Redundant control for a compressor system

Abstract

Redundant control systems, methods, and techniques for providing a virtual redundant transmitter for monitoring and controlling operation of a compressor system are described. The virtual redundant transmitter can be used to continue operating a compressor system in a safe manner in the event of a failure of one or more sensors configured to sense a physical parameter of the operating compressor system, and / or can be used to determine a failure of one or more transmitters configured to transmit data from the sensors to a controller controlling overall operation of the compressor system. Using a virtual redundant transmitter as part of a control system for a compressor or multi-compressor system can limit or completely eliminate the need for dual redundant hardware or even triple redundant hardware.

Description

Technical Field

[0001] This disclosure relates generally to the operation of industrial compressor systems. More specifically, this disclosure relates to redundant control systems for controlling and providing safe operation of industrial compressors. Background Technology

[0002] Various industries (such as, but not limited to, the oil and gas industry) utilize centrifugal and axial compressors to increase the pressure of various fluids, such as natural gas, for transporting these fluids from one location to another or as part of refining and petrochemical processes. Using natural gas as an example, natural gas can be supplied to the inlet of a compressor system that may include one or more compressors, where individual compressors may be arranged in series or parallel with each other. Furthermore, each compressor may consist of several sections, each with its own inlet and outlet. After leaving the compressor system, the compressed natural gas may be coupled into pipelines for transport to one or more different locations, or directed for further processing, such as fractionation, or for other processes that may exist in the oil and gas industry.

[0003] Compressors play a crucial role in many processes and consume a major portion of the total energy demand. Therefore, reliable and efficient operation of compressors constitutes a key priority for operators. To this end, each compressor can be equipped with a control system that includes anti-surge control and protection, as well as capacity control.

[0004] The operation of a capacity control system alters the energy input to the compressor driver, which can be a steam or gas turbine, or an electric motor, thereby changing the compressor's speed and thus its throughput. Alternatively, the compressor driver can act directly on the compressor throughput via, for example, a throttling valve. The capacity control system matches the throughput of the compressor network to the demands of the overall process, minimizing power consumption. Centrifugal and axial compressors, or turbo compressors, have low throughput limitations, specifically determined by the maximum pressure rise the machine can deliver. This low flow boundary is known as the surge limit; exceeding the surge limit causes the compressor's operating point to enter the so-called surge region, leading to unstable operation that can potentially damage the machine. Anti-surge control systems monitor the compressor's throughput and, if the flow rate drops below a minimum acceptable level, act on a recirculation (recovery) valve or vent valve to prevent any further reduction in throughput. Typically, safe operation of turbo compressors requires anti-surge control to prevent process turbulence, interruptions, and machine damage. The correct operation of both the capacity control system and the anti-surge control system depends on receiving accurate field measurements, such as flow rate, pressure, and temperature, via sensors and transducers installed at various locations throughout the process and around the machine. Failure of field instruments may prevent the normal operation of the control system, resulting in reduced efficiency or potentially unsafe operation relative to compressor surge. Summary of the Invention

[0005] The embodiments described in this disclosure include systems, apparatus, methods, and techniques for providing redundant control over compressor systems, such as, but not limited to, industrial compressor systems.

[0006] An exemplary and non-limiting embodiment includes a method comprising: determining one or more control values ​​to be applied by a compressor control application to control operations being performed by a compressor system, wherein determining the one or more control values ​​comprises: determining that a transmitter of data indicating operating parameters of the compressor system has failed; determining alternative input values ​​of the operating parameters of the control system previously provided by the failed transmitter; and providing the alternative input values ​​to the compressor control application via a virtual redundant transmitter (VRT) to continue operating the compressor system using the alternative input values, wherein determining the alternative input values ​​comprises: using a last known good value provided by the transmitter prior to the transmitter failure based on the determination that the compressor system is still operating under steady-state conditions in the event of a transmitter failure; and using an estimate of the alternative input values ​​when it is determined that the compressor system is not operating under steady-state conditions after the transmitter failure.

[0007] Additionally or alternatively, the method may further include: wherein the operating parameters represent control input parameters required for the process control application to maintain control of the compressor system. Additionally or alternatively, the method may further include: wherein the steady-state condition of the compressor system's operation is defined as data provided for the compressor system's operating parameters, having a set of all transmitters that have not yet failed and are providing data indicating operating parameter values, all of which are within a range determined to represent the normal operating range of each parameter. Additionally or alternatively, the method may further include: continuing to operate the compressor system using a primary signal value that includes the last known good value that existed before the transmitter failure. Additionally or alternatively, the method may further include: wherein determining whether the compressor system is still operating under steady-state conditions in the event of a transmitter failure uses the physical principles of turbine operation to determine whether the compressor system is operating under steady-state conditions.

[0008] Additionally or alternatively, the method may further include: wherein the VRT internally generates a last known good value as an alternative input value based on a plurality of input signals provided to the VRT according to an input signal processing algorithm that operates on a plurality of input signals provided by a plurality of transmitters of the compressor system. Additionally or alternatively, the method may further include: providing the last known good value as an alternative input value to a compressor control application to continue operating the compressor system using the alternative input value while the compressor system is operating under steady-state conditions; determining that the compressor system is no longer operating under steady-state conditions; and providing an estimate of the alternative input value for continuing to operate the compressor system based on the determination that the compressor system is no longer operating under steady-state conditions. Additionally or alternatively, the method may further include: determining a region of operation for the compressor system in which it is safe to control the operation of the compressor system using the estimate of the alternative input value.

[0009] Additionally or alternatively, the method may further include: applying a statistical correlation between the static and dynamic behavior of the compressor system to determine the effectiveness of using estimated values ​​as alternative input values ​​to control the operation of the compressor system. Additionally or alternatively, the method may further include: automatically adjusting the configuration of the compressor system, including adjusting the configuration of the anti-surge system such that the surge margin increases when using the last known good value or estimated value. Additionally or alternatively, the method may further include: performing a mathematical transformation on a secondary signal being provided by a health transmitter, the health transmitter operating to provide data indicating operating parameters of the compressor system to match the value of a primary signal previously provided by a faulty transmitter.

[0010] Another non-limiting exemplary embodiment includes a process control system for controlling the operation of a compressor system, the process control system comprising: a computer system including a processor and at least one memory device communicatively coupled to the processor, the at least one memory device including program instructions that, when executed by the processor, cause the processor to: determine one or more control values ​​to be applied by the compressor control application to control the operation being performed by the compressor system while the compressor system is operating to receive gas or vapor at a first pressure at the input of the compressor system and output compressed gas or vapor at a second pressure higher than the first pressure at the output of the compressor system; wherein the determination of one or more control values ​​is... The instructions for controlling the value include instructions for causing the processor to: determine that the transmitter of data indicating the operating parameters of the control system has failed; determine alternative input values ​​for the operating parameters of the control system previously provided by the failed transmitter; and provide alternative input values ​​to the compressor control system via a virtual redundant transmitter (VRT) to continue operating the compressor system using the alternative input values, wherein determining the alternative input values ​​includes: using the last known good value provided by the transmitter before the failure, based on the determination that the compressor system is still operating under steady-state conditions in the event of a transmitter failure; and using an estimate of the alternative input values ​​when it is determined that the compressor system is not operating under steady-state conditions after the failure of the transmitter.

[0011] Additionally or alternatively, the process control system may further include: wherein the process control system is configured to continue operating the compressor system using a primary signal value including a last known good value that existed prior to the transmitter failure. Additionally or alternatively, the process control system may further include: the process control system being further configured to: provide the last known good value as an alternative input value to the compressor control application to continue operating the compressor system using the alternative input value while the compressor system is operating under steady-state conditions; determine that the compressor system is no longer operating under steady-state conditions; and provide an estimate of the alternative input value for continuing to operate the compressor system based on the determination that the compressor system is no longer operating under steady-state conditions. Additionally or alternatively, the process control system may further include: wherein the process control system is further configured to determine a region of operation for the compressor system in which it is safe to control the operation of the compressor system using the estimate of the alternative input value.

