Flow stabilization in fluid handling systems

Abstract

A fluid handling system includes a working chamber with a driven element to draw in and expel fluid during each operational cycle. Each operational cycle includes a suction phase and a suction stabilization phase. In the suction phase, fluid enters the working chamber as volume of the working chamber increases and pressure of the fluid fluctuates, while in the suction stabilization phase, volume of the working chamber remains substantially constant and pressure of the fluid stabilizes. A modulation valve is configured to redirect a portion of the fluid from the suction stabilization zone to the suction zone. A controller monitors a flow parameter indicative of fluid demand and modulates the valve to maintain the flow parameter within a predetermined operating range, thereby preventing cyclic unloading and reloading of the system and improving operational stability and efficiency.

Description

FLOW STABILIZATION IN FLUID HANDLING SYSTEMSTECHNICAL FIELD

[0001] The present subject matter relates, in general, to flow stabilization in fluid handling systems and in particular, to flow stabilization in compressor systems, vacuum systems, and blower systems.BACKGROUND

[0002] Fluid handling systems are used in various industries, such as manufacturing, chemical processing, water treatment, pharmaceuticals, HVAC (Heating, Ventilation, and Air Conditioning), and the like. The fluid handling systems are used for various processes, including flow regulation, dispensation, transportation, storage of fluids, and the like. As an example, generating compressed gas, creating vacuum, blowing gas with higher flow rate, and the like. The fluid handling systems may include compressor systems, blower systems, and vacuum systems, for carrying out one or more operations corresponding to fluids.

[0003] As an example, a compressor is used to generate compressed gas by reducing the volume of the gas. The compressed gases are used for various industrial and commercial applications. While atmospheric air is the most commonly compressed gas, compressors are also designed to handle various other gases depending on the applications. The compressed gases are typically stored in a reservoir and distributed across multiple utility points within an industry or a plant. Some of these utility points could include powering pneumatic tools and machinery, spray painting and coating applications, and various automated production processes. A compressor generally includes a prime mover and a compressor element provided within a working chamber. The prime mover serves as a power source for the compressor and can be an electric motor, hydraulic motor, diesel engine, or the like. The compressor element is the component that facilitatescompression of the gas. Common types of compressor element include pistons, screws, and centrifugal impellers. Depending on the type of compressor element employed, the compressor may be classified as reciprocating compressor, screw compressor, centrifugal compressor, and so on. While each of these compressors achieves compression through different mechanical means, but all the compressors work to increase pressure of the gas by decreasing volume of the gas.

[0004] The compressed gas is expelled into a reservoir through the discharge to be distributed to the utility points through one or more outlets. In some cases, a plurality of working chambers may be arranged in series, where compressed gas from the output of one working chamber is fed into the input of a subsequent working chamber to achieve higher pressures. This configuration allows for stepwise compression, enabling the system to reach higher overall pressures than a single compressor could achieve efficiently.

[0005] As another example of the fluid handling systems, the vacuum systems are used to create and maintain a vacuum environment, typically by removing gas from a sealed space or container. These systems are essential in various industrial and medical applications where a vacuum environment is required for specific processes. As a yet another example of the fluid handling systems, the blower systems are to circulate gas at higher flow rates but typically at lower pressures than compressors. The blower systems are commonly used in various industrial, commercial, and environmental applications where the movement of gas is required for ventilation, cooling, or conveying purposes.BRIEF DESCRIPTION OF DRAWINGS

[0006] Fig. 1 a illustrates a fluid handling system having a single stage working chamber, in accordance with an example implementation of the present subject matter.

[0007] Fig. 1 b illustrates the operational cycle of a fluid handling system, in accordance with an example implementation of the present subject matter.

[0008] Fig. 1c illustrates a table showing operational states of a first modulation valve and a release valve at varying demand levels in a fluid handling system, in accordance with an example implementation of the present subject matter.

[0009] Fig. 2a illustrates a fluid handling system having two working chambers arranged in series, in accordance with an example implementation of the present subject matter.

[0010] Fig. 2b illustrates a table showing operational states of a first modulation valve, a second modulation valve, and a release valve at varying demand levels in a fluid handling system, in accordance with an example implementation of the present subject matter.

[0011] Figs. 3a and 3b illustrate a method for stabilizing flow in a fluid handling system having a single stage working chamber, in accordance with an example implementation of the present subject matter.

[0012] Figs. 4a and 4b illustrate a method for stabilizing flow in a fluid handling system having two working chambers arranged in series, in accordance with an example implementation of the present subject matter.

[0013] Fig. 5a illustrates an example flow stabilization in a fluid handling system having a single stage working chamber, in accordance with an example implementation of the present subject matter.

[0014] Fig. 5b illustrates an example flow stabilization in a fluid handling system having two working chambers arranged in series, in accordance with an example implementation of the present subject matter.

[0015] Fig. 6a represents a chart corresponding to experiments that illustrate the results and performance, in accordance with an example implementation of the present subject matter.

[0016] Fig. 6b represents graphs corresponding to experiments that illustrate the results and performance, in accordance with an example implementation of the present subject matter.

[0017] Throughout the drawings, identical reference numbers designate similar elements, but may not designate identical elements. The figures are not necessarily to scale, and the size of some parts may be exaggerated to illustrate the example shown with better clarity. Moreover, the drawings provide examples and / or implementations consistent with the description; however, the description is not limited to the examples and / or implementations provided in the drawings.DETAILED DESCRIPTION

[0018] The present subject matter relates to flow stabilization in fluid handling systems which may include compressors, vacuum systems, and blowers. As an example, the fluid handling systems include compressors that increase pressure of gases by reducing volume of gas. The compressed gas is used for various industrial and commercial applications. The compressed gas is typically stored in a reservoir and distributed across multiple utility points within an industry or a plant. Some of these utility points could include powering pneumatic tools and machinery, spray painting and coating applications, and various automated production processes.

[0019] Generally, the compressor operates in two modes, namely, a loaded mode and an unloaded mode. In the loaded mode, the compressor functions to compress the gas and supply the compressed gas to the reservoir from where it is supplied to the utility points. When the demand for the compressed gas exceeds the capacity of the compressor, the compressor operates at a lower pressure than its rated value, struggling to meet the requirement of the plant from a pressure perspective. In contrast, when there is less demand for the compressed gas, the compressor entersthe unloaded mode. In the unloaded mode, the compressor runs with an intake valve closed and a blow down valve opened, therefore no compression takes place, consuming minimal energy. Eventually, if there is no demand for the compressed gas, the compressor transitions into a standby or a hibernation state, essentially turned off to save energy.

[0020] A capacity and a rated pressure of the compressor are typically selected based on the maximum demand for the compressed gas within the industry or the plant in which the compressor is installed. However, the actual demand for the compressed gas is not constant. The demand for the compressed gas fluctuates continuously in view of the varying operational requirements of the different utilities and the patterns in their utilization.

[0021] The actual demand for the compressed gas is not constant. The demand for the compressed gas fluctuates continuously in view of the varying operational requirements of the different utilities and the patterns in their utilization. In such scenarios where the demand of the plant is inconsistent, the compressor system operates under fluctuating pressure, which results in a cyclic cut-in and cut-out of the compressor. The cut-in of the compressor refers to the moment when the compressor enters the loaded mode, while the cut-out of the compressor refers to the moment when the compressor enters the unloaded mode. Generally, the cut-in and the cut-out of the compressor are determined by a line pressure. The pressure with which the gas is supplied from the reservoir to the utility point is known as line pressure. During the operation, if the line pressure exceeds a set cut-out pressure, which happens due to a low demand, the compressor cuts out, i.e. , the compressor enters into the unloaded mode. Similarly, if the line pressure drops below a set cut-in pressure, which happens due to an increased demand, the compressor cuts in, i.e., the compressor enters into the loaded mode, to compress the gas and restore the required pressure.

