大流量煤气压力调节阀流固耦合机理及动态特性研究
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摘要
钢厂在生产过程中会产生大量的焦炉和高炉煤气,为了降低钢厂的总体能耗和物耗、减少环境污染,目前许多钢厂开始利用废煤气发电,发展循环经济。但在钢厂循环发电工程中,气体供给量大,对混合煤气的流量要求高达54000Nm3/h以上。在混合煤气的输送管路中采用调节阀进行流量和压力的控制,调节阀公称通径超过200mm,阀内大流量煤气的流动是复杂的非定常三维可压湍流流动,调节阀和混合煤气之间的相互作用是典型的流固耦合问题,这种流固耦合作用会对调节阀及混合煤气流场产生较大影响,因此从流固耦合问题出发对大流量调节阀及其流场的准确的分析是调节阀设计制造和优化的重要前提。本文主要针对发电工程所涉及到的基于流固耦合的大流量调节阀进行了研究。
阐述了流固耦合的基本内涵及研究基础,综述了流固耦合问题的国内外研究概况,介绍了调节阀流固耦合的特点,对在循环发电工程中大流量调节阀流固耦合亟待解决的问题进行了探讨。
针对大流量调节阀建立了流固耦合系统数学模型,采用流固耦合有限元数值计算方法,分析了调节阀结构振动的有限元方程和流体的有限元方程,探讨了大流量调节阀的流固耦合系统基本方程和边界条件；采用Galerkin有限元方法建立了调节阀与混合煤气流固耦合的有限元方程,采用模态分析法进行了动力响应分析；揭示了混合煤气与调节阀的耦合振动机理,并对阀芯进行了动态特性分析；建立了大流量调节阀低频噪声耦合数学模型,从而得到了符合设计要求的耦合振动和噪声的理论分析,为进一步展开流固耦合研究奠定了理论基础。
以大流量混合煤气压力调节阀为研究对象,将数值仿真方法应用于大流量调节阀流固耦合系统的研究中,探讨了流固耦合对大流量调节阀及其流场的影响。揭示了在不同工况下,基于流固耦合的大流量调节阀内混合煤气流场及速度矢量分布,研究了流体旋涡形成的原因、位置及其对调节阀振动产生的影响；探讨了流固耦合对流场压力及压力损失情况、流量及压力控制精度、气流脉动频率的影响。所建立的流固耦合仿真模型对提高模拟的精度以及分析结构的流激振动问题均有实际意义,得到的结果为大流量调节阀的优化设计、噪声研究和试验研究提供了理论指导。
在流固耦合的基础上对大流量调节阀流动特性和噪声进行了研究,得到了不同工况下的流量系数和流阻系数的数值以及噪声水平,绘制出大流量调节阀的实际工作流量特性曲线和流阻特性曲线,采用最小二乘参数辨识的方法建立了流阻系数随开度变化的控制模型,可以为大流量调节阀在较宽工况范围内的流动阻力实现良好的模拟和预测。仿真结果为大流量调节阀优化设计提供了结构和流场参数的量化数据,为理论分析提供了实验基础和理论依据,是降低结构噪声和进行结构优化设计的基础和必要措施。
为使大流量调节阀结构参数和流场参数达到最优,以结构、流场和噪声分析结果为设计准则,提出了大流量调节阀的多学科设计优化框架,实现了涉及到多学科、多物理场的大流量调节阀的建模、分析以及优化的一体化集成。以保证煤气输送能力为前提,在追求减小调节阀噪音的系统优化目标下,减小了调节阀的壁厚和流体速度,满足了雷诺数、应力强度和阀体总质量的要求,即优化后在降低噪音的同时,可以降低产品价格成本、使流动趋于稳定、并且提高调节阀疲劳强度。
分别对基于流固耦合的调节阀阀体和阀芯的动力学特性进行了分析,得到了流体对调节阀阀体和阀芯固有频率及振型的影响,并对其持续动力响应情况进行了探讨,从而能够判断调节阀在受到不同频率的载荷时能否成功地克服共振、疲劳,及其它受迫振动所引起的不良效果。
以调节阀模态分析和结构强度分析为基础,提出了针对大流量调节阀流固耦合系统的结构损伤识别方法,根据阀芯的固有频率的变化来判断损伤裂纹的出现,根据频率变化的多少确定裂纹的大小,从而能够快速有效的诊断出工作环境比较特殊的大流量调节阀内部阀杆的损伤情况,避免煤气泄漏以及阀的动作缓慢或不能正常调节等故障的发生。
通过试验方法,对大流量调节阀动力学模型的有效性和流固耦合数值仿真的可靠性进行了验证。结果表明所建立的调节阀动力学分析模型用于模态的研究具有较高精度,所建立的基于流固耦合的调节阀模型具有较高可靠性,并且对流量和压力的控制精度以及得到的流量系数和流阻系数要比不考虑流固耦合时的精度要高。
从流固耦合问题出发研究大流量混合煤气压力调节阀,提高调节阀的综合性能,实现调节阀在流固耦合作用下的结构优化设计,对于提高我国大流量调节阀的设计研究水平,推动钢厂的燃气-蒸汽联合循环发电工程的进一步发展具有重要的理论意义和工程实践价值。
本课题得到国家863高技术研究发展计划项目“钢厂循环发电工程中大流量煤气的智能优化控制及应用技术(2008AA04Z130)”和高等学校博士学科点专项科研基金资助项目“大流量高频响核电控制阀的多场耦合振动与泄漏自感知机理研究”(20110131110042)的支持。
The steel mills generate vast amounts of blast furnace gas (BFG) and coke-oven gas (COG) in the production. In order to reduce the energy consumption and environmental pollution, some steel mills build combined cycle power plants (CCPP) to make use of the mixed gas. But in this cycle power generation engineering, gas supply is large, and the flow requirement is up to54000Nm3/h. The control valve is used in delivery lineto contril flow and pressure. The nominal size of control valve is more than7.874in. The flow of gas in control valve is complex three-dimensional unsteady turbulence. This is a tiplcal fluid-structure interaction (FSI) problem between control valve and gas, which would produce great influence on control valve and flow. Therefore accurate analysis of control valve and flow about FSI is important premise in control valve designing, manufacting and optimizing. This article mainly aims at high flow control valve based on FSI in generation engineering.
This paper expounds the basic connotation of FSI and research foundation, summarizes the general research situation at home and abroad about FSI. The FSI characteristic of control valve is introduced. The problems of control valve based on FSI that urgently need to be solved in cycle power generation engineering are discussed.