[0012] Additionally or alternatively, the process control system may further include: wherein the process control system is further configured to apply a statistical correlation covering both the static and dynamic behavior of the compressor system to determine the effectiveness of using estimated values ​​as alternative input values ​​to control the operation of the compressor system. Additionally or alternatively, the process control system may further include: wherein the process control system is further configured to perform a mathematical transformation on a secondary signal being provided by a health transmitter, the health transmitter operating to provide data indicating operating parameters of the compressor system to match the value of a primary signal previously provided by a faulty transmitter.

[0013] Another non-limiting exemplary embodiment includes a non-transitory computer-readable medium storing computer-readable instructions that, when executed by a processor, cause the processor to: determine one or more control values ​​to be applied by a compressor control application to control the operation being performed by the compressor system while the compressor system is operating, wherein the instructions for determining the one or more control values ​​include instructions for causing the processor to: determine that a transmitter of data indicating operating parameters of the control system has failed; determine alternative input values ​​for the operating parameters of the control system previously provided by the failed transmitter; and provide the alternative input values ​​to the compressor control system via a virtual redundant transmitter (VRT) to continue operating the compressor system using the alternative input values, wherein determining the alternative input values ​​includes: using the last known good value provided by the transmitter before the transmitter failure based on the determination that the compressor system is still operating under steady-state conditions in the event of the transmitter failure; and using an estimate of the alternative input values ​​when it is determined that the compressor system is not operating under steady-state conditions after the transmitter failure.

[0014] Additionally or alternatively, the non-transitory computer-readable medium may further include: wherein the computer-readable instructions, when executed by a processor, cause the processor to apply a statistical correlation covering both the static and dynamic behavior of the compressor system to determine the effectiveness of using an estimated value as an alternative input value to control the operation of the compressor system. Additionally or alternatively, the non-transitory computer-readable medium may further include: wherein the computer-readable instructions, when executed by a processor, cause the processor to: provide a last known good value as an alternative input value to the compressor control application to continue operating the compressor system using the alternative input value when the compressor system is operating under steady-state conditions; determine that the compressor system is no longer operating under steady-state conditions; and provide an estimated value of the alternative input value for continuing to operate the compressor system based on the determination that the compressor system is no longer operating under steady-state conditions. Attached Figure Description

[0015] To gain a more complete understanding of this disclosure, reference is now made to the following description in conjunction with the accompanying drawings. The figures discussed below, and the various embodiments used to illustrate the principles of the invention in this patent document, are merely illustrative and should not be construed as limiting the scope of the invention in any way. Those skilled in the art will understand that the principles of the invention can be implemented in any suitably arranged device or system.

[0016] Figure 1 It is a schematic block diagram of a multi-segment compressor system with various flow, pressure and temperature measurement points based on various implementation schemes.

[0017] Figure 2 This is a block diagram illustrating a specific implementation of a virtual redundancy transmitter (VRT) in a compressor control system according to various implementation schemes.

[0018] Figure 3 It is a functional block diagram of the specific implementation of VRT logic according to various implementation schemes.

[0019] Figure 4 It is a diagram of the state machine for the operation states of VRT function blocks according to the definitions of various implementation schemes.

[0020] Figure 5 It is a flowchart of a method for operating a compressor control system according to various implementation schemes.

[0021] Figure 6 This is a block diagram illustrating computer systems according to various implementation schemes. Detailed Implementation

[0022] The software implementation of a compressor control system may include one or more applications, such as capacity control or performance applications, and anti-surge applications. Each application receives process measurements about the operation of the compressor system from a transmitter coupled to a sensor that measures one or more parameters of the compressor control system, such as temperature, pressure, and flow rate. The transmitter generates signals indicative of sensed parameters of a control system (such as a computer control system) configured to monitor and control the operation of the compressor system. Whenever a transmitter or sensor fails, the control application switches to a special operating mode called a “backoff strategy.” These backoff strategies are designed to improve the robustness of the control system and ultimately improve equipment availability. However, in many cases, the activation of backoff strategies can disrupt the entire process because a balance must be struck between keeping the process running as efficiently as possible and maintaining unit safety when not all measurements are available.

[0023] To prevent process disruptions, unsafe operation, or complete loss of productivity due to transmitter failure, users sometimes install dual-redundant or even triple-redundant transmitters, increasing installation cost and complexity due to the additional wiring and instrumentation. Meanwhile, the measurements received by the compressor control system often already possess a degree of redundancy, as gas parameters such as pressure may not change significantly at different sensor locations along the gas path. Measurements may differ due to frictional losses or the presence of other equipment (such as heat exchangers and valves) at the measurement locations; however, their behavior may allow one measurement to be used in place of another under certain conditions.

[0024] Compared to non-redundant (simplex) installations, traditional redundancy requires additional materials and physical space, thus increasing installation and maintenance costs. For example, Figure 1 The possible measurement results shown demonstrate that this new method will allow users to benefit from redundancy without installing additional physical equipment. This method will increase the reliability of the system without requiring additional equipment.

[0025] This disclosure describes an implementation of a method for improving the reliability of control systems for turbines, such as compressors, by replacing primary process measurements with secondary measurements when primary measurements fail and secondary measurements have been determined to be a valid representation of the primary measurements. Turbines in process applications (such as the oil and gas and petrochemical industries) have multiple operating modes, some of which may preclude the use of secondary values ​​as a valid representation of primary values. Secondary measurements can be signals from another transmitter connected to the system, or values ​​generated by a digital model of the compressor and through associated processes in the control system. The proposed method uses the statistical correlation and physical relationship between primary and secondary measurements, as well as the physical operating principles of the turbine unit, to determine:

[0026] • When can a turbine unit continue to utilize the primary signal value (last known good value or LGV) that existed before the fault and without needing to operate with the secondary value? This method uses the physical principles of turbine operation to determine the unit's steady-state conditions. If a steady-state condition exists, the system uses the LGV, thus completely avoiding switching to the secondary signal.

[0027] • Mathematical transformations of the secondary signal are used to match the primary signal in order to minimize the impact on the process when the control system switches from the primary signal to the secondary signal, since the secondary signal will typically not have the same value as the primary signal. The system begins to use the secondary signal when steady-state conditions no longer exist and LGV is no longer a valid representation of the associated process parameters. In addition to the primary signal itself, the transformation can use other parameters to develop an estimate of the primary signal.

[0028] • In the operating area of ​​the turbine unit, it is safe to use the secondary signal as a replacement for the primary signal.

[0029] • Statistical correlation, which covers both the static and dynamic behavior of the signal, is used to determine the effectiveness of using a secondary signal as a representation of the primary signal. Automatic adjustments in the configuration of control systems (especially anti-surge systems) increase surge margin when using secondary values.

[0030] Anti-surge control systems for turbo compressors utilize several measurements, including pressure, temperature, and differential pressure from flow measurement devices (FMDs). In the event of a failure in any of these signals, a so-called rollback strategy is employed to allow the unit to continue operating, despite the most likely reduced throughput, negatively impacting plant key performance indicators (KPIs). Rollback strategies use different algorithms that exclude fault signals; however, the system operates under worst-case assumptions, often resulting in recirculation around the compressor, thus reducing efficiency.