[0022] The transitioning of the loaded mode from the unloaded mode or the hibernate state is referred to as a load count. Due to the fluctuating demand for the compressed gas, the load count increases. Excessive load counts leads to unstable operation of the compressor, which adversely affects the performance of flow and kinematic related components of the compressor. For example, during the transition between the unloaded and loaded mode, an inlet valve should be closed and opened and vice versa. The closing and the opening of the inlet valve is performed by an actuator assembly. The valves and the actuator assemblies can lead to wear and tear and are under stress due to such excessive load count.

[0023] Similarly, the cyclical transitioning between the unloaded mode and the loaded mode causes varying pressure of the gas that is compressed and consequently, a variable flow in the compressor. In other words, various components of the compressor, for example, a compression chamber, an inlet manifold, and a discharge manifold are subject to varying flow. The varying flow leads to increased stress on such components. Therefore, the increased load counts causes increased stress on the kinematic and flow related components of the compressor system. The resulting stress, wear, and tear of the components of the compressor can reduce the reliability of the compressor systems, potentially leading to failures and increased downtime. The failures and increased downtime of the compressor system disrupts operations and increases maintenance costs. Moreover, such increased load counts lead to energy inefficiency, as the compressors are often running at suboptimal conditions.

[0024] Several techniques have been used in the past to mitigate the increased load count. One such technique involves Variable Frequency Drives (VFDs). In compressor systems, the VFDs offer a method to modulate the output of the compressors by adjusting the speed of the motor that drives the compressor element to match demand of the compressed gas. The VFDs work by controlling frequency of the electrical supply to theelectric motor, thereby varying the speed of the motor. For example, when the demand for compressed gas increases, the frequency of the electrical supply to the motor is raised, which increases the speed of the motor and, in turn, the amount of compressed gas produced to meet the higher demand. Similarly, when the demand decreases, the frequency of the electrical supply is reduced, slowing down the motor and decreasing the amount of compressed gas produced in line with the lower demand. By adjusting the motor speed according to the compressed gas demand, the compressor avoids the cyclic cut-in and cut-out process, which helps reduce stress on the kinematic components of the system. While the VFDs can reduce stress on the components of the compressor and improve energy efficiency, they introduce their own set of challenges. The varying speed of the motor leads to fluctuating gas flow of the gas into the compressor. The fluctuating gas flow, generating stress on the flow components of the compressor. The VFDs often require additional components such as sinusoidal filters and switchgear. The switchgear refers to electrical devices used to control, protect, and isolate electrical equipment, including the VFD and the motor it controls. The switch gear includes circuit breakers, contactors, disconnectors, fuses, and overload relays. The sinusoidal filter is installed between the VFD output and the motor to smooth the waveform, reduce harmonics, and provide a cleaner sinusoidal signal to the motor. The use of these additional components not only increases costs but also reduces reliability, contributing to potential reliability issues. The high cost of VFDs can make them unaffordable for many plants, limiting their widespread adoption. The VFDs place additional strain on the electrical systems, including the motors and the switchgears. Therefore, the compressor systems driven by the VFD can negatively impact the overall electrical performance of the plant in which they are installed.

[0025] Conventionally, mechanical solutions, such as suction modulation or spiral valves also attempt to match compressor output with demand. The suction modulation is a technique that adjusts the capacity ofthe compressor to match the demand of the compressed gas. The suction modulation is done by throttling the gas at the inlet to match the demand of the compressed gas. For example, when the demand for compressed gas decreases, the throttle valve at the inlet is partially or fully closed to reduce the amount of gas entering the compressor. Conversely, when the demand increases, the throttle valve is partially or fully opened to allow more gas to enter the compressor. Similarly, the spiral valves, typically used in the screw compressors, modulate the capacity and match the output of the com pressor with demand of the compressed gas. The spiral valves changes the length of the rotor engagement, which in turn adjusts the volume of the gas being compressed. As the spiral valve turns, it opens or closes ports along the length of the compressor rotor, allowing for a variable reduction in the output of the compressor, potentially reducing energy consumption during periods of lower demand compared to fixed -capacity systems. Still there is varying flow of gas within the compressor. Therefore, they also fail to alleviate the stress on the flow and kinematics components of the compressor, which continue to experience stress due to constant pressure changes. Further, the use of spiral valves and suction modulation remain inefficient from an energy consumption standpoint. For example, the spiral valves themselves can be prone to leakage. This is because, even when the spiral valve closes all the ports, a gap remains between the valve and the ports, allowing gas to leak through. The leakage further contributes to system inefficiency, as compressed gas is lost through the spiral valves rather than being used productively in the utility point. The ongoing stress and potential for leakage contribute to maintenance issues and potential reliability problems in the long term.

[0026] In traditional compressor systems, the VFDs were also used in conjunction with a bypass mechanism that redirected compressed gas from a high-pressure region back to a low-pressure region. However, this approach introduces inefficiencies into the system. The act of bypassing compressed gas back into the low-pressure area results in wasted energy,as the compressed gas is not being utilized effectively. Instead of being directed to the utility points within the plant, it is recycled within the system, leading to reduced overall efficiency. Additionally, this technique inherits the disadvantages of using VFDs as discussed above. The bypass mechanism was also attempted with a dual pole motor instead of a VFD, which resulted in significant electrical fluctuations, cost issues, and reliability concerns.

[0027] Therefore, conventional compressor systems face numerous disadvantages that limit their efficiency and effectiveness. While the problem has been discussed with respect to compressor systems, it is evident to a person skilled in the art that these challenges extend to vacuum systems and blower systems as well, which also face similar pressure fluctuations and instability.

[0028] The present subject matter discloses techniques for stabilizing flow in fluid handling systems such as compressors, vacuum systems, and blowers. The present subject matter aims to dynamically balance capacity of the system with varying demand while ensuring stable and reliable operation. The present subject matter aims to prevent frequent cut-in and cut-out cycles, reduce stress on components of the system, optimize energy efficiency, and maintain consistent performance across a wide range of demand scenarios in compressors, vacuums, and blowers.

[0029] A fluid handling system may include a working chamber having an element driven within the working chamber to handle fluid. For example, in a compressor system, the element may compress gas which may then be expelled from the working chamber and may be supplied to various utility points such as pneumatic tools, spray painting applications, and material handling systems. In a vacuum system, the element may create a vacuum by removing gas from a sealed space. In a blower system, the element may circulate gas at higher flow rates for ventilation or conveying purposes.

[0030] During each cycle of operation of the working chamber, fluid may be drawn into and expelled from the working chamber. Each cycle mayinclude multiple phases including a suction phase, a suction stabilization phase, a compression phase, and a discharge phase. The suction phase may occur where fluid may be drawn into the working chamber while a volume of the working chamber may be increasing and pressure of the fluid may be fluctuating. A zone of the working chamber where the suction phase is to occur may correspond to a suction zone. Following the suction phase, a suction stabilization phase may occur where the volume of the working chamber may remain substantially constant and pressure of the fluid may stabilize. As used herein, the term "substantially constant" when referring to the volume of the working chamber during the suction stabilization phase means that the volume does not change significantly compared to the volume changes that occur during the suction phase or the compression phase. The volume may be considered substantially constant if it varies by less than 10% of the maximum volume of the working chamber, or in some implementations, by less than 5%, less than 3%, or less than 1 % of the maximum volume. A zone of the working chamber where the suction stabilization phase is to occur may correspond to a suction stabilization zone. During the discharge phase, the handled fluid may be expelled from the working chamber into a discharge zone downstream of the working chamber.

