value respective to the same secondary beat fluctuation frequency to, in a first case, define a hazardous mechanical vibration status if any such comparing operation shows an amplitude attribute in excess of a respective threshold value and, in a second case, define an acceptable mechanical vibration status if no such comparing operation shows an amplitude attribute in excess of its respective threshold value for all frequency components respective to the critical frequencies in said useful primary set and for all frequency components respective to the secondary beat fluctuation frequencies in said useful secondary set; and

using said hazardous mechanical vibration status and said acceptable mechanical vibration status in controlling said axial compressor.

2. Process according to claim 1, wherein at least one said critical frequency is defined as a torsional vibration basic frequency of said rotor and stator blades.

3. Process according to claim 2, wherein at least one said critical frequency is defined as a higher harmonic of said torsional vibration basic frequency of said rotor and stator blades.

4. Process according to claim 1, wherein at least one said critical frequency is defined as a bending vibration basic frequency of said rotor and stator blades.

5. Process according to claim 4, wherein at least one said critical frequency is defined as a higher harmonic of said bending vibration basic frequency of said rotor and stator blades.

6. Process according to claim 1, wherein at least one mechanical vibration sensing device is mounted at said housing detecting a mechanical vibration excitation of said housing and wherein a second status change signal is generated, indicative of an excess excitation status of said housing in case of said mechanical vibration sensing device detecting an excess vibrational excitation status of said housing, said second status change signal also being used for controlling said axial compressor.

7. Process according to claim 6, wherein said at least one mechanical vibration sensing device is located, in a first case, near said inlet and, in a second case, near said outlet.

8. Process according to claim 1, wherein said pressure sensing means comprises a piezoresistive pressure sensor.

9. Process for measuring mechanical vibrations of rotor blades and stator blades in an axial compressor, said axial compressor comprising:

a rotor,

a housing,

an inlet where, in operation, gas enters at a first pressure, and

an outlet where, in operation, gas exits at a second pressure higher than said first pressure,

said rotor being rotatably mounted within said housing for rotation about a rotational axis,

said axial compressor further comprising at least one axial compressor stage, each said axial compressor stage comprising;

a row of said rotor blades mounted on said rotor and being arranged one following the other in a circumferential direction with respect to said rotational axis, and

a row of stator blades mounted on said housing and being arranged one following the other in a circumferential direction with respect to said rotational axis,

each said axial compressor stage having, in operation, a dynamic pressure field surrounding each said rotor in the region of said housing,

each said axial compressor stage further having, in operation, a characteristic frequency defined as the product of the number of rotor blades mounted in said row of rotor blades and the rotational speed of said rotor,

said process comprising the following steps;

setting the rotational speed of said rotor to a known value;

measuring the pressure fluctuations of at least one said dynamic pressure field with a pressure sensing means responsive at the characteristic frequency for the known value of rotational speed and generating thereby at least one sensor signal;

deriving a plurality of frequency components from each sensor signal, wherein each frequency component has an associated frequency attribute and an associated amplitude attribute as a value pair; and

combining the plurality of associated frequency attribute and associated amplitude attribute value pairs respective to said plurality of frequency components to establish a set of associated frequency attribute and associated amplitude attribute value pairs characterizing the measurement of mechanical vibrations of said rotor and stator blades at said known value of rotational speed.

10. Process according to claim 9, wherein said pressure sensing means is connected to said housing between the rotor blades and the stator blades of one of said axial compressor stages.

11. Process according to claim 9, wherein said plurality of frequency components are derived by fast Fourier transformation (FFT).

12. Process according to claim 9, wherein said plurality of frequency components are derived by fast Hartley transformation (FHT).