[0031] In many process compressor applications, several measurements may provide similar readings under certain circumstances. For example, in a multi-stage compressor, when the unit is running and there is a forward flow from the first stage to the second stage, the suction measurement of the second stage will be closely related to the discharge pressure of the first stage. See also Figure 1 If the check valves between sections remain open, PT-12 and PT-21 can provide similar measurement results. However, the measurement results will differ due to pressure losses at the pipes, heat exchangers, and inlet scrubbers. Therefore, in these cases, it may be beneficial to use a health signal from one section instead of a fault signal from an adjacent section. However, these two issues preclude the use of adjacent measurement results to replace each other:

[0032] 1. Inconsistent Signals—Differences will exist due to pressure drops in pipes, containers, and coolers. These differences may be large enough to cause overly conservative operation of the control system (leading to recirculation) or unsafe operation, i.e., compressor surge. There may also be varying degrees of time delay between the signals.

[0033] 2. In some cases, such as when each section is recirculating and the check valves between sections are closed, the signals may not be usable interchangeably. In this situation, the pressure between the first and second sections represents different measurement points that are unrelated to each other.

[0034] The implementation of the methods and techniques described in this paper addresses the issues related to Project 1 above by:

[0035] 1. The secondary signal is transformed to match the primary signal using physical principles (e.g., pressure drop is proportional to the square of the mass flow rate in the pipe) and statistical regression methods. Secondary values ​​may include safety factors or biases representing uncertainties in their calculations. In practice, this bias is always applied in a direction that enhances turbine protection based on its use in control algorithms that include limit loops.

[0036] 2. Identify the operating region where replacements can be applied with high reliability. For example, if the cell is already operating within a certain region, the transformation described in (a) can be derived. If the operating point moves outside that region, the replacement may no longer be effective. This also applies to cases where the model generates secondary signals. Such models can only have high reliability within a specific operating region.

[0037] 3. Automatically adjust the parameters of the control system to operate in a more conservative manner. For example, when operating with secondary signal values, the anti-surge margin can be increased by a certain amount, which can be dynamically determined based on the degree of uncertainty of the secondary signal used (e.g., the maximum error of the prediction).

[0038] The implementation of the methods and techniques described in this paper addresses the issues related to Project 2 above by:

[0039] - Statistical correlation is used to ensure that the replacement can occur with high confidence; and

[0040] - Using physical principles, such as estimating the forward flow rate of the compressor section, to determine the position of the check valve as a condition for permissible replacement. Physical signals, such as indications of the position of isolation valves, can also be used.

[0041] The embodiments disclosed herein also include a steady-state detector that allows the use of the fault signal's LGV while steady-state conditions remain valid, thereby avoiding switching to secondary values ​​for as long as possible. The steady-state detector monitors several turbine parameters (i.e., pressure, flow rate, speed, etc.). As long as these are determined to be stationary, the entire unit is considered to be operating in a steady state.

[0042] The advantages of the systems, apparatus, methods, and techniques described in this disclosure over existing compressor control systems include, but are not limited to, the following:

[0043] 1. Use the last known good value as an alternative value for data that is no longer provided to the compressor control application due to transmitter failure;

[0044] 2. Use continuous monitoring to determine the steady-state model for operating the compressor control system;

[0045] 3. Correlation between adjacent data sensors / transmitters, which provide data from different locations within the compressor system but are determined to be correlated in a definable manner, such that this correlation can be used to generate a virtual redundant transmitter capable of outputting acceptable values ​​to replace operational data no longer provided by a faulty or unhealthy transmitter; and

[0046] 4. When replacing measurement data from compressor control applications that no longer provide data for controlling the operation of the compressor system with control parameters already generated by the virtual redundancy transmitter for operating the compressor system, a safety factor is used.

[0047] Figure 1 This is a schematic block diagram of a multi-segment compressor system 100 with typical sensors and transmitters, based on various implementation schemes. (Example) Figure 1 The multi-stage compressor system (system 100) shown includes a three-stage compressor comprising a first compressor stage 110, a second compressor stage 120, and a third compressor stage 130. All stages are coupled to the same compressor shaft 102 and connected to a prime mover 101, which provides rotational motion to the compressor. The prime mover can be a steam turbine or gas turbine, an electric motor, etc. Gas flows from the inlet suction manifold 103 into the suction scrubber 119, and then into the suction pipe 113 of the first compressor stage 110, where it is compressed and delivered to the discharge pipe 115. A cooler 116 cools the gas before it enters the suction container 129 of the second compressor stage via the suction pipe 123. Stage 120 further compresses the gas and delivers it to the suction scrubber 139 of the third stage 130 via the discharge pipe 125 and the second stage cooler 126. Gas enters the third section from the suction scrubber via pipe 133 and is discharged into pipe 135. Finally, the gas is cooled in the third section cooler 136 and delivered to the discharge manifold 104.

[0048] Each compressor section 110, 120, and 130 has a corresponding recovery line and anti-surge control valves 111, 121, and 131. A control system 150 is used to prevent surge in the compressor sections by recirculating part or all of the flow via the anti-surge control valves (ASVs) 111, 121, and 131. One-way valves or check valves 117, 127, and 137 prevent backflow from downstream pipes and containers into each compressor section, which may occur if there is no forward flow from the suction manifold 103 to the compressor and the flow entering each section is recirculated via the corresponding anti-surge valve without flow from the previous section. The control system 150 can also maintain relevant process parameters, such as the flow rate from the compressor to the downstream process, or the compressor suction or discharge pressure, by adjusting the drive speed to match process requirements. The compressors used as compressor sections 110, 120, and 130 are centrifugal and axial compressors, commonly referred to as turbo compressors.

[0049] System 100 includes multiple sensor and transmitter devices located at various locations throughout system 100. These sensors and transmitter devices sense various parameters occurring within system 100, such as pressure, temperature, and flow rate, and transmit these values ​​to control system 156. By way of non-limiting example, PT-1 and PT-2 are pressure transmitters that measure the pressure at the inlet manifold 103 and outlet manifold 104 of system 100, respectively. Each compressor section has suction pressure transmitters and discharge pressure transmitters: PT-11 and PT-12 for section 110, PT-21 and PT-22 for section 120, and PT-31 and PT-32 for section 130. Temperature is also measured at the suction and discharge points of each section using TT-11, TT-12, TT-21, TT-22, TT-31, and TT-32. The flow rate of each section can be measured using transmitters FT-1, FT-2, and FT-3 via flow measurement devices installed in the suction pipe of each section.

[0050] The control system 156 receives input signals from various transmitters via electrical connections or other communication components, processes these signals in a software control application, calculates its response, and transmits its response via output signals to the anti-surge valves of each segment 111, 121, and 131, respectively, and to the prime mover 101.

[0051] like Figure 1As shown, controller 150 includes a Virtual Redundant Transmitter (VRT) 154 and a control application 156. VRT 154 includes software modules or blocks. Each VRT block receives and processes data provided by transmitters included in system 100, which (e.g., PT-12 and PT-21) have similar values ​​during normal operation. Transmitters with similar values ​​are shown connected via links 151, 152, and 153. Other input signals are directly passed to the control application. As part of processing the data received from the transmitters included in system 100, each VRT block of 154 detects faults in the input signals based on the data being provided by the associated transmitter or due to wiring or control system hardware failure.

[0052] In a first possible scenario of the operating system 100, all transmitters included in system 100 are operating normally and are transmitting valid data to controller 150. In this first scenario, VRT 154 processes the incoming data, determines that all transmitters are healthy (i.e., transmitting valid data), and passes the data as actual measured data values ​​to control application 156. Control application 156 is configured to process the inputs received from VRT 154 and provide control outputs to various devices included in system 100 to control the operation of the compressor system.