[0031] The demand for the handled fluid may vary based on how much fluid may be being utilized at the utility points. For example, in a compressor system, when more pneumatic tools may be operating, the demand for compressed gas may increase. When fewer tools may be in use, the demand may decrease. The controller may monitor a flow parameter indicative of this demand for the handled fluid. The flow parameter may be, for example, pressure or flow rate of the handled fluid at a discharge side.

[0032] To dynamically match the system capacity with the varying demand, the fluid handling system may include a first path connecting the suction stabilization zone to the suction zone. A modulation valve may bepositioned in the first path to direct at least a portion of the fluid from the suction stabilization zone to the suction zone. The modulation valve may be controlled by a controller that may be operably connected to the modulation valve. Based on the flow parameter, the controller may cause the modulation valve to modulate at least a portion of the fluid flow from the suction stabilization zone to the suction zone to maintain the flow parameter within a predetermined operating range, thereby preventing cyclic unloading and reloading of the fluid handling system.

[0033] In some implementations, the fluid handling system may include a second path connecting the discharge zone to the suction zone, and a release valve may be positioned in the second path to direct at least a portion of the fluid from the discharge zone to the suction zone. The release valve may be an on / off valve that the controller may actuate between an open state and a closed state based on the flow parameter. In the open state, the release valve may redirect at least a portion of the handled fluid from the discharge zone back to the suction zone. In the closed state, the release valve may prevent fluid flow from the discharge zone to the suction zone.

[0034] The controller may determine that demand for the handled fluid has decreased based on the flow parameter. For example, when utility points such as pneumatic tools or material handling systems may be shutting down or operating at reduced capacity, the demand for the handled fluid may decrease, which may cause the flow parameter to rise. In response to this determination that demand may be decreasing, the controller may cause the modulation valve to be opened in proportion to the decrease in demand. As the modulation valve may open, at least a portion of the fluid from the suction stabilization zone may be redirected back to the suction zone, which may reduce the effective capacity of the system to match the lower demand. The controller may cause the modulation valve to be opened until the modulation valve reaches a fully open position.

[0035] If the demand may continue to decrease further, for example, when additional utility points may stop operating or when the plant may enter a low-demand period, the modulation valve alone may no longer be sufficient to balance the system capacity with the reduced demand. In such scenarios, if the controller determines that demand continues to decrease after the modulation valve has reached the fully open position, the controller may cause the release valve to be actuated to an open state. In the open state, the release valve may redirect at least a portion of the handled fluid from the discharge zone back to the suction zone, which may further reduce the effective system capacity and may prevent the flow parameter from exceeding a predetermined cut-out threshold.

[0036] Conversely, the controller may determine that demand for the handled fluid has increased based on the flow parameter. For example, when additional utility points such as pneumatic tools, spray painting applications, or automated production processes may start operating or may increase their usage, the demand for the handled fluid may increase, which may cause the flow parameter to drop. In response to the determination that demand may be increasing, the controller may first cause the release valve to be actuated to a closed state to prevent fluid flow from the discharge zone to the suction zone. By closing the release valve, the full capacity of the system may be restored to meet the increasing demand.

[0037] As the demand may continue to increase further, the controller may cause the modulation valve to be closed in proportion to the increase in demand. As the modulation valve may close, less fluid may be redirected from the suction stabilization zone back to the suction zone, which may progressively increase the effective capacity of the system to match the higher demand. The controller may continue to adjust the modulation valve until it may reach a fully closed position, at which point the system may be operating at its maximum capacity to meet the full demand of the utility points.

[0038] Throughout these varying demand scenarios, the controller may continuously monitor the flow parameter and may dynamically adjust the modulation valve and the release valve to maintain the flow parameter within the predetermined operating range, thereby preventing cyclic unloading and reloading of the fluid handling system and ensuring stable, efficient operation.

[0039] In multi-stage implementations, the fluid handling system may include a second working chamber having an element driven within the second working chamber to handle the fluid discharged from the first working chamber. During each cycle of the second working chamber, a fluid may be drawn into the second working chamber from the first working chamber and may be expelled from the second working chamber. Each cycle of the second working chamber may include a suction phase that may occur in a second suction zone of the second working chamber and a suction stabilization phase that may occur in a second suction stabilization zone of the second working chamber. A third path may connect the second suction stabilization zone to the second suction zone, and a second modulation valve may be positioned in the third path to direct at least a portion of the fluid from the second suction stabilization zone to the second suction zone. The controller may be operably connected to the second modulation valve and may cause the second modulation valve to modulate at least a portion of the fluid flow based on the flow parameter.

[0040] While the multi-stage implementation has been explained with reference to a two-stage system having a first working chamber and a second working chamber, it may be understood that the fluid handling system may include a plurality of working chambers arranged in series. For example, in compressor systems with a plurality of working chambers arranged in series, each working chamber may have a compressor element driven within the working chamber to compress gas. The gas may be progressively compressed as it may pass through each successive workingchamber in the series, allowing the system to achieve higher final pressures than may be possible with a single-stage system.

[0041] A plurality of paths may connect the suction stabilization zones to the suction zones of the respective working chambers. A plurality of modulation valves that may be positioned in the respective paths to direct at least a portion of the gas from the suction stabilization zones to the suction zones. The controller may be operably connected to the plurality of modulation valves and may cause each of the plurality of modulation valves to be adjusted based on the flow parameter.

[0042] When demand for the compressed gas may decrease, the controller may sequentially cause the plurality of modulation valves to be opened in proportion to the decrease in demand. The plurality of modulation valves may be sequentially opened based on their position in the series from the first working chamber to the final working chamber. For example, the modulation valve of the first working chamber may begin opening first, and a subsequent modulation valve in the series may begin opening after a preceding modulation valve in the series may reach a fully open position. This sequential opening may allow for gradual capacity reduction as demand may decrease.

[0043] Similarly, when demand for the compressed gas may increase, the controller may sequentially cause the plurality of modulation valves to be closed based on their position in the series from the final working chamber to the first working chamber. For example, the modulation valve of the final working chamber may begin closing first, and a preceding modulation valve in the series may begin closing after a subsequent modulation valve in the series may reach a fully closed position. This sequential closing may allow for gradual capacity increase as demand may increase.

[0044] The present subject matter may also relate to methods for stabilizing flow in fluid handling systems. A method for stabilizing flow in afluid handling system may include operating a working chamber having an element driven within the working chamber to handle fluid. The method may include operating the working chamber through cycles, wherein during each cycle a quantity of fluid may be drawn into and expelled from the working chamber.

[0045] Each cycle may include a suction phase that may occur in a suction zone of the working chamber where fluid may be drawn into the working chamber while a volume of the working chamber may be increasing and pressure of the fluid may be fluctuating. Following the suction phase, a suction stabilization phase may occur in a suction stabilization zone of the working chamber where the volume of the working chamber may remain substantially constant and pressure of the fluid may stabilize. During a discharge phase, the handled fluid may be expelled from the working chamber into a discharge zone.

[0046] The method may include monitoring a flow parameter indicative of demand for the handled fluid. For example, the flow parameter may be monitored continuously to assess whether utility points may be increasing or decreasing their consumption of the handled fluid. The flow parameter may be, for example, pressure or flow rate of the handled fluid at a discharge side.