The mathematical model of FSI system of control valve is established. Using the finite element numerical calculation method, the structural vibration equation and fluid eauation are analysized. The basic equation and boundary conditions are discussed. The finite element equation aout FSI is established using Galerkin method and the dynamic response is analysed using modal method. Coupling vibration mechanism is revealed. The dynamics characteristic on valve plug is discussed. Low frequency noise coupling mathematical modal is established, which lays a theoretical foundation on further expansion of FSI.
The numerical simulation method is used to analyse the FSI system of high flow control valve. The effect of FSI on control valve and flow field is discussed. The mixed gas flow field and veloctity vector distribution in control valve at different opening is revealed. The cause and location of the formation of vortex flow are studyed, and the effect on control valve vibration is analysed. The impact of FSI on pressure and flow is discussed. The model of FSI has a practical significance to improve the accuracy of simulation and analyse the problem of flow inducing vibration. The results provide the therretical guide for optimization design, the noise and experimental research.
On the basis of FSI of high flow control valve, flow characteristic and the noise are studied. The flow coefficient and flow resistance coefficient at different opening and noise level are got. And the curves are drawed. The relation of flow resistance coefficient and opening is fitted out using the least square parameter identification method, which realize the valve are good simulation and prediction in a wider condition. The results provide the quantitative data of structure and flow field for optimization design, offer the experimental foundation and theoretical basis for the theoretical analysis. This is basis and necessary measure to reduce noise and optimization.
In order to make the structure parameters of high flow control valve and flow field parameters to achieve optimal, using the structure and fluid analysis results as design criteria, the multidisciplinary design optimization (MDO) framework is present. This realizes the integration which involves modeling, analysis and optimization of multidisciplinary and two field control valve. To ensure that gas transmission capacity as the prerequisite, making reducing valve noise as optimization goals, the wall thickness of valve and fluid velocity are reduced. These meet the Reynolds, stress intensity and body total quality requirements. When reducing noise, the product price cost is lowered, flow tends is made to be stable and fatigue strength of valve plug is improved.
The dynamic characteristics of control valve body and valve plug based on FSI are analyzed. The effect on natural frequency and vibration mode is achieved and the continuous dynamic response is discussed, which can judge the control valve in different frequency overcome resonance, fatigue and other vibration successfully.
Using the analysis of modal and structure strength as the foundation, the structure damage identification method is proposed, which can judge the emergence of crack damage according to the natural frequency and determine how much the size of the crack according to the frequency change. Thus the internal plug damage of control valve in special work environment can be diagnosed fastly and effectively, avoiding the failure of gas leakage and unnormal regulation.
Through the test method, the validity of the dynamic model and the reliability of the numerical simulation method is confirmed. The results show that the model has a high precision. Control accuracy of flow and pressure, flow coefficient and resistance coefficient has high accuracy when considering FSI.