[0053] In a second possible scenario for operating system 100, the transmitter either completely fails and stops sending data to controller 150, or is otherwise defective and is sending invalid data values. VRT 154 is configured to detect data loss from the transmitter, or, in instances where some data is still being sent from the transmitter to controller 150, determine that the data being provided by the transmitter is invalid, and thus determine that the transmitter is unhealthy. Upon determining that the transmitter is unhealthy, VRT 154 is configured to generate alternative values ​​for a Virtual Redundant Transmitter (VRT), if possible, to replace the data previously provided by the now unhealthy transmitter. VRT 154 has several options for generating alternative VRT values. In one implementation, VRT 154 utilizes data received from different but still healthy transmitters operating in system 100. Data received from different but still healthy transmitters is considered an acceptable replacement, and in some implementations where a bias factor and / or security factor are added, this data is considered replacement data for the data previously provided by the now unhealthy transmitter.

[0054] As an illustrative example, at a certain point in time, PT-12, located at output 115 of compressor 110, serves as an example of a faulty or defective transmitter. Given the missing or invalid data received from the transmitter associated with PT-12, VRT 154 determines that the data being provided by PT-21, located at input 123 of compressor 120, is an acceptable replacement, as indicated by link 152, for the data previously provided by the unhealthy transmitter associated with PT-12. Since these points within system 100 are coupled via cooler 116, check valve 117, and scrubber 129, they should still have similar values ​​and response ranges. VRT 154 can be configured to consider that intermediate devices 116, 117, and 129 add correction factors to the data being provided by the transmitter associated with PT-21, and / or add safety factors to the data values, and then provide these alternative values ​​to control application 156 in place of the measurements previously provided by the now unhealthy transmitter associated with PT-12. Using alternative values ​​generated by VRT 154, the operation of compressor system 100 can continue uninterrupted.

[0055] When steady-state conditions are present, as determined by monitoring other health inputs of compressor system 100, VRT 154 may determine the last known good value as the value previously received from the now unhealthy transmitter, as an alternative to using data from a different and healthy transmitter to replace data previously provided by the now unhealthy transmitter, and provide the last known good value as an alternative value to control application 156 to replace the measurement data value previously provided by the now unhealthy transmitter. On the other hand, when steady-state conditions no longer exist, or when a failure occurs when the initial steady-state conditions did not exist, VRT 154 may determine an estimate that is determined as an acceptable replacement value for the data value previously provided by the now unhealthy transmitter, and provide the estimate as an alternative value to control application 156 to replace the measurement data value previously provided by the now unhealthy transmitter, as discussed in paragraph 037. Acceptability criteria are based on statistical correlation calculated just before the primary measurement result fails, and may have additional logic based, for example, on an estimate of the forward flow from section 110 to section 120. Similarly, the estimate can be a factor with a safety margin or bias before being provided to the control application 156. Using an alternative value generated by VRT 154 as the last known good value or as an estimate, the operation of the compressor system 100 can continue uninterrupted. Further details of implementation schemes for the methods and techniques used to generate the last known good value and the estimate are described below.

[0056] In limited instances, VRT 154 determines that it cannot generate or otherwise provide an acceptable value to replace data previously provided by a now unhealthy transmitter, or as a result of, for example, the failure of multiple transmitters within system 100. In such cases, VRT 154 may be configured to indicate a “fault” state to control application 156. Upon receiving the indication of a “fault” state, control application 156 may be configured to provide output control signals to one or more devices of system 100 to safely control further operation of the system, which may include shutting down one or more compressors included in system 100.

[0057] The ability to create virtual transmitters within system 100 to replace faulty or otherwise unhealthy transmitters allows system 100 to continue operating safely at a certain capacity without requiring double or even triple redundancy regarding hardware sensors and transmitters. Therefore, the implementation described herein provides an improvement in the technical field of compressor system operation by reducing costs, eliminating downtime, and assuming safe and continuous operation of the compressor system even in the event of failure of sensors and / or associated transmitters configured to provide data related to the physical parameters of the compressor system while it is operating. Using alternative values ​​generated by virtual redundant transmitters (such as, but not limited to, VRT 154) to provide data input to control applications (such as, but not limited to, control application 156), and allowing the compressor system to continue operating despite one or more unhealthy transmitters, provides pre-incident applications using virtual redundant transmitters as described herein and any equivalents thereof.

[0058] Figure 2 This is a block diagram 200 illustrating a specific implementation of a virtual redundancy transmitter (VRT) 230 in a compressor control system according to various embodiments. Diagram 200 includes a main signal input processing block 210, an alternative value input processing block 212, and an application-specific logic block 214 coupled to the inputs of the VRT 230, as well as outputs provided by the VRT 230 coupled to a compressor control application 260 via an output block 250. Figure 2 One, some, or all of the illustrated functional blocks can be implemented as computer circuitry that executes program applications included in the compressor controller, such as, but not limited to, those described above. Figure 1 Any embodiment of the compressor controller application 156 illustrated and described, and configured to perform any function and provide any feature attributed to the compressor control application 156, and / or as described below regarding computer system 602 and Figure 6 Perform as illustrated and described. In various implementations, VRT 230 is Figure 1The VRT 154, and can be configured to perform any function and provide any feature attributed to the VRT 154. In various embodiments, compressor control application 260 is... Figure 1 The compressor control application 156 can be configured to perform any function and provide any feature attributable to the compressor control application 156.

[0059] As shown in Figure 200, input processing block 210 is configured to receive or access input 203 from transmitter 202. Input 203 may include data in the form of measurements provided as data signals from each transmitter in transmitter 202, which are related to sensed physical parameters of the compressor system to which VRT 230 is configured to supervise. In various embodiments, input processing block 210 is configured to determine, for example, based on data recently received from each of the transmitters, whether the transmitter is healthy and functioning properly. The determination of the health status of a particular transmitter may be based on a comparison of the latest data value received from the transmitter (i.e., at input 203) with the expected range of values ​​for that particular transmitter.

[0060] If the latest value of the data received from a particular transmitter is within the expected range, input processing block 210 considers the transmitter to be healthy. Based on the determination that the transmitter in question is healthy, input processing block 210 is configured to pass the measurement value provided by the transmitter (as indicated by arrow 211) to VRT 230, and to pass an indication signal to VRT 230 (as indicated by arrow 213) indicating that the measurement value is being provided by a healthy transmitter. Based on the measurement value and the corresponding health signal indication received from input processing block 210, VRT 230 is configured to pass the measurement value from VRT 230 to compressor control application 260 via one of VRT switches 240, 242, as further described below. In addition to passing the measurement value of a particular transmitter to compressor control application 260, VRT 230 can also be configured, for example, to use output 250 to pass a status indication that a particular measurement value provided at output 250 is valid.

[0061] Upon receiving a measured output value and an indication of validity of that value from output block 250, compressor control application 260 is configured to apply the output value to a control process being provided by compressor control application 260 to operate and control the compressor system. Multiple measured output values ​​may be provided at output block 250, along with a set of corresponding validity indications for each of the output values ​​provided simultaneously and in parallel at output block 250, for example, as provided by an operating cycle of VRT 230. In various embodiments, VRT 230 may be implemented as a function block in a PLC / programmable logic controller that runs control applications such as anti-surge or speed control applications. The inputs of this function block are connected to the system inputs of the controller via input processing blocks 210 and 212, and to application-specific logic block 214. The outputs of this block are connected to control application 260.

[0062] like Figure 2 As shown, VRT 230 includes multiple virtual switches 240, 242. Although shown as having two switches 240 and 242, implementations of VRT 230 may include any number of switches, as illustratively represented by dashed line 233. In some implementations, the number of virtual switches is at least equal to the number of transmitters 202 that VRT 230 is configured to control individually, with respect to which the output of each transmitter is coupled via output block 250 to pass control values ​​to control application 260. Using switch 240 as an example, switch 240 has a first input 240A coupled to measurement input block 220, a second input 240B coupled to VRT logic block 232, and an output 240C coupled to output block 250. VRT logic block 232 is configured to control the operating state of virtual switch 240 using switch control pipeline 241. In various implementations, regarding switch 240, VRT logic block 232 is configured to use control pipeline 241 to set switch 240 such that switch 240 couples input 240A having a measurement value for a specific transmitter in transmitter 202 to output 240C and output block 250, wherein the value provided at output block 250 is passed to control application 260. The setting of switch 240 for coupling input 240A to output 240C can be determined by VRT logic block 232, for example, based on a validity signal provided by main signal processing block 210 for the same transmitter, to determine whether the input provided by main signal processing block 210 for the specific transmitter value associated with switch 240 is valid.