[0047] The method may include adjusting a modulation valve positioned in a first path connecting the suction stabilization zone to the suction zone, based on the flow parameter to maintain the flow parameter within a predetermined operating range to prevent cyclic unloading and reloading of the system. By adjusting the modulation valve based on realtime demand, the method may enable the system to operate stably without frequent cycling between loaded and unloaded modes.

[0048] When demand for the handled fluid may decrease, for example when utility points such as pneumatic tools may shut down or may reduce their operation, the method may include determining that demand for thehandled fluid has decreased based on the flow parameter. In response to determining that demand for the handled fluid has decreased, the method may include opening the modulation valve in proportion to the decrease in demand. As the modulation valve may open, at least a portion of the fluid from the suction stabilization zone may be redirected to the suction zone, which may reduce the effective capacity of the system to match the lower demand.

[0049] The method may include opening the modulation valve until the modulation valve may reach a fully open position. If demand may continue to decrease further, for example when additional utility points may stop operating, the method may include determining that demand continues to decrease after the modulation valve has reached the fully open position. In response to determining that the demand continues to decrease, the method may include actuating a release valve positioned in a second path connecting a discharge zone to the suction zone to an open state. In the open state, the release valve may redirect at least a portion of the handled fluid from the discharge zone to the suction zone, which may further reduce system capacity and may prevent the flow parameter from exceeding a cutout threshold.

[0050] Conversely, when demand for the handled fluid may increase, for example when additional utility points such as spray painting applications or automated production processes may start operating or may increase their usage, the method may include determining that demand for the handled fluid has increased based on the flow parameter. In response to determining that demand has increased, the method may include actuating the release valve to a closed state to prevent fluid flow from the discharge zone to the suction zone. By closing the release valve, the full system capacity may be restored to meet the increasing demand.

[0051] After actuating the release valve to the closed state, as demand may continue to increase, the method may include determining that demandfor the handled fluid continues to increase based on the flow parameter. The method may include closing the modulation valve in proportion to the increase in demand. As the modulation valve may close, less fluid may be redirected from the suction stabilization zone to the suction zone, which may progressively increase the effective system capacity to match the higher demand.

[0052] In some implementations, the method may include actuating a release valve positioned in a second path connecting the discharge zone to the suction zone of the working chamber. The method may include actuating the release valve between an open state and a closed state to redirect at least a portion of the handled fluid from the discharge zone to the suction zone based on the flow parameter. This actuation may provide additional capacity control beyond what the modulation valve alone may provide, enabling the system to handle a wider range of demand variations.

[0053] Throughout the method, the flow parameter may be continuously monitored and the modulation valve and release valve may be dynamically adjusted to maintain the flow parameter within the predetermined operating range. This continuous adjustment may prevent rapid cycling of the system between loaded and unloaded modes, which may reduce wear on system components, may improve energy efficiency, and may enhance overall system reliability.

[0054] For multi-stage fluid handling systems, the method may be applied to systems including a plurality of working chambers arranged in series. While the method has been explained with reference to a single working chamber, it may be understood that the method may be extended to systems with two or more working chambers connected in series.

[0055] In multi-stage implementations, each working chamber may operate through cycles including suction phases and suction stabilization phases occurring in respective suction zones and suction stabilization zones. The method may include adjusting a plurality of modulation valves,each positioned in a respective path connecting the suction stabilization zone to the suction zone of a respective working chamber.

[0056] When demand for the handled fluid may decrease, the method may include sequentially adjusting the plurality of modulation valves based on their position in the series. For example, when utility points may reduce their consumption, the method may include first opening the modulation valve of the first working chamber. As demand may continue to decrease, the method may include opening the modulation valve of the second working chamber after the modulation valve of the first working chamber may reach a fully open position. This sequential opening may continue through all working chambers in the series from the first working chamber to the final working chamber, allowing for gradual capacity reduction that may match the decreasing demand.

[0057] Similarly, when demand for the handled fluid may increase, the method may include sequentially adjusting the plurality of modulation valves in reverse order. For example, when utility points may increase their consumption, the method may include first closing the modulation valve of the final working chamber. As demand may continue to increase, the method may include closing the modulation valve of the preceding working chamber after the modulation valve of the final working chamber may reach a fully closed position. This sequential closing may continue through all working chambers in the series from the final working chamber to the first working chamber, allowing for gradual capacity increase that may match the increasing demand.

[0058] The sequential adjustment of modulation valves based on their position in the series may provide fine-grained control over system capacity, enabling the multi-stage system to efficiently handle a wide range of demand variations while maintaining stable operation and preventing cyclic unloading and reloading. As used herein, the term "preventing cyclic unloading and reloading" refers to reducing the frequency of load countcycles in which the fluid handling system transitions between loaded and unloaded modes.

[0059] The present subject matter may offer numerous advantages that may significantly enhance the performance, efficiency, and longevity of fluid handling systems, including compressor systems, vacuum systems, and blower systems. The present subject matter may achieve dynamic adjustment of system capacity using at least one modulation valves and a release valve controlled by a controller based on flow parameters. By maintaining the flow parameter within a predetermined operating range, the system may prevent cyclic unloading and reloading. By preventing frequent cut-in and cut-out cycles through continuous adjustment of the modulation valves and release valve, the present subject matter may significantly reduce wear and tear on critical components. This may extend the lifespan of both mechanical components such as inlet valves and actuator assemblies, and electrical components such as motors and switchgear, may reduce maintenance requirements, may minimize downtime, and may ensure more stable operation of the system. The present subject matter may maintain stable flow conditions.

[0060] The modulation valves may redirect fluid from the suction stabilization zone where pressure may be stable, thereby maintaining more consistent flow conditions within the working chamber. The use of a release valve positioned in a path between the discharge zone and the suction zone may provide additional capacity control for low-demand scenarios. The release valve may redirect at least a portion of the handled fluid from the discharge zone to the suction zone, which may raise the suction pressure and may reduce the overall compression ratio, thereby minimizing energy loss and improving efficiency. Unlike conventional bypass mechanisms that may waste energy by recycling fluid ineffectively, the present subject matter may strategically redirect fluid to reduce the compression ratio and improve energy efficiency.

[0061] In multi-stage implementations with a plurality of working chambers arranged in series, the independent control of modulation valves in each stage may allow for optimal performance across varying operational conditions. The sequential adjustment of modulation valves based on their position in the series may provide fine-grained control, enabling the system to efficiently handle a wide range of demand variations while maintaining stable operation. The controller-based operation may simplify system control by continuously monitoring flow parameters and automatically adjusting the modulation valves and release valve in real-time. This automated control may ensure optimal capacity matching with demand without complex manual adjustments, enhancing system reliability and uptime.

[0062] The above and other features, aspects, and advantages of the subject matter will be better explained with regard to the following description, and accompanying figures. It should be noted that the description and figures merely illustrate the principles of the present subject matter along with examples described herein and, should not be construed as a limitation to the present subject matter. It is thus understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and examples thereof, are intended to encompass equivalents thereof. Further, for the sake of simplicity, and without limitation, the same numbers are used throughout the drawings to reference like features and components.

[0063] Fig. 1a illustrates a fluid handling system (FHS) 100 having a single stage working chamber 104, in accordance with an example implementation of the present subject matter. The FHS 100 may be part of an industrial plant, such as manufacturing plants, automotive industrial plants, water treatment plants, and so on. The FHS 100 may include a compressor 102. In an example, the compressor 102 may be a single stage compressor. The compressor 102 may include a compressor element (notshown in Figs) and a first working chamber 104. The compressor element may be provided in the first working chamber 104. The compressor element may facilitate compression of gas. The compressor element may be a piston, screws, a centrifugal impeller, and the like. To compress the gas, the compressor element may have to be reciprocated or rotated depending on the compressor element, which may be done by a prime mover 106. The prime mover 106 may be an electric motor, a hydraulic motor, a diesel engine, and so on. In an example, the prime mover 106 may be controlled by a VFD. The FHS 100 may include an intake valve 108 to allow and to regulate the flow of gas into the first working chamber 104.

