CN114136573B - Method for calculating early warning amplitude of key component of hydroelectric generating set and related equipment - Google Patents
Method for calculating early warning amplitude of key component of hydroelectric generating set and related equipment Download PDFInfo
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Abstract
The application provides a calculation method of early warning amplitude of key components of a hydroelectric generating set, which comprises the following steps: establishing a finite element model of key components of the hydroelectric generating set; based on the finite element model, analyzing the vibration stress of the key component under excitation of different vibration frequencies to obtain the frequency response characteristic of the key component; compiling a vibration amplitude power spectrum of key components of the water turbine generator set in a service life period under a typical working condition; based on the frequency response characteristic, loading a vibration amplitude power spectrum as input excitation into a finite element model, and obtaining the fatigue life of a key component through fatigue simulation analysis; setting a fatigue life threshold, wherein the fatigue life threshold is smaller than the fatigue life; the vibration amplitude power after the vibration amplitude is adjusted by a preset multiple is used as input excitation to be loaded into a finite element model, and the output fatigue life of the key component is obtained through simulation solution; when the output fatigue life is close to the fatigue life threshold value, setting the corresponding vibration amplitude as the early warning amplitude.
Description
Technical Field
The application relates to the technical field of hydroelectric generating sets, in particular to a method for calculating early warning amplitude of key components of a hydroelectric generating set and related equipment.
Background
The safety pre-warning method aims at the key components of the hydroelectric generating set, and mainly comprises the step of setting pre-warning amplitude for each measuring point of on-line monitoring. Therefore, the arrangement of the early warning amplitude has important significance for the safe operation of the hydroelectric generating set.
In the traditional method for setting the early warning amplitude, a larger safety coefficient (early warning amplitude) is selected when the safety coefficient (early warning amplitude) is selected, or too severe vibration conditions are limited for equipment. In most occasions, the evaluation method is conservative, and adopts a single vibration amplitude standard aiming at units with different operation characteristics, so that the influence of the operation characteristics of the units on the vibration amplitude is not fully considered, and the evaluation method cannot be applied to various units with different operation characteristics, therefore, the operation requirements of all water-turbine generator units cannot be met, and the power generation benefit of a power plant can be reduced.
Disclosure of Invention
In view of this, the present application aims to provide a method and related equipment for calculating early warning amplitudes of key components of a hydro-generator set.
Based on the above objects, the present application provides a method for calculating early warning amplitude of key components of a hydro-generator set, including:
establishing a finite element model of key components of the hydroelectric generating set;
based on the finite element model, analyzing the vibration stress of the key component under excitation of different vibration frequencies to obtain the frequency response characteristic of the key component;
compiling a vibration amplitude power spectrum of key components of the water turbine generator set in a service life period under a typical working condition;
loading the vibration amplitude power spectrum into the finite element model as input excitation based on the frequency response characteristic, and obtaining the fatigue life of the key component through fatigue simulation analysis;
setting a fatigue life threshold, the fatigue life threshold being less than the fatigue life;
loading vibration amplitude power with the vibration amplitude adjusted by a preset multiple into the finite element model as input excitation, and obtaining the output fatigue life of the key component through simulation solution; when the output fatigue life is close to the fatigue life threshold, setting the corresponding vibration amplitude as the early warning amplitude.
In some embodiments, the fatigue life threshold is set according to the fatigue life and the full service life; when the fatigue life exhibits infinite life, the value of the ratio x of the output fatigue life to the fatigue life threshold satisfies 0.1< x <1.
In some embodiments, the compiling a vibration amplitude power spectrum of key components of the water turbine generator set in a service life period under a typical working condition specifically comprises:
calculating the proportion of the working time of each typical working condition to the service life of the unit;
the load spectrum under each typical working condition is obtained through testing and recombined according to the actual specific gravity of each typical working condition;
and carrying out time-frequency conversion on the recombined result to compile a vibration amplitude power spectrum of key components of the water turbine generator set in the service life period under the typical working condition.
In some embodiments, the recombining the load spectrum under each typical working condition according to the actual specific gravity of each typical working condition specifically includes:
according toRecombination is carried out; wherein n is 1 The running time is the running time of the static working condition; n is n 2 The running time is the rated working condition; n is n 8 The operation time of the superposition working conditions; n is the sum of the operating times of the various operating conditions.
In some embodiments, the building the finite element model of the key components of the hydro-generator set specifically includes:
establishing an initial finite element model of key components of the hydroelectric generating set by establishing a solid model, meshing and controlling unit quality;
and (3) simulation calculation: calculating the simulation frequency and the simulation vibration shape of the initial finite element model of the key component to obtain a simulation result;
Field test: acquiring the field frequency and the field vibration shape of the key component to obtain a field test result;
comparison result: comparing the simulation result with the field test result, correcting the initial finite element model when the simulation result is inconsistent with the field result, and repeating the steps of simulation calculation and the field test until the simulation result is close to the field test result.
In some embodiments, the step of comparing the results further comprises:
calculating vibration amplitude and vibration stress distribution of the finite element model obtained by the comparison result under typical working conditions to obtain a typical working condition simulation result;
counting the parts with larger stress values of the simulation results of the typical working conditions, and identifying potential dangerous points which are easy to fail;
obtaining the vibration amplitude of the central part of the key component under the typical working condition to obtain the field test result of the typical working condition;
statistically analyzing the field test result of the typical working condition to obtain the extreme working condition of the key component;
calculating vibration amplitude and vibration stress distribution of potential dangerous points of the finite element model obtained through the comparison result under extreme working conditions to obtain an extreme working condition simulation result;
obtaining vibration amplitude and vibration stress distribution of potential dangerous points of the key component under extreme working conditions to obtain an extreme working condition field test result;
And comparing the simulation result of the extreme working condition with the field test result of the extreme working condition, correcting the finite element model obtained by the comparison result when the simulation result is inconsistent, and repeating the steps of simulation calculation and field test until the simulation result is close to the field result.