13. Process according to claim 9, wherein said pressure sensing means comprises a piezoelectric pressure sensor.

14. Process according to claim 9, wherein each said frequency attribute is between 0 Hz-20000 Hz.

15. Process according to claim 14, wherein each said frequency attribute is between 100 HZ-2000 Hz.

16. Process according to claim 9, wherein said pressure sensing means comprises a piezoresistive pressure sensor.

17. Computer implemented system for measuring mechanical vibrations of rotor blades and stator blades in an axial compressor, said axial compressor comprising:

a rotor,

a housing,

an inlet where, in operation, gas enters at a first pressure, and

an outlet where, in operation, gas exits at a second pressure higher than said first pressure,

said rotor being rotatably mounted within said housing for rotation about a rotational axis,

said axial compressor further comprising at least one axial compressor stage, each said axial compressor stage comprising;

a row of said rotor blades mounted on said rotor and being arranged one following the other in a circumferential direction with respect to said rotational axis, and

a row of said stator blades mounted on said housing and being arranged one following the other in a circumferential direction with respect to said rotational axis,

each said axial compressor stage having, in operation, an associated dynamic pressure field surrounding each said rotor in the region of said housing,

each said axial compressor stage further having, in operation, a characteristic frequency defined as the product of the number of rotor blades mounted in said row of rotor blades and the rotational speed of said rotor,

said computer implemented system comprising;

a compressor control unit for setting the rotational speed of said rotor to a known value;

pressure sensing means responsive at said characteristic frequency for measuring the pressure fluctuations of at least one said dynamic pressure field with for the known value of rotational speed and generating thereby at least one sensor signal; and

an evaluation unit for deriving a plurality of frequency components from each sensor signal, wherein each frequency component has an associated frequency attribute and an associated amplitude attribute as a value pair, and for combining the plurality of associated frequency attribute and associated amplitude attribute value pairs respective to said plurality of frequency components to establish a set of associated frequency attribute and associated amplitude attribute value pairs characterizing the measurement of mechanical vibrations of said rotor and stator blades at said known value of rotational speed.

18. Computer implemented system according to claim 17, wherein said pressure sensing means is connected to said housing between the rotor blades and the stator blades of one of said axial compressor stages.

19. Computer implemented system according to claim 17, wherein said pressure sensing means comprises a piezoelectric pressure sensor.

20. Computer implemented system according to claim 17, wherein said evaluation unit comprises a fast Fourier transformation unit.

21. Computer implemented system according to claim 17, wherein said evaluation unit comprises a fast Hartley transformation unit.

22. Computer implemented system according to claim 17, wherein at least one mechanical vibration sensing device is mounted at said housing.

23. Computer implemented system according to claim 22, wherein said at least one mechanical vibration sensing device is located, in a first case, near said inlet and, in a second case, near said outlet.

24. Computer implemented system according to claim 22, wherein a signal evaluation unit is connected to said mechanical vibration sensing device, generating a second status change signal in case of housing being in an excess vibrational excitation status.

25. Computer implemented system according to claim 24, wherein a status indicating unit is provided, receiving said second status change signal and indicating the respective operational status of said axial compressor.

26. Computer implemented system according to claim 17, wherein said pressure sensing means comprises a piezoresistive pressure sensor.

27. Computer implemented system for controlling mechanical vibrations of rotor blades and stator blades in an axial compressor, said axial compressor comprising:

a rotor,

a housing,

an inlet where, in operation, gas enters at a first pressure, and

an outlet where, in operation, gas exits at a second pressure higher than said first pressure,

said rotor being rotatably mounted within said housing for rotation about a rotational axis,

said axial compressor further comprising at least one axial compressor stage, each said axial compressor stage comprising;

a row of said rotor blades mounted on said rotor and being arranged one following the other in a circumferential direction with respect to said rotational axis, and

a row of said stator blades mounted on said housing and being arranged one following the other in a circumferential direction with respect to said rotational axis,

each said axial compressor stage having, in operation, an associated dynamic pressure field surrounding each said rotor in the region of said housing,

each said axial compressor stage further having, in operation, a primary rotor stage set of a plurality of primary pressure fluctuation frequencies defined at the rotational speed of said rotor wherein each primary pressure fluctuation frequency is respectively associated with the dynamic pressure influence of each said row of rotor blades in said axial compressor upon the dynamic pressure field of said axial compressor stage,

each said axial compressor stage further having, in operation, a secondary beat set of secondary beat fluctuation frequencies and associated respective secondary threshold values defined at the rotational speed of said rotor wherein each secondary beat fluctuation frequency in the secondary beat set is respectively associated with the difference value of a unique combination of two said primary pressure fluctuation frequencies in the primary rotor stage set,

each said axial compressor stage further having, in operation, a critical frequency set at least one critical frequency wherein each critical frequency has an associated respective critical frequency threshold value and predetermined frequency range,