[0064] During operation, gas may be drawn through the intake valve 108 into the first working chamber 104, where the gas may be compressed by the compressor element. The compressed gas may then be supplied to a reservoir 110, from where the compressed gas may be distributed to various utility points 112-1 , 112-2 ... 112-N within the industrial plant. For example, in the manufacturing plant, the utility points may be powering pneumatic tools and machinery, spray painting and coating applications, material handling systems. To optimize the compressed gas for use, the FHS 100 may include a gas cooler (not shown in Figs) to reduce the temperature of the compressed gas, followed by a moisture separator (not shown in Figs) to remove any condensed water. In an example, the gas being compressed may be atmospheric air. In another example, the compressor 102 may be designed to handle various other gases, such as refrigerant gas, hydrogen, and helium, depending on the applications.

[0065] In an example, to monitor consumption of the compressed gas and determine demand for the compressed gas, a flow sensor (not shown) may be installed at the outlet of the reservoir 110. In another example, the demand for compressed gas may also be determined by monitoring a pressure corresponding to supply of the compressed gas to the utility points 112.1 , 112.2 ... 112.N. The pressure with which the gas is supplied from the110 reservoir to the utility points 112.1 , 112.2 ... 112. N is referred to as line pressure. Accordingly, in such examples, in addition to or as alternate to the flow sensor, a pressure sensor (not shown in figs) may be provided at an outlet of the reservoir 110 for this purpose.

[0066] Fig. 1 b illustrates the operational cycle of a fluid handling system, in accordance with an example implementation of the present subject matter. The operational cycle of the fluid handling system 102 is illustrated in terms of the rotation angle of the prime mover 106 (on the x- axis), along with the volume of the first working chamber 104 (in cubic capacity (cc), shown on the left side of the y-axis) and the pressure (in bar, shown on the right side of the y-axis). As used herein, the term 'volume of the working chamber' may refer to an active working volume within the chamber that varies during the operational cycle as the element moves, as distinguished from the fixed total internal volume of the housing or casing that encloses the working chamber. The active working volume changes continuously as the compressor element progresses through different phases of operation. In reciprocating compressors, the active working volume corresponds to the volume, which varies between the clearance volume and the maximum volume during each stroke. In screw compressors, the working volume refers to the progressively changing inter lobe space between the meshing rotors as the gas advances along the rotor length. In centrifugal compressors, the concept of working volume relates to the effective flow passage within the impeller and diffuser regions through which the gas moves during compression. The operational cycle highlights the various phases of the operational cycle over one complete rotation of the prime mover 106, which spans from 0° to 360°. The operational cycle may include a plurality of phases, such as a suction phase, a suction stabilization phase, a compression phase, a delivery stabilization phase, and a delivery phase.

[0067] During the suction phase, volume of the first working chamber 104 may reach a maximum capacity, for example, around 100 cc, as the element within the compressor draws in gas. The pressure of the gas within in the first working chamber 104 of the compressor 102 may remain around 1 bar, indicating that the gas is being drawn in at atmospheric pressure. A zone or the physical region of the working chamber where the suction phase may occur may correspond to a suction zone. For example, the suction zone may include a region where the inlet valve 108 allows gas to enter the first working chamber 104 and the region within the first working chamber 104 where the gas is being drawn in while the volume of the first working chamber 104 may be increasing and the pressure of the gas may be fluctuating. The suction phase, for example, may occur during the 0° to 100° rotation of the prime mover 106.

[0068] The suction phase is followed by the suction stabilization phase. In the suction stabilization phase, the volume of the first working chamber 104 may remain substantially constant, for example, may be around 100 cc, as the gas within the first working chamber 104 may stabilize. The pressure of the gas during the suction stabilization phase rises slightly above the suction pressure, reaching a point just above 1 bar, as the gas within the working chamber 104 of the compressor 102 adjusts to achieve consistent pressure and flow with minimal energy expenditure. The suction stabilization phase, for example, may occur during the 100° to 120° rotation of the prime mover. A zone or a physical region of the working chamber 104 where the suction stabilization phase may occur may correspond to a suction stabilization zone. That is, the suction stabilization zone may include the region within the first working chamber 104 where the volume of the first working chamber 104 remains substantially constant and the pressure of the gas stabilizes.

[0069] Next is the compression phase, where volume of the first working chamber 104 decreases significantly, for example, may reduce to around 40 cc, as the gas is compressed. The pressure of the gas mayincrease substantially during the compression phase, for example, may rise from 1 bar to approximately 8 bar, as the volume of the first working chamber 104 may be reduced and pressure may be elevated in preparation for delivery. The compression phase, for example, may occur during the 120° to 270° rotation of the prime mover 106. A zone or physical region in the working chamber 104 where the compression phase may occur may correspond to a compression zone.

[0070] During the delivery stabilization phase, the volume of the working chamber 104 may remain stable, for example, at around 40 cc. The pressure of the gas may stabilize at, for example, 8 bar, as the first working chamber 104 may prepare for the final expulsion of the compressed gas. The delivery stabilization phase may ensure that the first working chamber 104 is ready for efficient gas delivery. A zone or physical region of the first working chamber 104 where the delivery stabilization phase may occur may correspond to a delivery stabilization zone.

[0071] Finally, during the delivery phase, the volume of the first working chamber 104 may return to almost zero cc as the compressed gas is expelled into a discharge zone. The discharge zone may be a physical region downstream of the first working chamber 104. The pressure of the gas may, for example, remain at 8 bar during this phase as the gas is discharged into the reservoir 110, completing one full operational cycle.

[0072] The operational cycle including all the phases is repeated as the prime mover completes one rotation, and the graph in Fig. 1 b effectively captures the dynamic changes in both volume and pressure throughout each phase, providing a clear visual representation of the operation of the compressor.

[0073] The compressor 102 operates within a predetermined cut-in parameter and a predetermined cut-out parameter. In other words, the predetermined cut-in parameter may correspond to the parameter value at which the compressor 102 starts to cut-in and the predetermined cut-outparameter may correspond to the parameter value at which the compressor 102 starts to cut-out. In other words, the cut-in of the compressor 102 may refer to moment when the compressor 102 enters the loaded mode. In the loaded mode, the compressor 102 may function to compress the gas and supply the compressed gas to the reservoir 110 from where it is supplied to the utility points. The cut-out of the compressor 102 may refer to the moment when the compressor 102 enters the unloaded mode. In the unloaded mode, the compressor 102 runs with an intake valve 108 closed and a blow down valve opened, therefore no compression takes place. In an example, the predetermined cut-in parameter and the predetermined cut-in parameter may be based on line pressures. For example, if the line pressure falls below a cut-in threshold due to increased demand of the compressed gas, the compressor 102 will cut-in. Conversely, if the pressure rises above the cutout threshold due to a decreased demand of the compressed gas, the compressor 102 will cut-out. For example, the utility points, such as pneumatic tools and machinery may not be in use and only spray painting and coating applications are in used. The spray painting and coating applications may use less compressed gas compared to the pneumatic tools and machinery. Therefore, there will be a decrease in demand for the compressed gas. The decreased demand may lead to increase in line pressure, leading to cut-out of the compressor 102. On the other hand, when the utility points, such as powering pneumatic tools and machinery which uses larger amount of compressed gas may be back in use along with spray painting and coating applications. Therefore, there will be an increase in demand for the compressed gas. The increased demand may lead to decrease in line pressure, leading to cut-in of the compressor 102.