Studying the control vavle based on FSI can improve the comprehensive performance and realize optimization, which has the important theoretical meaning and engineering practical value for improving the research level of high flow control valve and promoting further development of the cycle power generation engineering.
This research is based upon work supported by National high-tech research development plan of China (863plans) under Grant No.2008AA04Z130and by Specialized Research Fund for the Doctoral Program of Higher Education under Grant No.20110131110042.
阐述了流固耦合的基本内涵及研究基础,综述了流固耦合问题的国内外研究概况,介绍了调节阀流固耦合的特点,对在循环发电工程中大流量调节阀流固耦合亟待解决的问题进行了探讨。
针对大流量调节阀建立了流固耦合系统数学模型,采用流固耦合有限元数值计算方法,分析了调节阀结构振动的有限元方程和流体的有限元方程,探讨了大流量调节阀的流固耦合系统基本方程和边界条件；采用Galerkin有限元方法建立了调节阀与混合煤气流固耦合的有限元方程,采用模态分析法进行了动力响应分析；揭示了混合煤气与调节阀的耦合振动机理,并对阀芯进行了动态特性分析；建立了大流量调节阀低频噪声耦合数学模型,从而得到了符合设计要求的耦合振动和噪声的理论分析,为进一步展开流固耦合研究奠定了理论基础。
以大流量混合煤气压力调节阀为研究对象,将数值仿真方法应用于大流量调节阀流固耦合系统的研究中,探讨了流固耦合对大流量调节阀及其流场的影响。揭示了在不同工况下,基于流固耦合的大流量调节阀内混合煤气流场及速度矢量分布,研究了流体旋涡形成的原因、位置及其对调节阀振动产生的影响；探讨了流固耦合对流场压力及压力损失情况、流量及压力控制精度、气流脉动频率的影响。所建立的流固耦合仿真模型对提高模拟的精度以及分析结构的流激振动问题均有实际意义,得到的结果为大流量调节阀的优化设计、噪声研究和试验研究提供了理论指导。
在流固耦合的基础上对大流量调节阀流动特性和噪声进行了研究,得到了不同工况下的流量系数和流阻系数的数值以及噪声水平,绘制出大流量调节阀的实际工作流量特性曲线和流阻特性曲线,采用最小二乘参数辨识的方法建立了流阻系数随开度变化的控制模型,可以为大流量调节阀在较宽工况范围内的流动阻力实现良好的模拟和预测。仿真结果为大流量调节阀优化设计提供了结构和流场参数的量化数据,为理论分析提供了实验基础和理论依据,是降低结构噪声和进行结构优化设计的基础和必要措施。
为使大流量调节阀结构参数和流场参数达到最优,以结构、流场和噪声分析结果为设计准则,提出了大流量调节阀的多学科设计优化框架,实现了涉及到多学科、多物理场的大流量调节阀的建模、分析以及优化的一体化集成。以保证煤气输送能力为前提,在追求减小调节阀噪音的系统优化目标下,减小了调节阀的壁厚和流体速度,满足了雷诺数、应力强度和阀体总质量的要求,即优化后在降低噪音的同时,可以降低产品价格成本、使流动趋于稳定、并且提高调节阀疲劳强度。
分别对基于流固耦合的调节阀阀体和阀芯的动力学特性进行了分析,得到了流体对调节阀阀体和阀芯固有频率及振型的影响,并对其持续动力响应情况进行了探讨,从而能够判断调节阀在受到不同频率的载荷时能否成功地克服共振、疲劳,及其它受迫振动所引起的不良效果。
以调节阀模态分析和结构强度分析为基础,提出了针对大流量调节阀流固耦合系统的结构损伤识别方法,根据阀芯的固有频率的变化来判断损伤裂纹的出现,根据频率变化的多少确定裂纹的大小,从而能够快速有效的诊断出工作环境比较特殊的大流量调节阀内部阀杆的损伤情况,避免煤气泄漏以及阀的动作缓慢或不能正常调节等故障的发生。
通过试验方法,对大流量调节阀动力学模型的有效性和流固耦合数值仿真的可靠性进行了验证。结果表明所建立的调节阀动力学分析模型用于模态的研究具有较高精度,所建立的基于流固耦合的调节阀模型具有较高可靠性,并且对流量和压力的控制精度以及得到的流量系数和流阻系数要比不考虑流固耦合时的精度要高。
从流固耦合问题出发研究大流量混合煤气压力调节阀,提高调节阀的综合性能,实现调节阀在流固耦合作用下的结构优化设计,对于提高我国大流量调节阀的设计研究水平,推动钢厂的燃气-蒸汽联合循环发电工程的进一步发展具有重要的理论意义和工程实践价值。
本课题得到国家863高技术研究发展计划项目“钢厂循环发电工程中大流量煤气的智能优化控制及应用技术(2008AA04Z130)”和高等学校博士学科点专项科研基金资助项目“大流量高频响核电控制阀的多场耦合振动与泄漏自感知机理研究”(20110131110042)的支持。
The steel mills generate vast amounts of blast furnace gas (BFG) and coke-oven gas (COG) in the production. In order to reduce the energy consumption and environmental pollution, some steel mills build combined cycle power plants (CCPP) to make use of the mixed gas. But in this cycle power generation engineering, gas supply is large, and the flow requirement is up to54000Nm3/h. The control valve is used in delivery lineto contril flow and pressure. The nominal size of control valve is more than7.874in. The flow of gas in control valve is complex three-dimensional unsteady turbulence. This is a tiplcal fluid-structure interaction (FSI) problem between control valve and gas, which would produce great influence on control valve and flow. Therefore accurate analysis of control valve and flow about FSI is important premise in control valve designing, manufacting and optimizing. This article mainly aims at high flow control valve based on FSI in generation engineering.