In some embodiments, the typical operating conditions include a stationary operating condition, a rated operating condition, and a superimposed operating condition; the key components comprise a mixed flow type turbine unit frame, a mixed flow type turbine unit top cover, a through flow type turbine unit water guide bearing or a through flow type turbine unit runner chamber.
In some embodiments, when the key component is a mixed flow turbine unit top cover, the typical operating conditions are a stationary operating condition, a rated operating condition, and a stacked operating condition.
The embodiment of the application also provides an electronic device, which comprises a memory, a processor and a computer program stored on the memory and capable of running on the processor, wherein the processor realizes the method according to any one of the previous claims when executing the program.
Embodiments also provide a non-transitory computer readable storage medium storing computer instructions for causing a computer to perform a method as described in any of the preceding.
From the above, the method for calculating the early warning amplitude of the key component of the hydroelectric generating set provided by the application is implemented by establishing a finite element model of the key component of the hydroelectric generating set; based on the finite element model, analyzing the vibration stress of the key component under excitation of different vibration frequencies to obtain the frequency response characteristic of the key component; compiling a vibration amplitude power spectrum of key components of the water turbine generator set in a service life period under a typical working condition; loading the vibration amplitude power spectrum into the finite element model as input excitation based on the frequency response characteristic, and obtaining the fatigue life of the key component through fatigue simulation analysis; setting a fatigue life threshold, the fatigue life threshold being less than the fatigue life; loading vibration amplitude power with the vibration amplitude adjusted by a preset multiple into the finite element model as input excitation, and obtaining the output fatigue life of the key component through simulation solution; when the output fatigue life is close to the fatigue life threshold, setting the corresponding vibration amplitude as the early warning amplitude. Based on the frequency response FRF characteristic, the vibration amplitude power spectrum of key components of the water turbine generator set in the service life cycle is taken as input under the typical working condition, and the fatigue life of the structure is obtained by simulating in combination with the S-N curve of the material. And continuously adjusting the vibration amplitude by taking the output fatigue life as a target, and setting by taking the adjusted vibration amplitude as a vibration amplitude of a key component as an alarm value by utilizing whether the simulated fatigue life is close to the fatigue life threshold.
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In order to more clearly illustrate the technical solutions of the present application or related art, the drawings that are required to be used in the description of the embodiments or related art will be briefly described below, and it is apparent that the drawings in the following description are only embodiments of the present application, and other drawings may be obtained according to these drawings without inventive effort to those of ordinary skill in the art.
Fig. 1 is a flow chart of a method for calculating early warning amplitudes of key components of a hydro-generator set according to an embodiment of the present application;
FIG. 2 is a schematic diagram showing the change of stress of a monitoring point of a top cover of a mixed flow turbine set according to the embodiment of the application along with the excitation of unit amplitude in the X direction;
FIG. 3 is a schematic diagram showing the variation of stress of a monitoring point of a top cover of a mixed flow turbine set according to the embodiment of the present application along with the excitation of unit amplitude in the Y direction;
FIG. 4 is a schematic diagram showing the change of stress of a monitoring point of a top cover of a mixed flow turbine set according to the embodiment of the present application along with the excitation of unit amplitude in the Z direction;
FIG. 5 is a schematic flow chart of the vibration amplitude power spectrum of key components of a hydroelectric generating set during a service life cycle under typical working conditions according to an embodiment of the present application;
FIG. 6 is a schematic diagram of the specific gravity of the operating time versus the total operating time for each typical operating condition of an embodiment of the present application;
FIG. 7 is a time domain plot of vibration amplitude of a critical component cap during a service cycle obtained by reassembly in accordance with an embodiment of the present application;
FIG. 8a is a density schematic diagram of a vibration amplitude power spectrum of a critical component cap in the X-direction during a unit service life cycle in accordance with an embodiment of the present application;
FIG. 8b is a density schematic diagram of a vibration amplitude power spectrum of a critical component cap in the Y-direction during a unit service life cycle in accordance with an embodiment of the present application;
FIG. 8c is a density schematic diagram of a vibration amplitude power spectrum of a critical component cap in the Z direction during a unit service life cycle in accordance with an embodiment of the present application;
FIG. 9 is a schematic flow chart of vibration fatigue analysis according to an embodiment of the present application;
FIG. 10 is a schematic diagram of a specific flow chart of vibration fatigue analysis according to an embodiment of the present application;
FIG. 11 is a schematic view of S-N curves of the key component cap of the present embodiment with Q235 as the primary material;
fig. 12 is a schematic structural diagram of an electronic device according to an embodiment of the present application.
Detailed Description
For the purposes of making the objects, technical solutions and advantages of the present application more apparent, the present application will be further described in detail below with reference to the accompanying drawings.
It should be noted that unless otherwise defined, technical or scientific terms used in the embodiments of the present application should be given the ordinary meaning as understood by one of ordinary skill in the art to which the present application belongs. The use of the terms "comprising" or "including" and the like in the embodiments of the present application is intended to cover an element or article appearing before the term and equivalents thereof, which are recited after the term, without excluding other elements or articles. The terms "connected" or "connected," and the like, are not limited to physical or mechanical connections, but may include electrical connections, whether direct or indirect. "upper", "lower", "left", "right", etc. are used merely to indicate relative positional relationships, which may also be changed when the absolute position of the object to be described is changed.