[0074] As discussed above, the frequent cut-in and cut-out of the compressor 102 increases load count. The transitioning of the loaded mode from the unloaded mode or a standby state is referred to as a load count. Excessive load counts leads to unstable operation of the compressor 102, which adversely affects the performance of flow and kinematic relatedcomponents of the compressor 102. Therefore, the present techniques aims to dynamically balance the capacity of the compressor 102 with varying demand for the compressed gas while ensuring stable and reliable operation, without introducing undue stress on the components of the compressor 102.

[0075] For this, the FHS 100 may include a first modulation valve 114. A first path 116 may be provided between the suction stabilization zone and the suction zone of the first working chamber 104. The first modulation valve 114 may be provided in the first path 116. The first modulation valve 114 may be progressively adjustable and may be controlled based on a flow parameter. The flow parameter may be indicative of demand for the handled fluid, such as compressed gas in a compressor system. In an example, the flow parameter may be the line pressure or the flow rate, such as the consumption of the handled fluid, such as compressed gas at a discharge side. Hereinafter, the flow parameter will be explained with reference to the line pressure as an example. As used herein, the term "predetermined operating range" refers to a range of values for the flow parameter within which the fluid handling system is intended to operate during normal loaded operation. The predetermined operating range may be bounded by a lower threshold, referred to as a cut-in threshold or cut-in pressure, and an upper threshold, referred to as a cut-out threshold or cutout pressure. The cut-in threshold may represent the flow parameter value at which the system would traditionally transition from an unloaded mode to a loaded mode, while the cut-out threshold may represent the flow parameter value at which the system would traditionally transition from a loaded mode to an unloaded mode. By maintaining the flow parameter within the predetermined operating range through dynamic adjustment of the first modulation valve 114 and, where applicable, a release valve 118, the system may avoid these transitions and may maintain continuous loaded operation. The gas from the suction stabilization zone may be regulated back to the suction zone unless the first modulation valve 114 isfully closed. By redirecting the gas from the suction stabilization zone to the suction zone, the first modulation valve 114 may help in maintaining the line pressure within a defined range, typically between the cut-in pressure and the cut-out pressure. The first modulation valve 114 may enable the system to bypass the flow progressively based on demand without any major power loss. The dynamic adjustment of the first modulation valve 114 may allow the fluid handling system, such as the compressor 102, to closely match the demand for the handled fluid, such as the compressed gas, optimizing efficiency and ensuring stable operation. The first modulation valve 114 may adjust the capacity of the fluid handling system, such as the compressor 102, up to a predefined threshold, often managing varying demand, for example, when demand is between approximately 70% to 100% of the total capacity of the fluid handling system, such as the compressor 102.

[0076] In some scenarios, the demand for the handled fluid, such as the compressed gas, may be even lower, for example less than approximately 70% of the total capacity of the fluid handling system, such as the compressor 102. To handle such low demands, the fluid handling system, such as the compressor 102, may include a release valve 118. The release valve 118 may be an on-and-off valve that may be actuated by an actuator controlled by the controller 122. The actuator may be electrically actuated, pneumatically actuated, hydraulically actuated, or a combination thereof. A second path 120 may be provided between the discharge zone and the suction zone. The release valve 118 may be positioned in the second path 120. For example, the release valve 118 may be provided in a path that connects the output of the fluid handling system, such as the compressor 102, or the output of the reservoir 110, and the suction zone. The second path 120 may allow the release valve 118 to redirect handled fluid, such as compressed gas, from a high-pressure discharge zone back to a low-pressure suction zone when necessary to maintain system stability and flow parameter control. The release valve 118may be activated based on the flow parameter representing demand for the handled fluid, such as the compressed gas, i.e., based on the line pressure or flow rate of the handled fluid, such as the compressed gas.

[0077] Fig. 1 c illustrates a table showing the operational states of the first modulation valve 114 and the release valve 118 at varying demand levels in the fluid handling system, such as a compressor system. As shown in the Fig. 1 c, when demand is between approximately 70% to 100% of the total capacity of the fluid handling system (CC), the first modulation valve 114 is operational and progressively adjusts to redirect at least a portion of the fluid from the suction stabilization zone to the suction zone based on the flow parameter, while the release valve 118 remains closed or inactive. When demand decreases below approximately 70% of the total capacity, ranging from 0% to 100% of the total capacity, both the first modulation valve 114 and the release valve 118 become operational. In this operating range, the first modulation valve 114 may be in a fully open position, and the release valve 118 may be actuated to an open state to redirect at least a portion of the handled fluid from the discharge zone to the suction zone to maintain the flow parameter within the predetermined operating range. The Fig. 1 c also indicates that when the system enters an unload mode, the release valve 118 may be opened to facilitate rapid unloading by quickly reducing pressure, thereby minimizing energy consumption during the unload mode. This coordinated operation of the first modulation valve 114 and the release valve 118, as illustrated in Fig. 1 c, enables the fluid handling system to maintain the flow parameter within the predetermined operating range across a wide range of demand conditions, from 0% to 100% of the total capacity, thereby preventing cyclic unloading and reloading of the system.

[0078] The release valve 118 helps maintain the balance between capacity of the fluid handling system, such as the compressor, and demand for the handled fluid, such as the compressed gas, by regulating fluid flowbetween the suction zone and discharge zones. While redirecting handled fluid, such as compressed gas, back to the suction zone introduces some energy loss, the loss is minimized by selecting the suction zone that raises the suction pressure, thereby reducing the overall compression ratio and improving energy efficiency. For example, consider a fluid handling system, such as a compressor, where the normal suction pressure at the inlet of the fluid handling system, such as the compressor 102, is 1 bar (atmospheric pressure) or slightly above atmospheric pressure and the discharge pressure at the outlet of the fluid handling system, such as the compressor 102, is 7 bar, indicating a compression ratio of 7:1. When the release valve 118 redirects handled fluid, such as compressed gas, back to the suction zone, instead of releasing it to the atmosphere or the main suction inlet (at 1 bar), it is directed to the suction zone where the pressure is already slightly elevated compared to the inlet of the fluid handling system, such as the compressor 102, for example, pressure may be at 1.5 bar. This raises the effective suction pressure from 1 bar to 1.5 bar, reducing the compression ratio to approximately 7:1 .5 or 4.67:1. Consequently, less work is required to compress the gas from 1 .5 bar to 7 bar compared to compressing from 1 bar to 7 bar. The energy loss from redirecting the handled fluid, such as the compressed gas, is partially offset by the reduced work needed for subsequent compression cycles, improving overall system efficiency. This approach allows the fluid handling system, such as the compressor 102, to operate more continuously at a reduced capacity, rather than cycling on and off, which enhances energy efficiency and reduces wear on system components.

[0079] For facilitating the operation of the first modulation valve 114 and the release valve 118, the FHS 100 may include a controller 122. The controller 122 may include a processing unit 124 and a memory 126. The processing unit 124 can be any suitable device, such as a microprocessor, microcomputer, microcontroller, digital signal processor, central processing unit, state machine, logic circuitry, or any device that manipulates signalsbased on operational instructions. The memory 126 may include volatile memory such as random access memory (RAM) for storing temporary data and non-volatile memory such as flash memory, EEPROM, or hard disk storage for storing control programs, calibration parameters, and threshold values. The controller 122 may be implemented using a programmable logic controller (PLC), a microcontroller, a digital signal processor (DSP), an application-specific integrated circuit (ASIC), or a general-purpose computer executing software instructions.