[0063] VRT logic block 232 is also configured to reuse control pipeline 241 to set switch 240 such that input 240B is coupled to output 240C, instead of input 240A being coupled to switch output 240C. When configured such that input 240B of switch 240 is coupled to output 240C, the value provided by VRT logic block 232, along with any valid signals provided to output block 250, can be provided to output block 250 via switch 240, wherein the value provided to output block 250 from VRT logic block 232 via switch 240 is passed to control application 260 via output block 250.

[0064] In a similar manner, switch 242 is configured to use control pipeline 243, provided by VRT logic block 232 via control pipeline 243, to operate switch 242 to couple input 242A to output 242C to provide the transmitter's measurement value to output block 250 when it is determined that the transmitter associated with switch 242 is providing valid data, and to operate switch 242 to couple input 242B to output 242C to provide the value provided at input 242B from VRT logic block 232 to output block 250 when it is determined that the transmitter associated with switch 242 is not providing valid data.

[0065] Therefore, each switch in VRT 230 (including switches 240, 242 and all additional switches 233 included in VRT 230) is configured to operate individually based on output signals provided individually to each switch from VRT logic block 232. The settings for each switch can be determined individually by VRT logic block 232 based on a determination made for that particular switch regarding whether a measurement value of the transmitter associated with each corresponding switch is valid or invalid. For a transmitter determined to provide a valid measurement data value, the switch associated with that particular transmitter can be set by VRT logic block 232 to provide the measurement data value as an output from the switch to output block 250. For a transmitter determined not to provide valid data, the switch associated with that particular transmitter can be set to provide alternative values, such as alternative values ​​generated by VRT logic block 232 and / or alternative values ​​provided to VRT logic block 232 by alternative value input processing block 212, and alternative values ​​provided as an output from the switch to output block 250.

[0066] At a certain point in time, for example, based on the scan cycle of the operation of VRT 230, and for example based on a trigger signal provided to output block 250 from VRT logic block 232 via control pipeline 251, output values ​​provided from all switches included in VRT 230 can be transferred from output block 250 to control application 260. Upon receiving these control values ​​from output block 250, control application 260 is configured to apply the received control values ​​for operation of the compressor system. In some embodiments, where all transmitters in transmitter 202 are determined to provide valid data, the output provided by output block 250 includes only the transmitter's measured values. In other embodiments, the output provided by output block 250 includes one or more alternative values ​​provided by VRT logic block 232 as replacement values ​​for one or more transmitters determined not to provide valid data.

[0067] In various implementations, one or both of boxes 210 and 212 may determine that the data being provided by the transmitter is unhealthy and should not be forwarded for use by the compressor control application 260, or that the transmitter has malfunctioned and is not providing data at all. Any combination of the standards described above or some combination of these determining techniques may be used, or box 210 may be configured to utilize some other method to determine unhealthy data or the absence of data from a particular transmitter.

[0068] In various implementations, the determination of unhealthy data or the absence of data from a particular transmitter may be provided as an indication from input processing block 210 to VRT 230, for example via link 213. Upon receiving an indication of unhealthy data or the absence of data from input processing block 210, VRT 230 is configured to determine, for example, using a state machine process and / or machine learning tools, whether a valid alternative value is available to replace the unhealthy or missing measurement. In various implementations, VRT 232 is configured to determine whether a valid alternative value is available using a state machine process further illustrated and described below, the implementation of which includes:

[0069] - Determine that measurement data from different and healthy transmitters can be safely replaced with application input values ​​to be used by the compressor control application 260, instead of the data values ​​previously provided by the now-failed transmitter;

[0070] - Determine that the last known good value received from the currently unhealthy transmitter can be safely used in the future as an application input value to be provided for use by the compressor control application 260, in place of the data value previously provided by the now-failed transmitter;

[0071] - Determine that the estimates generated by the model input processing block 220, for example using machine learning tools, can be safely used in the future as application input values ​​to be provided to the compressor control application 260, in place of the data values ​​previously provided by the now-faulty transmitter; and

[0072] - It is determined that no valid alternative value is available, which can be safely used in the future as an application input value to be provided for use by the compressor control application 260, in place of the data value previously provided by the now-faulty transmitter.

[0073] In various implementations, based on the determination by VRT 230 that there is at least one alternative value that can be safely used by the compressor control application 260 to replace a measurement previously provided by a now unhealthy transmitter, VRT 230 is configured to provide the alternative value to output block 250 by setting a switch associated with that particular transmitter, along with an indication of validity provided by control pipeline 251 regarding the validity of the alternative value. Based on the receipt of the alternative input value or replacement input value and the indication of validity of the alternative input value or replacement input value, compressor control application 260 can be configured in some implementations to continue operation in normal operating mode using the alternative value or replacement value provided by model input processing block 220 through switch 242 of VRT 230.

[0074] In implementations where no acceptable value is available or can be determined to be safe to use as an application input value in place of measurement data previously provided by a now unhealthy transmitter, the signal may be provided, for example, via a switch or directly from the VRT 232 logic block, and a signal may be provided at output block 25 to indicate to the compressor control application 260 the unavailability of alternative data as a replacement for data previously provided by a now unhealthy transmitter. In various implementations, in response to receiving an indication of a fault mode, the compressor control application 260 may be configured to generate an output control signal to one or more devices included in the compressor system and controlled by the compressor control application 260, which, given the lack of data provided to the compressor control application, will safely control further operation of the compressor system.

[0075] Figure 3This is a functional block diagram 300 of a specific implementation of VRT logic block 320 according to various embodiments. VRT logic block 320 includes VRT logic 321, which may include software, software applications, hardware, and / or firmware configured to allow VRT logic block 320 to perform any functions and provide any features attributable to the characteristics of the virtual redundant transmitter as described herein. As shown in Figure 300, VRT logic block 320 includes VRT block 320 having inputs including a main input, an Alt value, and Alt-valid inputs, as well as outputs Out, an estimate, a status, and AE. The main input may include measurement data provided directly from a transmitter of the compressor control system, and / or data processed by a main input processing block (such as main signal input processing block 210). Figure 2 The data processed by VRT logic block 320 is coupled to receive data inputs that provide potential alternative values ​​for the primary measurement data and supplement with alternative values ​​for quality health or unhealthy conditions. Alt value inputs can be processed by, for example, block 212 ( Figure 2 Input processing blocks such as ) are provided. The valid Alt input can be coupled to receive a signal, in some implementations, a binary "valid" or "invalid" signal indicating whether the data provided at the Alt value input is valid. In various implementations, this can be obtained from, for example, application-specific logic block 214 ( Figure 2 Application-specific logic blocks, such as those that provide valid Alt input, can be used to provide Alt input.

[0076] In various implementations, the signal-1, signal-2, and signal-3 inputs to VRT block 320 are measurement data directly from the transmitter and / or have been input via blocks 210 and 212 ( Figure 2 The same type of input processing block processes transmitter data-related process monitoring signals, which can be used to determine the stability of the compressor system's operating state. These signals can be used to determine whether data provided by another transmitter offering sensing information related to the compressor system can be replaced with alternative values ​​of data previously provided by the transmitter that has now been determined to be invalid. For example, signal-1, signal-2, and signal-3 inputs can be used to confirm that the last known good value of the substituted transmitter data is valid, as further described below.