The method for evaluating the early warning amplitude of the key components of the water turbine structure mainly depends on a theoretical formula and design experience, adopts static strength to check structural safety, and uses a dynamic load system to consider the influence of vibration on structural safety. Because the stress level under rated work is difficult to quantitatively calculate by the traditional experience and theoretical formula, the dynamic characteristics of the structure and the additional stress caused by vibration response cannot be calculated, and the damage of vibration to the structure cannot be calculated; in the actual running process, as the vibration excitation sources are more and the characteristics are complex, the dynamic characteristics of the system structure are difficult to master and control, the prior early warning amplitude selects a larger safety coefficient when selecting the safety coefficient, or the equipment is limited with too severe vibration conditions.
The existing method for evaluating the early warning amplitude in most occasions is conservative, and according to the actual running condition of the equipment and after safety evaluation, some hydroelectric generating set equipment can continue to run stably under the condition of exceeding the alarm threshold. However, due to the current early warning amplitude value, the centralized control scheduling of the hydropower plant can limit the load of a unit with an alarm threshold, and the power generation benefit of the hydropower plant is affected. In addition, the existing method for evaluating the early warning amplitude is easy to evaluate the real risk part due to the fact that the vibration response and influence of each part cannot be evaluated.
Based on the method, the device and the system, the dynamic response of the critical parts of the water turbine under the rated static working condition stress and the rotation excitation of the critical parts of the water turbine is calculated based on the finite element model, the multi-working condition fatigue life prediction is carried out, the early warning amplitude is obtained by combining the safety analysis of the actual operation of the device, and the problem that the setting of the early warning amplitude is conservative can be solved to a certain extent.
Referring to fig. 1, an embodiment of the present application provides a method for calculating early warning amplitudes of key components of a hydroelectric generating set, including:
s100, establishing a finite element model of key components of the hydroelectric generating set;
s200, analyzing the vibration stress of the key component under excitation of different vibration frequencies based on the finite element model to obtain the frequency response characteristic of the key component;
s300, compiling a vibration amplitude power spectrum of key components of the water turbine generator set in a service life cycle under typical working conditions;
s400, loading the vibration amplitude power spectrum into the finite element model as input excitation based on the frequency response characteristic, and obtaining the fatigue life of the key component through fatigue simulation analysis;
s500, setting a fatigue life threshold value, wherein the fatigue life threshold value is smaller than the fatigue life;
S600, loading vibration amplitude power with the vibration amplitude adjusted by a preset multiple into the finite element model as input excitation, and obtaining the output fatigue life of the key component through simulation solution; when the ratio of the output fatigue life to the fatigue life threshold value is in a preset range x, setting the corresponding vibration amplitude as an early warning amplitude.
In some embodiments, in step S100, the key component of the hydro-generator set may be any key component that may generate fatigue failure or be prone to crack or break after the hydro-generator set is operated for a long period of time. For example, the main load bearing components of a hydroelectric generating set: a mixed flow type turbine unit frame, a mixed flow type turbine unit top cover, a through flow type turbine unit water guide bearing or a through flow type turbine unit runner chamber, etc. In the running process of the mixed flow type water turbine unit, the top cover mainly bears the pressure of the downflow, unbalanced force of a shafting and the weight of accessories of the unit; the frame bears the weight of the whole rotating part, the thrust of water and the self weight.
In some embodiments, the building the finite element model of the key components of the hydro-generator set specifically includes:
establishing a finite element model of key components of the hydroelectric generating set through grid division and unit quality control;
And (3) simulation calculation: calculating the simulation frequency and the simulation vibration shape of the initial finite element model of the key component to obtain a simulation result;
field test: acquiring the field frequency and the field vibration shape of the key component to obtain a field test result;
comparison result: comparing the simulation result with the field test result, correcting the initial finite element model when the simulation result is inconsistent with the field result, and repeating the steps of simulation calculation and the field test until the simulation result is close to the field test result. The accuracy of the finite element model can be improved as much as possible by comparing the results obtained by the field test with the results of the simulation calculation.
In some embodiments, the drawings of the key components can be combined with the actual mapping dimensions to simulate the mechanical structure of the real object as much as possible, and the entity model is built in advance according to the unit characteristics provided by HYPERMESH. Cell quality control is understood to mean the quality inspection of cells that are meshed. The quality inspection of the grid cells may include taking values of parameters such as jacobian coefficients, warp, aspect ratios, etc., exactly as required.
In some embodiments, the simulation results may include vibration amplitude and stress distribution clouds of the critical components.
It should be noted that the parameters applied during the simulation calculation and the field test are identical.
In some embodiments, when comparing results, the proximity of the simulation results to the field test results can be determined according to actual experience and specific design requirements.
In some embodiments, the step of comparing the results further comprises:
calculating vibration amplitude and vibration stress distribution of the finite element model obtained by the comparison result under typical working conditions to obtain a typical working condition simulation result;
counting the parts with larger vibration stress values of the simulation results of the typical working conditions, and identifying potential dangerous points which are easy to fail;
obtaining vibration amplitude and vibration stress distribution of the central part of the key part under a typical working condition to obtain a typical working condition field test result;
statistically analyzing the field test result of the typical working condition to obtain the extreme working condition of the key component;
calculating vibration amplitude and vibration stress distribution of potential dangerous points of the finite element model obtained through the comparison result under extreme working conditions to obtain an extreme working condition simulation result;
obtaining vibration amplitude and vibration stress distribution of potential dangerous points of the key component under extreme working conditions to obtain an extreme working condition field test result;
And comparing the simulation result of the extreme working condition with the field test result of the extreme working condition, correcting the finite element model obtained by the comparison result when the simulation result is inconsistent, and repeating the steps of simulation calculation and field test until the simulation result is close to the field result. The accuracy of the finite element model can be improved as much as possible by identifying potential dangerous points through field tests, acquiring and simulating the potential dangerous points, and comparing the results.