This paper expounds the basic connotation of FSI and research foundation, summarizes the general research situation at home and abroad about FSI. The FSI characteristic of control valve is introduced. The problems of control valve based on FSI that urgently need to be solved in cycle power generation engineering are discussed.
The mathematical model of FSI system of control valve is established. Using the finite element numerical calculation method, the structural vibration equation and fluid eauation are analysized. The basic equation and boundary conditions are discussed. The finite element equation aout FSI is established using Galerkin method and the dynamic response is analysed using modal method. Coupling vibration mechanism is revealed. The dynamics characteristic on valve plug is discussed. Low frequency noise coupling mathematical modal is established, which lays a theoretical foundation on further expansion of FSI.
The numerical simulation method is used to analyse the FSI system of high flow control valve. The effect of FSI on control valve and flow field is discussed. The mixed gas flow field and veloctity vector distribution in control valve at different opening is revealed. The cause and location of the formation of vortex flow are studyed, and the effect on control valve vibration is analysed. The impact of FSI on pressure and flow is discussed. The model of FSI has a practical significance to improve the accuracy of simulation and analyse the problem of flow inducing vibration. The results provide the therretical guide for optimization design, the noise and experimental research.
On the basis of FSI of high flow control valve, flow characteristic and the noise are studied. The flow coefficient and flow resistance coefficient at different opening and noise level are got. And the curves are drawed. The relation of flow resistance coefficient and opening is fitted out using the least square parameter identification method, which realize the valve are good simulation and prediction in a wider condition. The results provide the quantitative data of structure and flow field for optimization design, offer the experimental foundation and theoretical basis for the theoretical analysis. This is basis and necessary measure to reduce noise and optimization.
In order to make the structure parameters of high flow control valve and flow field parameters to achieve optimal, using the structure and fluid analysis results as design criteria, the multidisciplinary design optimization (MDO) framework is present. This realizes the integration which involves modeling, analysis and optimization of multidisciplinary and two field control valve. To ensure that gas transmission capacity as the prerequisite, making reducing valve noise as optimization goals, the wall thickness of valve and fluid velocity are reduced. These meet the Reynolds, stress intensity and body total quality requirements. When reducing noise, the product price cost is lowered, flow tends is made to be stable and fatigue strength of valve plug is improved.
The dynamic characteristics of control valve body and valve plug based on FSI are analyzed. The effect on natural frequency and vibration mode is achieved and the continuous dynamic response is discussed, which can judge the control valve in different frequency overcome resonance, fatigue and other vibration successfully.
Using the analysis of modal and structure strength as the foundation, the structure damage identification method is proposed, which can judge the emergence of crack damage according to the natural frequency and determine how much the size of the crack according to the frequency change. Thus the internal plug damage of control valve in special work environment can be diagnosed fastly and effectively, avoiding the failure of gas leakage and unnormal regulation.
Through the test method, the validity of the dynamic model and the reliability of the numerical simulation method is confirmed. The results show that the model has a high precision. Control accuracy of flow and pressure, flow coefficient and resistance coefficient has high accuracy when considering FSI.
Studying the control vavle based on FSI can improve the comprehensive performance and realize optimization, which has the important theoretical meaning and engineering practical value for improving the research level of high flow control valve and promoting further development of the cycle power generation engineering.
This research is based upon work supported by National high-tech research development plan of China (863plans) under Grant No.2008AA04Z130and by Specialized Research Fund for the Doctoral Program of Higher Education under Grant No.20110131110042.
引文
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