[0080] The controller 122 may be operably connected to the first modulation valve 114 and, where applicable, the release valve 118, through one or more actuators. The actuators may be electrically actuated, pneumatically actuated, hydraulically actuated, or a combination thereof. In implementations using electrically actuated actuators, the controller 122 may generate electrical control signals, such as analog voltage signals, pulse-width modulation (PWM) signals, or digital communication commands, that are transmitted to the actuators. The electrically actuated actuators may include stepper motors, servo motors, solenoids, linear actuators, or other electromechanical devices that convert electrical signals into mechanical motion to adjust the valve positions. In implementations using pneumatically actuated actuators, the controller 122 may control electro-pneumatic converters or pneumatic control valves that regulate air pressure supplied to pneumatic cylinders or diaphragm actuators coupled to the valves. The pneumatic actuators may provide advantages in environments where electrical sparks must be avoided or where high force is required. In implementations using hydraulically actuated actuators, the controller 122 may control electro-hydraulic valves that regulate hydraulic fluid pressure supplied to hydraulic cylinders coupled to the valves. The hydraulic actuators may provide advantages where very high forces are required or where precise position control is needed. The actuators may include position feedback sensors, such as potentiometers, encoders, or linear variable differential transformers (LVDTs), that provide feedbacksignals to the controller 122 indicating the actual position of the valves, enabling closed-loop control.

[0081] The controller 122 may be configured to execute control logic stored in the memory 126 using the processing unit 124 to dynamically adjust the first modulation valve 114 and the release valve 118 based on the flow parameter. The controller 122 may receive signals from one or more sensors, such as pressure sensors positioned at the discharge side of the system or flow sensors positioned at the outlet of the reservoir 110, to continuously monitor the flow parameter. For example, the controller 122 may receive signals from pressure sensors or flow sensors, and by processing the received signals, the controller 122 can accurately assess the real-time demand of the handled fluid, such as compressed gas, allowing the controller 122 to make precise adjustments to the first modulation valve 114 and the release valve 118 to maintain optimal pressure and flow conditions throughout the system. The processing unit 124 may sample the flow parameter at regular intervals, for example, every 0.1 to 5 seconds, and may compare the measured flow parameter value to predetermined threshold values stored in the memory 126. These predetermined threshold values may include a cut-in threshold, a cut-out threshold, and one or more intermediate threshold values that define the predetermined operating range. The controller 122 may determine that demand for the handled fluid is decreasing when the flow parameter increases toward the cut-out threshold, and may determine that demand is increasing when the flow parameter decreases toward the cut-in threshold.

[0082] To calculate the degree of valve modulation, the controller 122 may implement a proportional control algorithm, a proportional-integral- derivative (PID) control algorithm, or a lookup table that maps flow parameter values to corresponding valve positions. In one implementation, the controller 122 may calculate a valve position command as a function of the deviation between the measured flow parameter and a target setpointwithin the predetermined operating range, such that larger deviations result in greater valve adjustments. The controller 122 may compare the desired valve position, calculated based on the flow parameter, with the actual valve position indicated by the feedback sensors from the actuators, and may adjust the control signals to the actuators to minimize any position error. For the release valve 118, which may be an on / off valve, the controller 122 may compare the flow parameter to specific threshold values and may generate a binary control signal to open the release valve 118 when the flow parameter exceeds an upper threshold and to close the release valve 118 when the flow parameter falls below a lower threshold. The controller 122 may also implement hysteresis logic to prevent rapid switching of the release valve 118, such that the threshold for closing the release valve 118 may be lower than the threshold for opening the release valve 118 by a predetermined margin. The operation of the controller 122 will be explained in detail with reference to flow charts illustrated in Figs. 3 and 4 later.

[0083] In multi-stage implementations, the controller 122 may implement sequential control logic wherein the modulation valves are adjusted in a predetermined sequence based on their position in the series of working chambers. When demand decreases, the controller 122 may begin opening the modulation valve of the first working chamber, progressively adjusting the valve position in proportion to the decrease in the flow parameter. The controller 122 may monitor the position of the first modulation valve and may only begin opening the modulation valve of the second working chamber after the first modulation valve has reached a fully open position, for example, when the valve is at 95% to 100% of its maximum open position. Conversely, when demand increases, the controller 122 may begin closing the modulation valve of the final working chamber first, and may only begin closing the modulation valve of the preceding working chamber after the final modulation valve has reached a fully closed position, for example, when the valve is at 0% to 5% of itsmaximum open position. The controller 122 may continuously monitor the flow parameter and may adjust the sequence dynamically if demand changes rapidly, allowing for responsive capacity control across all stages.

[0084] In the above examples, the fluid handling system 100 was explained with reference to compressor 102. However, in other example, the fluid handling system 100 can be the vacuum systems or the blower systems. While the above examples describe the fluid handling system with reference to compressor systems, the present subject matter is equally applicable to vacuum systems and blower systems. In vacuum systems, the element within the working chamber may create a vacuum by removing gas from a sealed space or container. During each cycle of operation, the vacuum system may draw gas from the space being evacuated during a suction phase, may stabilize pressure during a suction stabilization phase, and may expel the gas to atmosphere or to a collection system during a discharge phase. The modulation valve may redirect at least a portion of the gas from the suction stabilization zone to the suction zone to dynamically match the vacuum system capacity with varying demand for vacuum, maintaining the flow parameter within a predetermined operating range. Similarly, in blower systems, the element within the working chamber may circulate gas at higher flow rates for ventilation, cooling, or conveying purposes. The blower system may operate through cycles including suction phases, suction stabilization phases, and discharge phases, with the modulation valve redirecting at least a portion of the gas from the suction stabilization zone to the suction zone based on the flow parameter to prevent cyclic unloading and reloading of the blower system.

[0085] Also, while above example of the compressor 102 uses single stage, in some scenarios, pressure requirements can be higher and, in such cases, multi-stage compressors are used, as will be explained below. Fig. 2a illustrates a fluid handling system having two working chambers arranged in series, in accordance with an example implementation of thepresent subject matter. The FHS 200 operates on similar principles to the FHS 100 as illustrated in Fig. 1 but with additional working chambers. For brevity, parts previously discussed in Fig. 1 a are not explained again in the description of Fig. 2a. The multi-stage compressor 202 may include two or more working chambers connected in series in which gas is gradually compressed to a required final pressure. Hereinafter, the multistage compressor will be explained with reference to a two stage compressor 202. In the two stage compressor 202, a second working chamber 204 may be provided in series with the first working chamber 104. The second working chamber 204 may receive partially compressed gas from the first working chamber 104 and further compresses the gas before delivering to the reservoir 110. A third path 216 may be provided between a suction stabilization zone and a suction zone of the second working chamber 204. The FHS 200 may include a second modulation valve 214 provided in the third path 216. The second modulation valve 214 would function in a manner analogous to the first modulation valve 114, connecting the suction stabilization zone of the second working chamber 204 to the suction zone of the second working chamber 204. The second modulation valve 214 may also be controlled by the controller 122 based on flow parameters. The second modulation valve 214 may be electrically actuated. The controller 122 may monitor and adjust both the modulating valves, i.e., the first modulation valve 114 and the second modulation valve 214, in response to real-time demand for the compressed gas. The second modulation valve 214 may enable to by-passes the flow progressively based on demand without any major power loss. By implementing the second modulation valve 214, the compressor 202 can achieve even more precise control over the compression process, allowing for dynamic adjustments at both stages of compression in response to changing demand conditions. Fig. 2b illustrates a table showing the operational states of the first modulation valve 114, the second modulation valve 214, and the release valve 118 at varying demand levels in a multi-stage fluid handling system. Similar to Fig. 1c, thetable demonstrates the coordinated operation of the valves, but with the addition of the second modulation valve 214 for the second working chamber 204. When demand is between approximately 70% to 100% of the total capacity, only the first modulation valve 114 is operational. When demand decreases to between approximately 40% to 100% of the total capacity, both the first modulation valve 114 and the second modulation valve 214 are operational. When demand falls below approximately 40% of the total capacity, ranging from 0% to 100%, all three valves, the first modulation valve 114, the second modulation valve 214, and the release valve 118 become operational to maintain the flow parameter within the predetermined operating range and prevent cyclic unloading and reloading of the multi-stage system.