[0077] In various implementations, such as the main signal input processing block 210 ( Figure 2Process monitoring blocks, such as VRT 320, can be configured to provide continuous process monitoring of parameter values ​​provided by all transmitters supplying data to the compressor system, allowing VRT 320 to determine when the last known good value is available for the operating parameter should a transmitter that previously provided sensing information for the operating parameter fails. Input 308 may include measurement data from the transmitters, and measurement data that may or may not be further processed by the process monitoring block is provided to VRT 320 as input 308. Deviation analysis block 310 receives measured values ​​and estimated values ​​304 as input via link 302 and provides an output to VRT 320 via link 311, indicating the deviation between the estimated value and the master measured value when both values ​​are healthy. Engineering documents and templates can be used to determine the estimated values, including, for example, compressor technical manuals, work instructions including typical application scenarios, application templates, user manual templates, and other engineering data related to the equipment and configuration of the compressor system.

[0078] Implementations of the VRT 300 may include the fbVRTDevAnalysis block 310. In various implementations, block 310 performs an analysis of the difference between the estimated value and the main input of the VRT block 320. The analysis of the difference (estimated value - main input) is performed continuously over a time window starting from the second before the last execution of the block and ending at the end of the last execution of the block. The time window is a configured value in the fbVRTDevAnalysis block 310. The results of the analysis of the difference (estimated value - main input) include, but are not limited to, the mean, minimum, and maximum values, the stability of the difference, and the statistical correlation between the estimated value and the main input. The analysis results are provided to the deviation analysis input of the VRT 320 from the status output of block 310 via link 311.

[0079] Regarding the inputs to VRT block 320, signals -1, -2, and -3 are input signals from the process monitoring block and are used to verify the Last Known Good Value (LGV) status. Deviation analysis input 311 is a data structure containing the analysis results of the (estimated value - main input) difference. In various implementations, VRT 320 operates as a state machine that, for any given operating parameters provided by VRT 320 to compressor control application 330, determines when to use the measured value and when to use an alternative value, and which alternative value to use as the output provided to the compressor control application at output 330.

[0080] In various implementations, Out is used to direct output 330 to applications such as control applications 260. Figure 2Control applications such as VRT 320 provide control value outputs. Estimated value outputs can be fed back to block 310 to determine the status output being provided by block 310, which in turn can be used by block 320 to determine the validity of one or more alternative values ​​being provided to block 320 at the Alt value input and / or generated by the VRT block itself. The status output of VRT block 320 provides diagnostic and other information related to the process being performed by VRT block 320 and / or other aspects, such as transmitter data received and processed by the VRT block. AE outputs can provide alarm signal outputs and / or event outputs configured to alert system users to various alarm conditions present or potentially present related to the operation of the compressor system being monitored by VRT 320.

[0081] Figure 4 This is a diagram of a state machine 400 representing the operational states of a VRT function block, as defined in various implementation schemes. In various implementation schemes, state machine 400 represents the operational states of the VRT function block as described above. Figure 2 The VRT block 230 illustrated and described above and / or as per the above description Figure 3 The state machine implemented in the operation of the illustrated and described VRT block 320.

[0082] Return to reference Figure 4 Figure 400 begins at initialization box 410. The process steps included at box 410 may include checking input connections, such as those from frames 210 and 212 (see Figure 400). Figure 2 The input connection for the input processing of the function block checks the correct configuration of the parameters used for process control operations, including calculated values. In various implementations, if the initial check fails, the function block displays an output flag (e.g., "AE.bad_config") and remains in the initialization state. If the initial check passes, the block leaves the initialization state and proceeds to the normal state (box 420).

[0083] Under normal state 420 and based on the determination that the main input providing data to the VRT is healthy (input 411), state machine 400 operates under normal state 420. Under normal state 420, the output from the VRT to the compressor control application at OUT is equal to the output of input 210 (see 411). Figure 2The main measurement input provided by the input processing block is supplied to the input IN of the VRT. In "No" 421, it is determined that the input measurement value is unhealthy. In response to "No" 421, state machine 400 advances to Last Known Good Value (LGV) 430. At LGV 430, the output from the VRT to the compressor control application at OUT is set to the Last Known Good Value from the main input plus a safety bias value "SafetyBiasValue". In various implementations, SafetyBiasValue is a pre-configured safety bias.

[0084] The process monitors whether signals -1, -2, and -3 continue to remain within a predefined range of their last known good values. If signals -1, -2, and -3 deviate from their stored values ​​at the moment the state machine switches to the LGV state, LGV state 430 fails, and state machine 400 advances to the estimated value state 440. In estimated value state 440, the output OUT provided by the VRT to the compressor control application is equal to the estimated value OUTest plus the predefined SafetyBiasValue. In estimated value state 440, the estimated output OUTest is based on an alternative value (see [link to alternative value]). Figure 3 (The Alt value input in box 320). In various implementations, alternative values ​​are transformed in the VRT to generate estimates. In various implementations, programming configurations are provided in the VRT to determine how the transformation will operate, and / or which of several transformations will be used. In various implementations, several alternative algorithms exist. In various implementations, by default, the estimate = alternative value. In gain and bias modes, the estimate = gain. (Alternative value) + bias. Applicable characterizer: Estimated value = f(gain) (Alternative value) + bias). If the alternative value fails, the default value can be used: estimated value = default value. This can be seen in... Figure 2 Block 214 in the application-specific logic implements a more complex model outside the VRT block. If an external model is used, the output of the external model is connected to the Alt value input of VRT block 320, see [link to relevant documentation]. Figure 3 .

[0085] If the quality of the alternative value becomes unhealthy or VRT block 320 (see...) Figure 3 If the alternative valid input becomes false, state machine 400 advances to fault 450. While in fault state 450, VRT can provide the compressor control application with values ​​of operating parameters that allow the compressor system to operate in a safe mode, such as slowing down the speed and / or pressure allowed in the compressor system, or in some instances, completely shutting down the compressors included in the compressor system.

[0086] Figure 5 This is a flowchart of a method 500 for operating a compressor control system according to various embodiments. Method 500 may be performed by components included in and / or coupled to a virtual redundancy transmitter, such as a virtual redundancy transmitter 154 included as part of a controller 150, which is configured to provide control input to a compressor control application 156, as described above. Figure 1 As illustrated and described. Embodiments of method 500 can be executed by computer processing circuitry including one or more processors that operate on computer instructions, which can be stored in one or more computer memory devices, for example, as described below with respect to computer system 600 and... Figure 6 Examples and descriptions.

[0087] Implementations of method 500 include determining one or more control values ​​(block 510) to be applied as input to a compressor control application to control the operations being performed by the compressor system. In various implementations, determining the one or more control values ​​to be applied as input to the compressor control application includes determining that each transmitter providing sensing data related to operating parameters of the compressor system is providing health data, and wherein the input to the compressor control application includes measurement data provided by the transmitters, and the VRT operates in a normal state by providing the measurement data as input to the compressor control application.

[0088] At box 510, an embodiment of method 500 also includes applying the control value to a compressor control application, such as control application 156 ( Figure 1 ) or compressor control application 260 ( Figure 2 This is for use by a control application when controlling the operation of the compressor system. In various embodiments, the control values ​​applied to the control application may consist only of measurements provided by the sensors and transmitters of the compressor system controlled by the control application. In other embodiments, the control values ​​applied to the control application may include one or more alternative values ​​generated by a virtual redundancy transmitter using any of the methods and techniques described in this disclosure or any equivalent thereof and provided as an output from the virtual redundancy transmitter.

[0089] Implementations of method 500 include determining that a transmitter providing data indicating operating parameters of the control system is unhealthy (block 512). In various implementations, unhealthy data is determined by determining that the data value being provided by the transmitter exceeds the expected range for maintaining the overall operation of the compressor system under steady-state conditions. In various implementations, unhealthy data is determined based on determining that data is no longer being received from the transmitter.

