0 evaluări0% au considerat acest document util (0 voturi)
31 vizualizări7 pagini
Air compressors are widely used in petroleum projects, process industries and refineries. Knowing about them ensuring that they are reliable and efficient is important. This book teaches one how to closely monitoring the condition by using appropriate sensors and other equipment
Air compressors are widely used in petroleum projects, process industries and refineries. Knowing about them ensuring that they are reliable and efficient is important. This book teaches one how to closely monitoring the condition by using appropriate sensors and other equipment
Air compressors are widely used in petroleum projects, process industries and refineries. Knowing about them ensuring that they are reliable and efficient is important. This book teaches one how to closely monitoring the condition by using appropriate sensors and other equipment
Condition monitoring of reciprocating air compressor using IR thermography S S Singh & A K Singh* Department of Aerospace Engineering, Defence Institute of Advanced Technology (Deemed University), Girinagar, Pune 411 025 *E-mail: draksingh@hotmail.com; aksingh@diat.ac.in Received 17 January 2010; revised 24 September 2010; accepted 9 November 2010 The usage of IR thermography as an effective condition monitoring tool on reciprocating air compressor has been studied. The technique allows monitoring of temperatures and thermal patterns while the equipments are running. The compressor cylinder fins tip temperatures are measured using infrared gun and thermocouple and have been further analysed by finite element method. Based on experiments and finite element analysis, equation is generated for internal surface temperature rise in the compressor cylinders due to running of the compressor. The analysis involved correlating the surface temperature with that obtained by finite element analysis. It is, further, highlighted in the paper that as the compressor under study does not cater for any kind of temperature measurement to analyse the performance of compressor, thermal imaging of such equipments can be beneficial in analysing the health of the equipments by acquiring thermal images over a specified interval of time which could be time specific. Keywords: Finite element analysis, Infrared, Thermograph, Thermocouple, Steady state 1 Introduction Infrared thermography is now being targeted as a versatile tool for condition monitoring of equipments 1,2 . Infrared imaging will help quickly and efficiently find the areas that are most in need of maintenance. The infrared thermal imaging method utilizes the radiant existence in the infrared spectral band from measured objects to measure temperature. It is non-intrusive, applicable remotely and suitable for measurement 3 of a large area, and can also serve to record data for subsequent storage and processing with a PC. Ay et al. 4 used an infrared thermal imaging camera to observe the surface temperature of a plate finned-tube heat exchanger and calculated the local heat transfer coefficient. IR thermography on equipments shows that the surface thermal patterns are a consequence of internal conditions. Basic aim of this study is to maintain the equipments by evaluating its performance at specified interval of time. Using finite element analysis 5,6 , we have shown that the internal conditions can be evaluated from the external surface conditions. The purpose of this study is to determine the applicability of IR thermography as a condition monitoring tool and also to evaluate inner surface temperature rise during compressor operation. 