In some embodiments, the vibration amplitude of the critical component may be measured in real time under various typical conditions by placing a sensor in the central portion of the critical component. Vibration amplitude and vibration stress fluctuation of dangerous points under various typical working conditions can be collected by arranging strain gauges at potential dangerous points of key components.
In some embodiments, in step S200, the Frequency Response (FRF) may be understood as the characteristic of a finite element model obtained from a known input and a known response, and a specific measurement object may include a spectrum of the input force and a synchronized vibration response. Specifically, the method may include applying unit displacement vibration excitation in the X direction, the Y direction, and the Z direction, respectively, using the mass points of the key components as load application excitation points, based on the finite element model obtained in step S100. The modal frequency range is set to be (0-100) Hz, the damping coefficient is input according to the measured dynamic damping curve, modal frequency response analysis is carried out on the finite element model, and the transfer function between the excitation frequency (0-50 HZ) and the vibration stress of the finite element model is obtained.
In the application scenario, when the top cover of the mixed flow type water turbine unit is analyzed, a unit with a larger stress position at the right angle of a plate on the top cover is selected as a monitoring point, so that the change of the stress along with X, Y and Z-direction unit amplitude excitation is obtained, and reference is made to fig. 2, 3 and 4. It can be seen that the stress response of the cell gradually and slowly increases with increasing X-direction vibration frequency and gradually and slowly decreases with increasing Y-and Z-direction vibration frequency. However, neither the increase nor the decrease in stress is significant, indicating that the stress is not very sensitive to the excitation frequency in the displacement excitation range of 0-50 HZ. The insensitivity is caused by that the structure has only one natural frequency point of 40HZ within 50HZ, the natural mode shape of 40HZ is a high-low two-lobe shape, and the whole center presents synchronous up-down vibration, namely the excitation mode shape is inconsistent with the natural mode.
In some embodiments, as shown in fig. 5, in step S300, the compiling a vibration amplitude power spectrum of key components of the water turbine generator set in a service life period under a typical working condition specifically includes:
s310, calculating the proportion of the working time of each typical working condition to the service life of the unit;
s320, recombining load spectrums obtained by testing under each typical working condition according to the actual specific gravity of each typical working condition;
S330, performing time-frequency conversion on the recombined result, and compiling to obtain the vibration amplitude power spectrum of the key components of the water turbine generator set in the service life cycle under the typical working condition.
The amplitude time domain curves of the typical working conditions are recombined, so that the amplitude time domain curves in the whole service life cycle can be formed, the influence of environments such as a water head of a hydroelectric generating set and the like along with the whole life cycle of the set is comprehensively considered, the trend that vibration and swing values gradually rise is caused to key parts, comprehensive and reliable vibration related data are obtained, the accuracy of subsequent fatigue life prediction is improved, and the accuracy of finally obtained early warning amplitude is further improved.
In some embodiments, typical operating conditions may include stationary operating conditions, rated operating conditions, superimposed operating conditions, and the like. Different typical working conditions can be selected for different key components to improve the accuracy of the finite element model.
Specifically, a static working condition, a rated working condition, a superposition working condition and the like are selected for the top cover of the mixed flow type water turbine set, so that the distribution of stress and strain of the top cover under the influence of the gravity of the self structure and the accessory, the counter-supporting force of the shaft sleeve and the rated water pressure, and the distribution of stress and strain of the top cover under the comprehensive influence of the X-direction force of the vibration source superposition rotating wheel on the top cover on the basis of the analysis of the rated working condition are obtained.
In an application scenario, the specific gravity of the running time of each typical working condition to the total running time may be as shown in fig. 6, for example.
In some embodiments, in step S320, the recombining the load spectrum under each typical working condition according to the actual specific gravity of each typical working condition specifically includes:
according toRecombination is performed. Wherein n is 1 The running time is the running time of the static working condition; n is n 2 The running time is the rated working condition; n is n 8 Is the operation time of the superposition working condition.
In the application scene, the vibration amplitude time domain diagram of the top cover of the key component in the service period obtained by recombination is shown in fig. 7.
In step S330, the time-frequency transformation is an existing time-frequency transformation (ALT, alternating Frequency/Time Domain Method), and the present application does not relate to an improvement of the existing time-frequency transformation. The obtained vibration amplitude power spectrum is a Power Spectrum Density (PSD), can measure the mean square value of a random variable, and is used for counting working conditions and is the Fourier transform of the self-correlation function of the vibration amplitude of the hydroelectric generating set. The Power Spectral Density (PSD) can be understood as "power" in a unit frequency band, which is a statistical result of the response of a key component structure under random dynamic load excitation, and is expressed as a relation curve of a power spectral density value and a frequency value. The density of the vibration amplitude power spectrum can describe random vibration, and reflects the acceleration and vibration times of each frequency component under the condition of random vibration for 1 second, and the frequency corresponding to the main power can be obtained through the displacement power spectrum density. It will be appreciated that the vibration amplitude power spectrum can reflect the power corresponding to each frequency component, i.e. the work equivalent to knowing the frequency component per second, since the work per vibration is known (from acceleration and frequency) the number of vibrations per second at that frequency can be deduced.