each axial compressor stage further having, in operation, a characteristic frequency defined as the product of the number of rotor blades mounted in said row of rotor blades and the rotational speed of said rotor,

said computer implemented system comprising;

a compressor control unit for setting the rotational speed of said rotor to a known value;

pressure sensing means responsive at said characteristic frequency for measuring the pressure fluctuations of at least one said dynamic pressure field for the known value of rotational speed and generating thereby at least one sensor signal; and

an evaluation unit, having a useful primary set of critical frequencies from the critical frequency set and a useful secondary set of secondary beat fluctuation frequencies from the secondary beat set, for deriving a first plurality of frequency components from each sensor signal, wherein each frequency component has an associated frequency attribute and amplitude attribute and wherein each frequency component is derived at frequencies within a critical frequency range so that the first plurality of frequency components has at least one value respective to each critical frequency range in said useful primary set, further deriving a second plurality of frequency components from each sensor signal, wherein each frequency component has an associated frequency attribute and an amplitude attribute and wherein each frequency component is derived at one of the secondary beat fluctuation frequencies so that the second plurality of frequency components has a value respective to each secondary beat fluctuation frequency in said useful secondary set, and defining the status respecting mechanical vibrations of said rotor blades and said stator blades by comparing each amplitude attribute from each frequency component respective to each primary pressure fluctuation critical frequency in said useful primary set with said associated critical frequency threshold value respective to the same critical frequency and comparing each amplitude attribute from each frequency component respective to each secondary beat fluctuation frequency in said useful secondary set with said associated secondary threshold value respective to the same secondary beat fluctuation frequency to, in a first case, define a hazardous mechanical vibration status if any such comparing operation shows an amplitude attribute in excess of a respective fluctuation threshold value and, in a second case, define an acceptable mechanical vibration status if no such comparing operation shows an amplitude attribute in excess of its respective fluctuation threshold value for all frequency components respective to the critical frequencies in said useful primary set and for all frequency components respective to the secondary beat fluctuation frequencies in said useful secondary set, and for sending said hazardous mechanical vibration status and said acceptable mechanical vibration status to said compressor control unit for use in controlling said axial compressor.

28. Computer implemented system according to claim 27, wherein said pressure sensing means is connected to said housing between the rotor blades and the stator blades of one of said axial compressor stages.

29. Computer implemented system according to claim 27, wherein said pressure sensing means comprises a piezoelectric pressure sensor.

30. Computer implemented system according to claim 27, wherein said evaluation unit comprises a fast Fourier transformation unit.

31. Computer implemented system according to claim 27, wherein said evaluation unit comprises a fast Hartley transformation unit.

32. Computer implemented system according to claim 27, wherein at least one mechanical vibration sensing device is mounted at said housing.

33. Computer implemented system according to claim 32, wherein said at least one mechanical vibration sensing device is located, in a first case, near said inlet and, in a second case, near said outlet.

34. Computer implemented system according to claim 32, wherein a signal evaluation unit is connected to said mechanical vibration sensing device, generating a second status change signal in case of said housing being in an excess vibrational excitation status.

35. Computer implemented system according to claim 34, wherein a status indicating unit is provided, receiving said second status change signal and indicating the respective operational status of said axial compressor.

36. Computer implemented system according to claim 35, wherein a second controlling unit is provided being supplied with said second status change signal for operational control of said axial compressor.

37. Computer implemented system according to claim 35, wherein said second status change signal is also used by said compressor control unit for operational control of said axial compressor.

38. Computer implemented system according to claim 27, wherein said pressure sensing means comprises a piezoresistive pressure sensor.

39. Computer implemented system according to claim 27, wherein at least one said critical frequency is defined as a torsional vibration basic frequency of said rotor and stator blades.

40. Computer implemented system according to claim 39, wherein at least one said critical frequency is defined as a higher harmonic of said torsional vibration basic frequency of said rotor and stator blades.

41. Computer implemented system according to claim 27, wherein at least one said critical frequency is defined as a bending vibration basic frequency of said rotor stator blades.

42. Computer implemented system according to claim 41, wherein at least one said critical frequency is defined as a higher harmonic of said bending vibration basic frequency of said rotor and stator blades.