2 Instrumentation To perform experiments reciprocating air compressor ELGI THPC 500 unit consisting of two sets of cylinders; one for high pressure and other for low pressure has been used. A portable Thermal Imaging camera (EEV make, Model P 4430) has been used for thermal imaging. It incorporates a video output which can be used for direct recording to a computer. The P4430 is a hand-held thermal imaging camera with pyroelectric vidicon detector having spectral response of 8-12 m. It is a self-contained battery/ac power operated unit incorporating a miniature display monitor and can be fitted with interchangeable lens (Focal length 50/75 mm f 0.8) and angle of view 17/11 deg. The equipment is for general thermal imaging applications and gives monochrome thermal pictures. The external video signal is 1 volt 625 lines 50Hz (CCIR compatible) or 525 lines 60 Hz (optional), 30 frames / s and 200 lines per picture height for a temperature difference of 2C (chopped) and 1C (panned). A personal computer having Q motion card for image acquisition and WINVIDEO with Windows operating system has been used. An IR thermometer gun OPTEX THERMO- HUNTER make (Model Q185) is used for direct temperature reading of the object surface having provision of emissivity adjustment. The temperatures have been measured using T type thermocouples. For the purpose, a data acquisition system using GENIE software comprising ADAM 4018 and ADAM 4520 data acquisition modules is used. The camera was calibrated with a hot plate (top surface cast iron) INDIAN J PURE & APPL PHYS, VOL 49, JANUARY 2011 36 having built-in heater and temperature controller and surface temperature was measured with t type thermocouples, placed on the top surface and IR temperature gun for calibration and comparison purpose. The fin tip temperature is measured using infrared thermometer for all the fins on both cylinders. The thermocouple is placed at fin tip for fins 1, 3, 6 and 8 for low pressure cylinder and 1, 3, 6 and 9 for high pressure cylinder as numbered from top. The measured values as obtained using infrared thermometer and thermocouple for both the cylinders are presented in Tables 1-4. The temperature scaling of the thermographs has been done by interpolating the gray scale value of the portion of the image to the temperature range as obtained by the infrared thermometer. 3 Experiments on Compressor The reciprocating air compressor ELGI THPC 500 unit consists of two sets of cylinders; one for high pressure (Fig. 1) and other for low pressure (Fig. 2). These are fitted in V-configuration on a crankcase. The first stage compression end temperature amounts to 70C while second stage amounts to 140C. The heat dissipation is through circular fins of reducing areas. The set-up for the thermal imaging of compressor cylinders is shown in Fig. 3. The thermal images have been acquired in two phases. The first phase incorporated acquisition of thermal images of low pressure cylinder for seven minutes of compressor running with images acquired for every minute of compressor running. The second phase incorporated acquisition of thermal images of high pressure cylinder for seven minutes of compressor Table 1 IR Temperature at fin tips of LP cylinder IR Temperature ( o C ) Fin no 1min 2min 3min 4min 5min 6min 7min No1 22.0 24.0 28.0 30.5 32.5 34.5 37.5 No2 22.0 24.0 26.5 30.0 32.0 34.0 37.0 No3 21.5 23.8 26.5 29.0 31.5 34.0 36.5 No4 21.5 23.8 25.5 28.5 31.0 33.8 36.3 No5 21.4 23.7 25.5 28.5 31.0 33.8 36.0 No6 21.4 22.6 24.5 28.0 30.8 33.6 36.0 No7 21.3 22.4 24.0 27.0 30.5 33.2 35.5 No8 21.3 22.2 24.0 26.0 30.0 33.0 35.0 No9 21.0 22.0 23.0 25.0 29.0 31.0 33.5 Table 2 Thermocouple temperature at fin tips of LP cylinder Thermocouple Temperature ( o C ) Fin no 1min 2min 3min 4min 5min 6min 7min No1 21.26 23.55 27.13 29.03 31.907 33.686 37.107 No3 21.26 23.52 25.57 28.48 31.44 33.596 36.387 No6 21.23 22.46 25.22 27.51 30.637 33.426 35.657 No8 21.23 21.94 23.844 25.69 30.00 32.906 34.576 Table 3 IR temperature at fin tips of HP cylinder IR Temperature ( o C ) Fin no 1min 2min 3min 4min 5min 6min 7min No1 28.0 29.0 31.0 36.0 42.0 48.0 55.0 No2 28.0 29.0 31.0 34.5 40.0 44.0 50.0 No3 27.8 28.5 30.5 34.5 37.5 39.0 40.0 No4 27.8 28.5 30.5 33.5 36.5 37.5 39.5 No5 27.6 28.3 30.5 33.0 36.0 36.5 39.0 No6 27.6 28.2 30.2 31.0 34.0 35.0 38.5 No7 27.6 28.2 30.2 30.5 34.0 35.0 38.0 No8 27.4 28.0 30.0 30.5 33.5 34.0 38.0 No9 27.4 27.5 30.0 30.5 33.0 33.5 