In the application scene, the vibration amplitude time domain signal of the top cover of the key component in the service life period of the unit is subjected to signal processing, and the density of the vibration amplitude power spectrum is obtained as shown in fig. 8a, 8b and 8 c. It can be seen that the X and Y-direction vibration amplitude power of the top cover is concentrated at the cusps within 1HZ, the Z-direction vibration amplitude power is concentrated at the cusps of 2.3 and 16.8HZ, and the frequency analysis thereof is wider.
In some embodiments, in step S400, referring to fig. 9 and 10, the steps of fatigue simulation analysis may specifically be: and multiplying a stress transfer function obtained by harmonic response analysis of the finite element model by a standard load power spectral density to obtain the stress power spectral density of the finite element model, then simulating by using a Dirlik method to obtain a stress probability density function (PSD), and finally carrying out fatigue life analysis according to a Miner criterion.
Specifically, assuming that the system is in accordance with the line elasticity assumption and is a transfer function between the stress response of the system and the excitation load, S (f) is the standard power spectral density of the excitation load, thereby calculating the stress response power spectral density G (f) of the system as shown in formula (2) and combining the i-order frequency f i And obtaining an i-order power stress rate spectrum density matrix m by stress response power spectrum i As shown in formula (3), and further according to the stress power spectral density moment m 2 And m 4 Obtaining the approximate value of stress cycle number E [ P ] per second]From this, the total number of stress cycles N in the loading time T is calculated as in equation (5) as in equation (4).
G(f)＝|H(f)| 2 X S (f) (2), wherein G (f) is the stress response power spectral density of the system; i H (f) is the transfer function between the stress response of the system and the excitation load; s (f) is the standard power spectral density of the excitation load.
m i ＝∫f i XG (f) df (3), where m i The power spectrum density matrix is of the i order; f (f) i Is the i-order frequency; df is the derivative of f, f being the frequency.
Wherein E [ P ]]An approximation of the number of stress cycles per second; m is m 2 A 2-order stress power spectral density moment; m is m 4 Is the 4 th order stress power spectral density moment.
N=e [ P ] ×t (5), where N is the total number of stress cycles in time T.
Certain oneThe number of cycles corresponding to the stress range can be calculated by using equation (6). n is n i ＝P(S i ) X dS x N (6), wherein S i Is the i-th stress range; p (S) i ) The probability density function value is the corresponding probability density function value; x dS is the differential to S, which is the stress.
The number of fracture cycles in the stress range can be calculated according to the curve of the material (i.e. the material of the critical parts of the hydro-generator set) using equation (7).
Wherein N is i =number of fracture cycles in stress range, K and m are constant parameters of the material; the damage caused by each stress range level is linearly added using the Miner linear damage rule. Once->Fatigue failure occurs, the cycle times of the fatigue failure are obtained, the corresponding stress range is obtained through calculation, and then the vibration amplitude is obtained according to the power spectrum density.
In some embodiments, in step S500, the fatigue life threshold is set according to the fatigue life and the service life. For example, for a mixed-flow turbine set, since the annual running time of the water turbine is 6000 hours, the service life of the mixed-flow turbine set is 50 years, and the fatigue life threshold of the top cover of the mixed-flow turbine set is set to be 1.5e9 seconds; and 1e10 seconds is used as a fatigue life threshold of the mixed flow type water turbine unit frame.
In some embodiments, in step S600, the proximity of the output fatigue life to the fatigue life threshold may be determined from a ratio of output fatigue life to the fatigue life threshold. Specifically, when the fatigue life exhibits an infinite life, the vibration amplitude may be continuously adjusted by a preset multiple until the value of the ratio x of the output fatigue life to the fatigue life threshold is satisfied, 0.1< x <1.1. Whether the wireless service life is presented or not can be judged according to the S-N curve of the material.
In the application scenario, for the key component mixed flow hydraulic turbine set top cover, the main material is Q235, the elastic modulus is 2.10e5MPa, the Poisson ratio is 0.3, when the tensile strength is more than 375MPa, the S-N curve of the material is created by inputting the elastic modulus E and the ultimate tensile strength UTS of Q235 into the material data manager through the material parameter setting panel in ANSYS NCODE fatigue analysis software, as shown in FIG. 11. It can be seen that the S-N curve is a two-segment wire combination with 10E7 times for infinite life times for steel. Thus, it exhibits an infinite life characteristic.
In the application scene, when the X-direction vibration allowable amplitude of the top cover of the mixed flow type water turbine unit is 6.8 times of the existing one, the axial vertical vibration allowable amplitude is 7 times of the existing one.
Examples
The early warning amplitude of a top cover of a hydropower station water turbine (hereinafter referred to as a water turbine) with the model of HLA855-LJ and rated power of 250MW is calculated. The main operating parameters are shown in table 1 below.
Table 1 main operating condition parameters of the turbine
| Model of water turbine | HLA855-LJ | Generator model | SF250 |
| Rated water head | 128m | Rated capacity | 277.8MVA |
| Range of water head | 97m～156.5m | Rated power | 250MW |
| Rated rotational speed | 166.67r/min | Rated voltage | 15.75KV |
| Upper guide wattage | 12 | Rated current | 10183A |
| Water guide wattage | 10 | Generator rotor | 560t |
| Fixed guide vane | 23 | Thrust wattage | 24 |
| Runner blade | 15 | Number of movable guide leaves | 24 |
| Bearing frame | Lower frame | Structural design | Full umbrella type |
| Nominal of runner | 5.05m | Flow rate | 217.81m 3 /s |
1) Analysis result of rigidity strength of water turbine
The displacement results of the top cover are shown in Table 2, and the stress statistics are shown in Table 3. Wherein the safety coefficient is checked according to a fourth intensity theory, the Q235 yield strength is taken as 235MPa, and the safety coefficient is determined according toAnd (5) performing calculation. Wherein sigma s Is the ultimate stress; sigma (sigma) max Is allowable stress.