[0090] Implementations of method 500 include determining alternative input values ​​(block 514) for operating parameters of the control system previously provided by a transmitter that has been determined to be unhealthy. Implementations of determining the alternative input values ​​may include determining a last known good value for the operating parameters previously provided by a now unhealthy transmitter and providing that last known good value as an alternative input value to be used by the compressor control application. Implementations of determining the alternative input values ​​may include determining an estimate of the operating parameters previously provided by a now unhealthy transmitter and providing that estimate as an alternative input value to be used by the compressor control application. Any of the techniques described in this disclosure may be used to determine the estimate.

[0091] After determining alternative input values ​​for the operating parameters previously provided by the unhealthy transmitter to the control system, the implementation can return to box 510, as indicated by arrow 520, where the input to the compressor control application includes providing the control values ​​being provided by the healthy transmitter along with the determined alternative values ​​for the operating parameters previously provided by the unhealthy transmitter as input to the compressor control application.

[0092] In various implementations, method 500 includes determining that no alternative value exists that can be safely used by the compressor control application to operate the compressor system. In such instances, implementations of method 500 include transitioning to a fault state (block 522). In the fault state, an indication may be provided to the compressor control application indicating that no valid or safe alternative value is available to replace the input associated with the operating parameters previously provided by the now unhealthy transmitter. Based on the received indication that no valid or safe alternative value is available to replace the previously provided operating parameters, the compressor control application may be configured to control the operation of the compressor system in a safe mode, or in some implementations in a shutdown mode, to prevent damage to the compressor system and / or avoid operating the compressor system in a configuration that may be unsafe for equipment and / or personnel in the compressor system area.

[0093] An implementation of method 500 includes determining that a transmitter identified as unhealthy has been recovered and is providing health data (box 516). This can be determined by receiving data from a transmitter having values ​​within the expected range of sensed operating parameters associated with a previously unhealthy transmitter.

[0094] An implementation of method 500 includes, in response to determining at box 516 that an unhealthy transmitter has been recovered, initiating the use of data values ​​from the recovered transmitter instead of alternative input values ​​as input to the compressor control application (box 518). A return to using data values ​​from the recovered transmitter is then made to box 510, as indicated by arrow 520, where input to the compressor control application includes providing the compressor control application with control values ​​being provided by the healthy transmitter, which includes data from the recovered transmitter.

[0095] Figure 6 This is a block diagram 600 illustrating a computer system 602 according to various embodiments. The computer system 602 may be configured to provide any of the features described herein and perform any functions related to controlling the operation of a compressor control system, including providing input values ​​for performing a compressor control application that controls the operation of the compressor system using both measured parameter values ​​and alternative operating parameters generated using a virtual redundant transmitter, as described above. In some embodiments, the computer system 602 is included or incorporated into controller 150 (…). Figure 1 In, and is configured to perform any function of the function and provide any feature attributable to and / or attributable to the controller 101.

[0096] Return to reference Figure 6 The computer system 602 includes a processor 610 communicatively coupled to computer memory 612 via a bus system 615. This processor may include multiple processors, multiple cores, multiple nodes, and / or implement multithreading, etc. Example types of processor 610 include microprocessors, microcontrollers, digital signal processors, field-programmable gate arrays, application-specific integrated circuits (ASICs), and discrete circuits.

[0097] like Figure 6 As shown, memory 612 can be an example of a storage device, which represents any structure capable of storing information (such as data, program code, and / or other suitable temporary or permanent information) and facilitating the retrieval of that information. Memory 612 can represent random access memory or any other suitable volatile or non-volatile storage device. Memory 612 may include short-term memory and may contain one or more components or devices supporting longer-term storage of data, such as read-only memory, hard disk, flash memory, or optical disk.

[0098] The memory 612 includes additional data and software modules that can be executed by the processor 610 to provide any of the features and perform any of the functions attributed to control and messaging communication with the controller and workload, as described above. Figure 6As shown, memory 612 includes machine learning tool 617, which can be executed to perform functions such as providing estimates of operating parameters associated with the compressor system, as described above.

[0099] Additional programs and applications may be stored in memory 612 or memory 630. Memory 630 may be communicatively coupled to bus 615 and includes programming, data, and / or instructions containing VRT 632, configuration data 634, and compressor control application 636. In various embodiments, VRT 632 is configured to perform any function and provides any features attributable to the virtual redundant transmitters throughout this disclosure and any equivalents thereof. Configuration data 634 may include any data, such as, but not limited to, engineering manual data, safety margin values, ranges of values ​​for normal operating conditions, and other data related to the operation and control of the compressor system. Configuration data 634 may include a mapping of transmitters that can be used to provide relevant or similar data values ​​that can be used to evaluate the last known good value to replace a value previously provided by a now unhealthy transmitter. Compressor control application 636 may include instructions that, when executed, provide outputs configured to control the operation of the compressor system, including operating parameters provided to compressor control application 636 by VRT 632.

[0100] The processor 610 may be configured to execute any instructions stored in and / or provided by the memory 612 and the additional memory storage device 630, in order to perform any function of the function and provide any feature of the various embodiments and any equivalents thereof in relation to the monitoring and control of the operation of the compressor system as described in this disclosure.

[0101] like Figure 6 As shown, computer system 602 includes a network interface 620 communicatively coupled to bus system 615 and thus to processor 610 and memory devices 612 and 630. Computer system 602 can access and / or access other devices via network interface 620 according to a network protocol corresponding to the type of network interface. Figure 6 Communication is conducted via transmission (not specifically shown), whether wired or wireless, and depending on the carrying medium. Furthermore, communication or transmission may involve other layers of communication protocols and / or communication protocol suites (e.g., transmission control protocol, Internet Protocol, User Datagram Protocol, Virtual Private Network Protocol, etc.).

[0102] Signal processor 614 can be configured to communicate messages to and from other devices in the process control system, such as, but not limited to, sensors and actuators included in the compressor control system. In some embodiments, signals including sensing data provided by sensors of the compressor system may be processed by signal processor 614, such as including analog-to-digital and noise cancellation processing, before being provided to processor 610 and / or memory 612 and additional memory 630 for further processing by the devices.

[0103] User interface 640 may be configured to operate as an interface for providing communication coupling between computer system 602 and one or more user input devices 642 and one or more output devices 644. User input devices 642 may include one or more devices, such as a computer mouse, computer keyboard, voice recognition hardware and software, and / or other devices such as a touchscreen, which allow a user to provide input to computer system 602. Output devices 644 may include one or more devices, such as computer monitors and / or speakers, which are configured to provide output information perceptible to a user, such as visual graphics displays and / or sound. Output devices 644 may include other types of output devices, such as printers. In various embodiments, input device 642 may be used to input information, such as controller configuration, and with compressor systems (such as, but not limited to, system 100). Figure 1 Other parameters related to the operation of the compressor system. In various embodiments, graphical information and depictions related to the status and operation of the compressor system incorporated into the computer system 602 can be generated and displayed on a monitor or display provided, for example, as part of output device 644, for use by users (such as process control engineers or technicians), as described above. Figure 2 Examples and descriptions.

[0104] Any of the functionalities described above may be implemented partially (or entirely) in hardware and / or on processor 610. For example, a functionality may be implemented using an application-specific integrated circuit (ASIC), logic implemented in processor 610, a coprocessor on a peripheral device or card, etc. Furthermore, implementation may include... Figure 6 Fewer components or additional components not illustrated herein (e.g., video cards, audio cards, additional network interfaces, peripherals, etc.). Although illustrated as coupled to bus 615, one or more of the memory and storage devices included in computer system 602 may be directly coupled to processor 610.