37.5 No10 27.2 27.5 29.5 30.0 31.0 33.0 36.0 No11 27.0 27.5 29.0 29.5 30.0 32.0 35.5 SINGH & SINGH: CONDITION MONITORING OF RECIPROCATING AIR COMPRESSOR 37 Fig. 1 High pressure cylinder Fig. 2 Low pressure cylinder running with images acquired for every minute of compressor running. The thermal images of high pressure and low pressure cylinders for alternate minutes are shown in Fig. 4. Fig. 3 Experimental set-up on compressor 4 Modelling and Analysis in ANSYS The cross-section of cylinders is modeled as per dimensions taken from instructional manual of the compressor. The model development and analysis has been carried out in Ansys software Version 8.0 environment. The material of the cylinders is cast iron of thermal conductivity 50 W/mK, density 7.272 kg/m 3 and specific heat 7 420 J/kg K, taken in the analysis. The cylinders have been meshed using PLANE 77 element. A transient conduction and convection analysis has been carried out to generate the fin tip temperature. A convection coefficient 7,8 of 45W/m 2 K has been used on the outer surface of the cylinders for analysis. The point of application of the thermal load has been evaluated by selecting the point of stroke length at which the delivery valve opens and to the point at which end of piston stroke occurs. The maximum temperature rise occurs within this portion of the cylinder and the inner cylinder surface temperature rises over a period of time due to hot compressed air and piston friction. At the outer surface, heat is dissipated to the environment via circular fins of varying sizes from top to bottom. The analysis is based on the evaluation that the outer surface temperature is a function of inner surface temperature and higher the outer surface temperature, Table 4 Thermocouple temperature at fin tips of HP cylinder Thermocouple Temperature ( o C ) Fin no 1min 2min 3min 4min 5min 6min 7min No1 27.86 28.65 30.92 35.57 41.24 47.42 53.65 No3 27.74 27.92 30.72 33.53 35.72 38.36 39.77 No6 27.48 26.98 28.62 30.89 33.16 33.62 37.64 No9 27.33 26.72 28.12 30.55 32.99 33.36 37.56 INDIAN J PURE & APPL PHYS, VOL 49, JANUARY 2011 38 Fig. 4 Thermographs of HP and LP cylinders it will be an indication of higher inner temperature rise. In accordance with the compressor manual, the first stage compression end temperature reaches 70 deg and second stage reaches 140 deg. The rise in temperature happens over a span of compressor operation. The IR gun and TC which give the fins temperature at different timings of operation is taken into account as reference during analysis in ANSYS. The thermal load is applied to modeled cross-section at an assumed value which would generate the fins tip temperature to the nearest values as obtained by IR gun and TC. The point of application of thermal load has been considered by selecting the point of stroke length at which the delivery valve opens and to the SINGH & SINGH: CONDITION MONITORING OF RECIPROCATING AIR COMPRESSOR 39 point at which end of piston stroke occurs. The inner surface thermal load and subsequent fin tip temperature to the nearest value with the ones as obtained by IR temperature gun and thermocouple, are analyzed for given duration of compressor running. The various analytical results as evaluated have been presented in Tables 5 and 6 and the FEM analysis of both the cylinders for alternate minutes have been shown in Fig. 5. 5 Results and Discussion The maximum accuracy is analysed for topmost fin. The comparison drawn for maximum fin temperatures as obtained from IR thermometer, thermocouple and FEA is presented in Tables 7 and 8 and the results are plotted in Figs 6 and 7. The Inner Surface Temperature for LP Cylinder can be evaluated as a function of time (t) in minutes of operation by using the following relation: Inner temperature (C) = 0.0694 (t) 3 + 1.1607 (t) 2 + 0.9444 (t) + 20.071 The Inner Surface Temperature for HP Cylinder can be evaluated as a function of time (t) in minutes of operation by using the following relation: Table 5 FEA temperature (C ) at fin tips