Table 2 summary of head cover displacement distribution
| Stationary working condition | Rated working condition | Superimposed working conditions | |
| X-direction displacement/mm | 0.01 | 0.33 | 0.47 |
| Y-direction displacement/mm | -0.036 | 1.26 | 1.45 |
| Z-direction displacement/mm | 0.01 | -0.45 | -0.51 |
| Total displacement/mm | 0.04 | 1.26 | 1.45 |
Table 3 summary of higher stress sites for Top cover stiffness analysis
2) Results of modal analysis of hydroturbine
The damping coefficient of the structure is set to be 0.025, a Block Lanczos method is adopted to extract the mode, a top cover model of the water turbine extracts the mode of the first 6 steps, and the natural frequency of the first 6 steps and the corresponding vibration shape are shown in the following table 4.
TABLE 4 Top cover front 6 order frequency and vibration shape
3) Analysis result of vibration stress of top cover of water turbine
The prior vibration early warning system is specified as follows: top cover horizontal vibration alarm limit value: 90 μm, top cover vertical vibration alarm limit value: 110 μm. However, the maximum amplitude of the top cover is 100% of the variable rotation speed, the amplitude in the X direction reaches 175 mu m, and the main vibration frequency is 0.7HZ. The alarm specified value has been exceeded, as shown in table 5 below.
Table 5 working conditions with maximum cap amplitude
| Amplitude in X-direction | Amplitude in Y direction | Amplitude in Z direction | Frequency of vibration | |
| The variable rotation speed is 100% | -161～175μm | -52～41μm | -12～10μm | 0.7HZ |
In view of this, it is necessary to analyze the stress of the top cover under the above-mentioned vibration limit conditions and evaluate the additional vibration stress caused by the limit amplitude to the top cover. During analysis, an established top cover dynamics model is still adopted, the amplitude of the working condition with the variable rotation speed of 100% is respectively applied to the dynamics model as an excitation displacement source, vibration response analysis is carried out, and additional stress caused by vibration is independently analyzed. On the basis, the comprehensive stress level of the top cover under the simultaneous action of the limit vibration working condition and the rated working condition is considered.
The analysis results are shown in Table 6. It can be seen that: the vibration stress under the working condition of changing the rotating speed to 100% is 40MPa, and the maximum stress part is arranged at the edge of the rectangular plate.
TABLE 6 vibration stress at maximum amplitude
| Total displacement of | Maximum stress | Maximum stress position | |
| The variable rotation speed is 100% | 0.18mm | 40MPa | Rectangular plate |
4) Analysis result of fatigue life of top cover of water turbine
The fatigue life analysis of the top cover of the water turbine is carried out based on the finite element model, and based on the hydraulic turbine rigid strength analysis result, the hydraulic turbine modal analysis result and the hydraulic turbine vibration stress analysis result, the finite element model can be adjusted from different dimensions, and the finite element model with high accuracy and precision is obtained.
The fatigue life of the cap was calculated to be at least 7e22 seconds, exhibiting infinite life characteristics.
On the basis, the amplitude was increased for a plurality of times, and the influence of the amplitude on the fatigue life was analyzed, and the influence of the amplitude in the X direction on the fatigue life was shown in Table 7. The effect of the amplitude of the vertical vibration in the Z direction on the fatigue life is shown in table 8. It can be seen that the amplitude of the X-direction and Z-direction vibrations has a significant impact on fatigue life. Since the hydraulic turbine operates for 6000 hours per year, taking 50 years (about 1.1e9 seconds) as an infinite life assumption, the X-direction vibration allowable amplitude is 6.3 times as large as the existing one, and the Z-direction vertical vibration allowable amplitude is 75 times as large as the existing one.
TABLE 7 influence of X directed vibration on fatigue life
| Amplitude of vibration | Amplitude of 1 time | Amplitude of 5 times | Amplitude of 9 times | Amplitude of 6 times | Amplitude of 7 times | Amplitude of 6.3 times |
| Life/second | 7e22 | 3.6e11 | 5e5 | 4.5e9 | 2.7e8 | 1.78e9 |
TABLE 8 influence of vertical vibration on fatigue life
| Amplitude of vibration | Amplitude of 1 time | Amplitude of 50 times | Amplitude of 60 times | 80 times amplitude | Amplitude of 75 times |
| Life/second | 7e22 | 6.8e14 | 6e11 | 4.1e8 | 1.6e9 |
5) Conclusion of the assessment
(1) The top cover meets the rigidity and strength requirement, and the maximum stress of the top cover under the rated working condition is 124MPa; the maximum stress of the rated working condition is 132MPa, and the safety coefficients of the existing early warning amplitude are 1.9 and 1.8 respectively.
(2) The top cover has good dynamic design. The excitation frequency is far away from the natural frequency of the top cover, and resonance phenomenon can not occur. The test result shows that the practical measurement vibration of the top cover and the rotor is mainly at low frequency within 4HZ, the main vibration frequency of the practical measurement vibration is obviously related to the rotor rotating frequency, the practical measurement vibration shows obvious forced vibration characteristics, and the vibration frequency is far away from the natural frequency of the structure.
(3) The vibration of the top cover has a more obvious effect on the stress. And under the working condition of 100% of maximum variable rotation speed of the top cover vibration, the vibration stress caused by the vibration is 40MPa.