[0105] although Figure 6An example of a computer system 602 supporting an industrial process using a compressor system is illustrated, but variations in the configuration of computer system 602 are possible. For example, various components in computer system 602 can be combined, further subdivided, or omitted, and additional components can be added as needed. Processor 610 can also be configured in many ways, and as... Figure 6 The configuration of the illustrated computer system 602 does not limit this disclosure to any particular configuration of a computing device.

[0106] While various aspects of this disclosure have been described with reference to specific embodiments and applications, it will be understood that these aspects are illustrative and the scope of the claims is not limited thereto. Generally, the techniques for controlling and regulating the operation of process control systems as described herein can be implemented using facilities consistent with any one or more hardware systems. Many variations, modifications, additions, and improvements are possible.

[0107] Multiple instances can be provided for the components, operations, or structures described herein as a single instance. Finally, the boundaries between various components, operations, and data storage areas are somewhat arbitrary, and a particular operation is illustrated within the context of a specific exemplary configuration. Other allocations of functionality are contemplated, and these allocations may fall within the scope of this disclosure. Typically, structures and functionalities presented as separate components in the example configuration can be implemented as composite structures or components. Similarly, structures and functionalities presented as separate components can be implemented as separate components. These and other variations, modifications, additions, and improvements fall within the scope of this disclosure.

[0108] In some embodiments, the various functions described in this patent document are implemented or supported by a computer program, which is formed by computer-readable program code and embodied in a computer-readable medium. The phrase "computer-readable program code" includes any type of computer code, including source code, object code, and executable code. The phrase "computer-readable medium" includes any type of medium that can be accessed by a computer, such as read-only memory (ROM), random access memory (RAM), hard disk drive, optical disc (CD), digital video disc (DVD), or any other type of storage. "Non-transitory" computer-readable medium excludes wired, wireless, optical, or other communication links that transmit transient electrical signals or other signals. Non-transitory computer-readable medium includes media that can permanently store data as well as media that can store and subsequently overwrite data, such as rewritable optical discs or erasable storage devices.

[0109] It may be advantageous to define certain words and phrases used throughout this patent document. The terms “application” and “program” mean one or more computer programs, software components, instruction sets, processes, functions, objects, classes, instances, associated data, or portions thereof that are suitable for implementation in appropriate computer code (including source code, object code, or executable code). The term “communication” and its derivatives encompass both direct and indirect communication. The terms “comprising” and “including” and their derivatives mean, but are not limited to, this. The term “or” is inclusive, meaning and / or. The phrase “associated with” and its derivatives may mean, including, contained within, interconnected with, contained, contained in, connected to or connected with, coupled to or coupled with, able to communicate with, cooperate with, interleave, juxtapose, proximate, combine with or combine with, have, possess the properties of, have a relationship with, or have a relationship with, etc. When used with a list of items, the phrase “at least one of” means that different combinations of one or more of the listed items may be used, and that only one item in the list may be required. For example, "at least one of A, B and C" includes any of the following combinations: A, B, C, A and B, A and C, B and C, and A and B and C.

[0110] The descriptions in this application should not be construed as implying that any particular element, step, or function is a fundamental or essential element that must be included within the scope of the claims. The scope of the subject matter protected by the patent is defined only by the permitted claims. Furthermore, none of the claims invokes 35 USC with respect to any of the appended claims or claim elements. 112(f), unless the exact words of the participle phrase “for a component” or “for a step” which is an identifying function are used explicitly in the specific claims. The use of terms such as (but not limited to) “mechanism,” “module,” “device,” “unit,” “component,” “element,” “part,” “device,” “machine,” “system,” “processor,” or “controller” within the claims is understood to refer to structures known to a person skilled in the art, further modified or enhanced by the features of the claims themselves, and is not intended to invoke 35 USC. 112(f).

[0111] While this disclosure has described certain embodiments and generally associated methods, variations and substitutions of these embodiments and methods will be apparent to those skilled in the art. Therefore, the foregoing description of exemplary embodiments does not limit or restrict this disclosure. Other changes, substitutions, and modifications are possible without departing from the spirit and scope of this disclosure as defined in the following claims.

Claims

1. A method, the method comprising: Determine one or more control values ​​to be applied by the compressor control application to control the operations being performed by the compressor system, wherein determining the one or more control values ​​includes: It has been determined that the transmitter of the data indicating the operating parameters of the compressor system has malfunctioned. Determine alternative input values ​​for the operating parameters of the control system previously provided by the faulty transmitter; and The alternative input value is provided to the compressor control application via a Virtual Redundancy Transmitter (VRT) to continue operating the compressor system using the alternative input value. Determining the alternative input value includes: using the last known good value provided by the transmitter before the transmitter failure, based on the determination that the compressor system is still operating under steady-state conditions in the event of a transmitter failure; and using an estimated value of the alternative input value when it is determined that the compressor system is not operating under steady-state conditions after the transmitter failure.

2. The method according to claim 1, wherein the operating parameters represent control input parameters required for process control applications to maintain control of the compressor system.

3. The method of claim 1, wherein the steady-state condition of operation of the compressor system is defined as data provided for the operating parameters of the compressor system from a set of all transmitters that have not yet failed and are providing data indicating operating parameter values, all of which are within a range determined to represent the normal operating range of each of the parameters.

4. The method according to claim 1, further comprising: The compressor system continues to operate using a primary signal value, including the last known good value that existed before the transmitter failed.

5. The method according to any one of claims 1 to 4, wherein the VRT internally generates the last known good value used as the alternative input value based on a plurality of input signals provided to the VRT according to an input signal processing algorithm that operates on a plurality of input signals provided by a plurality of transmitters of the compressor system.

6. The method according to any one of claims 1 to 4, further comprising: While the compressor system is operating under the steady-state conditions, the last known good value is provided as the alternative input value to the compressor control application so that the compressor system can continue to operate using the alternative input value; It is determined that the compressor system no longer operates under the steady-state conditions; as well as The estimated values ​​of the alternative input values ​​for continuing to operate the compressor system are provided based on the determination that the compressor system is no longer operating under the steady-state conditions.

7. The method according to any one of claims 1 to 4, further comprising: Determine the operating region of the compressor system, in which it is safe to control the operation of the compressor system using the estimated value of the alternative input value.

8. The method according to any one of claims 1 to 4, further comprising: The configuration of the compressor system is automatically adjusted, including the configuration of the anti-surge system, so that the surge margin is increased when using the last known good value or the estimated value.

9. The method according to any one of claims 1 to 4, further comprising: A mathematical transformation is performed on the secondary signal being provided by the health transmitter, which operates to provide data indicating the operating parameters of the compressor system to match the value of the primary signal previously provided by the faulty transmitter.

10. A process control system for controlling the operation of a compressor system, the process control system comprising: A computer system comprising a processor and at least one memory device communicatively coupled to the processor, the at least one memory device comprising program instructions that, when executed by the processor, cause the processor to: When the compressor system is operating to receive gas or vapor at a first pressure at the input of the compressor system and to output the compressed gas or vapor at a second pressure higher than the first pressure at the output of the compressor system, one or more control values ​​are determined to be applied by the compressor control application to control the operation being performed by the compressor system. The instructions for determining the one or more control values ​​include instructions for causing the processor to perform the following operations: If it is determined that the transmitter of the data indicating the operating parameters of the control system has failed, an alternative input value for the operating parameters previously provided by the failed transmitter to the control system is determined. as well as The alternative input values ​​are provided to the compressor control system via a Virtual Redundancy Transmitter (VRT) to continue operating the compressor system using the alternative input values. Determining the alternative input value includes: using the last known good value provided by the transmitter before the transmitter failure, based on the determination that the compressor system is still operating under steady-state conditions in the event of a transmitter failure; and using an estimated value of the alternative input value when it is determined that the compressor system is not operating under steady-state conditions after the transmitter failure.

Images