of LP cylinder Fin no 1min 2min 3min 4min 5min 6min 7min No1 22.227 23.365 26.549 29.505 32.463 35.648 39.287 No2 22.227 23.365 26.549 29.505 32.463 35.648 39.287 No3 22.182 23.092 25.641 28.007 30.374 32.923 35.835 No4 22.137 22.82 24.732 26.508 28.284 30.197 32.383 No5 22.091 22.547 23.824 25.009 26.195 27.472 28.931 No6 22.091 22.547 23.824 25.009 26.195 27.472 28.931 No7 22.091 22.547 23.824 25.009 26.195 27.472 28.931 No8 22.091 22.547 23.824 25.009 26.195 27.472 28.931 No9 22.091 22.547 23.824 25.009 26.195 27.472 28.931 Table 6 FEA temperature (C ) at fin tips of HP cylinder Fin no 1min 2min 3min 4min 5min 6min 7min No1 28.076 29.712 31.115 36.023 41.164 47.708 54.719 No2 28.076 29.712 31.115 36.023 41.164 47.708 54.719 No3 26.923 28.248 29.384 33.36 37.525 42.826 48.506 No4 26.923 28.248 29.384 33.36 37.525 42.826 48.506 No5 25.769 26.783 27.653 30.697 33.886 37.944 42.293 No6 24.165 25.319 25.922 28.034 30.246 33.062 36.079 No7 24.165 25.319 25.922 28.034 30.246 33.062 36.079 No8 24.165 25.319 25.922 28.034 30.246 33.062 36.079 No9 24.165 25.319 25.922 28.034 30.246 33.062 36.079 No10 24.165 25.319 25.922 28.034 30.246 33.062 36.079 No11 24.165 25.319 25.922 28.034 30.246 33.062 36.079 Table 7 Comparison of temperature (C ) at Fin No 1 of LP cylinder 1min 2min 3min 4min 5min 6min 7min IR 22.0 24.0 28.0 30.5 32.5 34.5 37.5 TC 21.26 23.55 27.13 29.03 31.907 33.686 37.107 FEA 22.227 23.365 26.549 29.505 32.463 35.648 39.287 Assumed Inner Temp 22.5 25.0 32.0 38.5 45.0 52.0 60.0 Table 8 Comparison of temperature (C ) at Fin No 1 of HP cylinder 1min 2min 3min 4min 5min 6min 7min IR 28.0 29.0 31.0 36.0 42.0 48.0 55.0 TC 27.86 28.65 30.92 35.57 41.24 47.42 53.65 FEA 28.076 29.712 31.115 36.023 41.164 47.708 54.719 Assumed Inner Temp 35.0 38.5 41.5 52.0 63.0 77.0 92.0 INDIAN J PURE & APPL PHYS, VOL 49, JANUARY 2011 40 Fig. 5 FEM analysis of HP and LP cylinders SINGH & SINGH: CONDITION MONITORING OF RECIPROCATING AIR COMPRESSOR 41 Fig. 6 Comparison of maximum fin temperature of LP cylinder Fig. 7 Comparison of maximum fin temperature of HP cylinder Inner temperature (C) = 0.0833 (t) 3 + 2.3512 (t) 2 4.6012 (t) + 37.714 6 Conclusions The thermal images of both the cylinders show variation in intensity due to rising surface temperature over a span of compressor operation. The compressor under study does not cater for any kind of temperature measurement to analyse the performance of compressor and hence, thermal imaging of the equipment can be beneficial in analysing the health of the equipment by showing similar thermal images over a specified interval of time which could be as per schedule may be quarterly or half-yearly or depending on the usage of the equipment. In case, the thermal images show a different thermal profile then further investigations can be initiated to identify the possible causes for different thermal pattern. For the cases where thermal patterns are found to be same then certain maintenance routines can be rescheduled which will be cost-effective in terms of manpower and spares replacements. Acknowledgement Authors are thankful to Vice-Chancellor, Defence Institute of Advanced Technology (Deemed University), Girinagar, Pune 411025 for granting permission to publish this work. References 1 Hung-Yi L, Chao S M & Tsai G L, Int J Heat Mass Transf, 48 (2005) 5386. 2 Centre for Power efficiency and environmental protection performance optimiser No: PO-EF-1001, CENPEEP, NTPC India, 2000. 3 Laskar J, Bagarvathiappan M, Sardar S, Jayakumar M, Philip T, J & Baldev Raj, Mat Lett, 62 (2008) 2740. 4 Ay H, Jang J Y & Yeh J N, Int J Heat Mass Transf, 45 (2002) 4069. 5 Jack M Kleinfeld, Finite element analysis as a tool for thermography, SPIE Vol 3700 (1999) 6. 6 Jack M Kleinfeld, Applying FEA to Perform Heat Transfer Calculations to Increase the Utility of IR Thermography, Kleinfeld Technical Services, Inc 2001. 7 Singh Sadhu, Mechanical Engineers Handbook, Khanna Publishers, 2000, Table 387, pp 859-861. 8 J P Holman, Heat transfer, 2002 Edition, Tata McGraw-Hill, pp 48.