(4) As the whole life cycle is mainly based on rated micro vibration working conditions, the duration of ultra-early warning vibration is very small. The amplitude of the existing working condition can not substantially influence the service life of the structure, and the top cover meets the infinite service life requirement.
(5) Taking 50 years (about 1.1e9 seconds) as the design life of the structure, the X-direction vibration allowable amplitude of the top cover is 6.3 times that of the existing one. The Z-direction vertical vibration allows an amplitude of 75 times that of the existing one.
It should be noted that, the method of the embodiments of the present application may be performed by a single device, for example, a computer or a server. The method of the embodiment can also be applied to a distributed scene, and is completed by mutually matching a plurality of devices. In the case of such a distributed scenario, one of the devices may perform only one or more steps of the methods of embodiments of the present application, and the devices may interact with each other to complete the methods.
It should be noted that some embodiments of the present application are described above. Other embodiments are within the scope of the following claims. In some cases, the actions or steps recited in the claims may be performed in a different order than in the embodiments described above and still achieve desirable results. In addition, the processes depicted in the accompanying figures do not necessarily require the particular order shown, or sequential order, to achieve desirable results. In some embodiments, multitasking and parallel processing are also possible or may be advantageous.
Based on the same inventive concept, the application also provides an electronic device corresponding to the method of any embodiment, which comprises a memory, a processor and a computer program stored on the memory and capable of running on the processor, wherein the method for calculating the early warning amplitude of the key component of the hydro-generator set according to any embodiment is realized when the processor executes the program.
Fig. 12 is a schematic diagram showing a hardware structure of a more specific electronic device according to the present embodiment, where the device may include: a processor 1010, a memory 1020, an input/output interface 1030, a communication interface 1040, and a bus 1050. Wherein processor 1010, memory 1020, input/output interface 1030, and communication interface 1040 implement communication connections therebetween within the device via a bus 1050.
The processor 1010 may be implemented by a general-purpose CPU (Central Processing Unit ), microprocessor, application specific integrated circuit (Application Specific Integrated Circuit, ASIC), or one or more integrated circuits, etc. for executing relevant programs to implement the technical solutions provided in the embodiments of the present disclosure.
The Memory 1020 may be implemented in the form of ROM (Read Only Memory), RAM (Random Access Memory ), static storage device, dynamic storage device, or the like. Memory 1020 may store an operating system and other application programs, and when the embodiments of the present specification are implemented in software or firmware, the associated program code is stored in memory 1020 and executed by processor 1010.
The input/output interface 1030 is used to connect with an input/output module for inputting and outputting information. The input/output module may be configured as a component in a device (not shown) or may be external to the device to provide corresponding functionality. Wherein the input devices may include a keyboard, mouse, touch screen, microphone, various types of sensors, etc., and the output devices may include a display, speaker, vibrator, indicator lights, etc.
Communication interface 1040 is used to connect communication modules (not shown) to enable communication interactions of the present device with other devices. The communication module may implement communication through a wired manner (such as USB, network cable, etc.), or may implement communication through a wireless manner (such as mobile network, WIFI, bluetooth, etc.).
Bus 1050 includes a path for transferring information between components of the device (e.g., processor 1010, memory 1020, input/output interface 1030, and communication interface 1040).
It should be noted that although the above-described device only shows processor 1010, memory 1020, input/output interface 1030, communication interface 1040, and bus 1050, in an implementation, the device may include other components necessary to achieve proper operation. Furthermore, it will be understood by those skilled in the art that the above-described apparatus may include only the components necessary to implement the embodiments of the present description, and not all the components shown in the drawings.
The electronic device of the foregoing embodiment is configured to implement the method for calculating the early warning amplitude of the corresponding key component of the hydro-generator set in any of the foregoing embodiments, and has the beneficial effects of the corresponding method embodiment, which is not described herein.
Based on the same inventive concept, corresponding to the method of any embodiment, the application further provides a non-transitory computer readable storage medium, wherein the non-transitory computer readable storage medium stores computer instructions, and the computer instructions are used for enabling the computer to execute the method for calculating the early warning amplitude of the key component of the hydro-generator set according to any embodiment.
The computer readable media of the present embodiments, including both permanent and non-permanent, removable and non-removable media, may be used to implement information storage by any method or technology. The information may be computer readable instructions, data structures, modules of a program, or other data. Examples of storage media for a computer include, but are not limited to, phase change memory (PRAM), static Random Access Memory (SRAM), dynamic Random Access Memory (DRAM), other types of Random Access Memory (RAM), read Only Memory (ROM), electrically Erasable Programmable Read Only Memory (EEPROM), flash memory or other memory technology, compact disc read only memory (CD-ROM), digital Versatile Discs (DVD) or other optical storage, magnetic cassettes, magnetic tape magnetic disk storage or other magnetic storage devices, or any other non-transmission medium, which can be used to store information that can be accessed by a computing device.
The computer instructions stored in the storage medium of the foregoing embodiments are used to make the computer execute the method for calculating the early warning amplitude of the key component of the hydro-generator set according to any one of the foregoing embodiments, and have the beneficial effects of the corresponding method embodiments, which are not described herein.
Those of ordinary skill in the art will appreciate that: the discussion of any of the embodiments above is merely exemplary and is not intended to suggest that the scope of the application (including the claims) is limited to these examples; the technical features of the above embodiments or in the different embodiments may also be combined within the idea of the present application, the steps may be implemented in any order, and there are many other variations of the different aspects of the embodiments of the present application as described above, which are not provided in detail for the sake of brevity.
Additionally, well-known power/ground connections to Integrated Circuit (IC) chips and other components may or may not be shown within the provided figures, in order to simplify the illustration and discussion, and so as not to obscure the embodiments of the present application. Furthermore, the devices may be shown in block diagram form in order to avoid obscuring the embodiments of the present application, and this also takes into account the fact that specifics with respect to implementation of such block diagram devices are highly dependent upon the platform on which the embodiments of the present application are to be implemented (i.e., such specifics should be well within purview of one skilled in the art). Where specific details (e.g., circuits) are set forth in order to describe example embodiments of the application, it should be apparent to one skilled in the art that embodiments of the application can be practiced without, or with variation of, these specific details. Accordingly, the description is to be regarded as illustrative in nature and not as restrictive.
While the present application has been described in conjunction with specific embodiments thereof, many alternatives, modifications, and variations of those embodiments will be apparent to those skilled in the art in light of the foregoing description. For example, other memory architectures (e.g., dynamic RAM (DRAM)) may use the embodiments discussed.
Claims (9)
1. A calculation method of early warning amplitude of key components of a hydroelectric generating set is characterized by comprising the following steps:
establishing a finite element model of key components of the hydroelectric generating set;
based on the finite element model, analyzing the vibration stress of the key component under excitation of different vibration frequencies to obtain the frequency response characteristic of the key component;
the method for compiling the vibration amplitude power spectrum of key components of the water turbine generator set in the service life period under the typical working condition comprises the following steps: calculating the proportion of the working time of each typical working condition to the service life of the unit; the load spectrum under each typical working condition is obtained through testing and recombined according to the actual specific gravity of each typical working condition; performing time-frequency conversion on the recombined result to obtain a vibration amplitude power spectrum of key components of the water turbine generator set in the service life period under the typical working condition;
Loading the vibration amplitude power spectrum into the finite element model as input excitation based on the frequency response characteristic, and obtaining the fatigue life of the key component through fatigue simulation analysis;
setting a fatigue life threshold, the fatigue life threshold being less than the fatigue life;
loading vibration amplitude power with the vibration amplitude adjusted by a preset multiple into the finite element model as input excitation, and obtaining the output fatigue life of the key component through simulation solution; when the output fatigue life is close to the fatigue life threshold, setting the corresponding vibration amplitude as the early warning amplitude.
2. The method for calculating the early warning amplitude of a critical component of a hydro-generator set according to claim 1, wherein the fatigue life threshold is set according to the fatigue life and the service life; when the fatigue life exhibits infinite life, the value of the ratio x of the output fatigue life to the fatigue life threshold satisfies 0.1< x <1.
3. The method for calculating the early warning amplitude of the key component of the hydro-generator set according to claim 1, wherein the recombining the load spectrum under each typical working condition according to the actual specific gravity of each typical working condition specifically comprises:
According toRecombination is carried out; wherein n is 1 The running time is the running time of the static working condition; n is n 2 The running time is the rated working condition; n is n 8 The operation time of the superposition working conditions; n is the sum of the operating times of the various operating conditions.
4. The method for calculating the early warning amplitude of the critical component of the hydro-generator set according to claim 1, wherein the establishing the finite element model of the critical component of the hydro-generator set specifically comprises:
establishing an initial finite element model of key components of the hydroelectric generating set by establishing a solid model, meshing and controlling unit quality;
and (3) simulation calculation: calculating the simulation frequency and the simulation vibration shape of the initial finite element model of the key component to obtain a simulation result;
field test: acquiring the field frequency and the field vibration shape of the key component to obtain a field test result;
comparison result: comparing the simulation result with the field test result, correcting the initial finite element model when the simulation result is inconsistent with the field result, and repeating the steps of simulation calculation and the field test until the simulation result is close to the field test result.
5. The method for calculating the early warning amplitude of a critical component of a hydro-generator set according to claim 4, wherein the step of comparing the results further comprises:
Calculating vibration amplitude and vibration stress distribution of the finite element model obtained by the comparison result under typical working conditions to obtain a typical working condition simulation result;
counting the parts with larger stress values of the simulation results of the typical working conditions, and identifying potential dangerous points which are easy to fail;
obtaining the vibration amplitude of the central part of the key component under the typical working condition to obtain the field test result of the typical working condition;
statistically analyzing the field test result of the typical working condition to obtain the extreme working condition of the key component;
calculating vibration amplitude and vibration stress distribution of potential dangerous points of the finite element model obtained through the comparison result under extreme working conditions to obtain an extreme working condition simulation result;
obtaining vibration amplitude and vibration stress distribution of potential dangerous points of the key component under extreme working conditions to obtain an extreme working condition field test result;
and comparing the simulation result of the extreme working condition with the field test result of the extreme working condition, correcting the finite element model obtained by the comparison result when the simulation result is inconsistent, and repeating the steps of simulation calculation and field test until the simulation result is close to the field result.
6. The method for calculating the early warning amplitude of the key components of the hydro-generator set according to claim 1, wherein the typical working conditions comprise a static working condition, a rated working condition and a superposition working condition; the key components comprise a mixed flow type turbine unit frame, a mixed flow type turbine unit top cover, a through flow type turbine unit water guide bearing or a through flow type turbine unit runner chamber.
7. The method for calculating the early warning amplitude of a critical component of a hydro-generator set according to claim 6, wherein the critical component is a top cover of the mixed flow hydro-generator set, and the typical working conditions are a static working condition, a rated working condition and a superposition working condition.
8. An electronic device comprising a memory, a processor and a computer program stored on the memory and executable on the processor, the processor implementing the method of any one of claims 1 to 7 when the program is executed.
9. A non-transitory computer readable storage medium storing computer instructions for causing a computer to perform the method of any one of claims 1 to 7.
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