[0086] The present subject matter maintains the flow parameters, for example, the line pressure, within a specified range, thereby preventing cyclic cut-in and cut-out of the compressor 102, 202. By continuously controlling the first modulation valve 114, the second modulation valve 214, and the release valve 118, in response to changing demand, the compressor can operate more smoothly and efficiently, avoiding the frequent cut-in and cut-out that typically occur in conventional compressors. The present techniques helps to reduce wear and tear on the compressor components, improve energy efficiency, and maintain more stable pressure levels throughout the system.

[0087] The present techniques for flow stabilization in FHS 100 can be effectively combined with Variable Frequency Drives (VFDs) to achieve superior results. While the first modulation valve 114, the second modulation valve 214, and the release valve 118 provide precise control over gas flow and pressure, the VFDs can complement the FHS 100 by allowing fine-tuned speed control of the prime mover 106. The combination offers enhanced flexibility in matching system output to demand, potentially leading to even greater energy efficiency and operational stability. Byintegrating the benefits of both approaches, the system can achieve optimal performance across a wider range of operating conditions, further reducing energy consumption and minimizing wear on both mechanical and electrical components.

[0088] Figs. 3a and 3b illustrate a method 300 for flow stabilization of fluids, according to an example implementation of the present subject matter. Herein, the flow stabilization of a gas is explained with reference to a single-stage compressor 102. The order in which the method 300 is described is not intended to be construed as a limitation, and any number of the described method blocks may be combined in any order to implement the method 300, or an alternative method. Furthermore, the method 300 may be implemented by processor(s) or computing device(s) through any suitable hardware, non-transitory machine-readable instructions, or a combination thereof.

[0089] It may be understood that steps of the method 300 may be performed by programmed computing devices and may be executed based on instructions stored in a non-transitory computer readable medium. The non-transitory computer readable medium may include, for example, digital memories, magnetic storage media, such as magnetic disks and magnetic tapes, hard drives, or optically readable digital data storage media. In an example, the method 300 may be performed by the controller 122. In particular, the method 300 may be performed by the processing unit.

[0090] Referring to Fig. 3a and Fig. 3b, at step 302, a flow parameter may be continuously monitored to determine the demand for the compressed gas in a facility, such as an industrial plant. For example, the flow parameter may be the line pressure, the flow rate, or another relevant indicator of the demand for the compressed gas.

[0091] At step 304, in response to the continuous determination of the demand for the compressed gas, it may be determined whether the demand for the compressed gas may be decreasing. At step 304, if it is determinedthat the demand for compressed gas may be decreasing, the method 300 may proceed to step 306. For example, the utility points, such as powering pneumatic tools and machinery may not be in use and only spray painting and coating applications are in used. Therefore, there will be a decrease in demand for the compressed gas. On the other hand, if it is determined that the demand for the compressed gas may be not decreasing, i.e., the demand for the compressed gas may be increasing, the method 300 may proceed to step 308. For example, the utility points, such as powering pneumatic tools and machinery may be back in use along with spray painting and coating applications. Therefore, there will be an increase in demand for the compressed gas.

[0092] At step 306, if it is determined that the flow parameter reaches a first predetermined value, the first modulation valve 114 may be modulated from a closed position to an open position, with the degree of opening increasing in proportion to the rise in the flow parameter. The modulation of the first modulation valve 114 may control the flow of gas from the suction stabilization zone to the suction zone of the first working chamber 104, allowing the gas flow to increase incrementally in response to the increasing flow parameter. The modulated opening may refer to adjusting the valve opening in small increments, thereby precisely regulating the gas flow rate from the suction stabilization zone to the suction zone.

[0093] After completing step 306, if there is a further decrease in demand, the flow parameter value will increase. At step 310, when the flow parameter reaches a second predetermined value, the first modulation valve 114 may be actuated to a fully open position. The second predetermined value may be greater than the first predetermined value. In this fully open position, the first modulation valve 114 may redirect the gas from the suction stabilization zone to the suction zone of the first working chamber 104 at the maximum capacity of the first modulation valve 114.The capacity of the valve refers to the rate at which the fluid can flow through the valve.

[0094] After completing step 310, if there is a further decrease in demand, the first modulation valve 114 may no longer be sufficient to control the pressure, as it is already redirecting gas from the suction stabilization zone to the suction zone of the first working chamber 104 at its maximum capacity. Accordingly, the flow parameter value will increase. At step 312, when the flow parameter reaches a third predetermined value, the release valve may be opened. The third predetermined value may be greater than both the first and second predetermined values. The release valve 118 may allow the compressed gas to return to the suction zone, preventing the flow parameter from exceeding the cut-out threshold. The first modulation valve 114 may remain in the fully open position.

[0095] Since the release valve 118 is in open position, the compressed gas returns to the suction zone from the discharge zone. The releasing of the compressed gas through the release valve 118 may reduce the flow parameter value significantly. At step 314, if it is determined that the flow parameter has decreased to a fourth predetermined value, the release valve 118 may be closed. The closing of the release valve 118 prevents further decrease in the flow parameter. In an example, the fourth predetermined value may be equal to the second predetermined value.

[0096] At step 316, if it is determined that the flow parameter has increased to the cut-out threshold value, the release valve 118 may be opened. The release valve 118 may facilitate rapid unloading by quickly reducing pressure of the reservoir 110, thereby minimizing energy consumption during the unload mode of the compressor 102.

[0097] At step 308, if it is determined that the flow parameter has decreased to a fifth predetermined value, the release valve 118 may be closed. In the closed position, the release valve 118 may not allow the compressed gas to return to the suction zone. In an example, the fifthpredetermined value may at least one of: lesser than the fourth predetermined value and equal to the first predetermined value.

[0098] Closing of the release valve of the first working chamber 104 may increase the flow parameter significantly. At step 318, if it is determined that the flow parameter has increased to a sixth predetermined value, the first modulation valve 114 may be opened. In an example, the sixth predetermined value may at least one of: equal to the third predetermined value and greater than fifth predetermined value. The release valve 118 continues to be in closed position.

[0099] After completing step 318, if there is a further increase in demand, the flow parameter value will decrease. At step 320, if it may be determined that the flow parameter has decreased to a seventh predetermined value, the first modulation valve 114 may be modulated from the open position to the closed position in proportion to the decrease in the flow parameter. The gradual closing of the first modulation valve 114 reduces the gas flow from the suction stabilization zone to the suction zone of the first working chamber 104 in proportion to the decrease in the flow parameter. The modulated closing refers to adjusting the valve opening in small decrements to precisely control the gas flow rate from the suction stabilization zone to the suction zone of the first working chamber 104. The seventh predetermined value may be equal to the second predetermined value.

[0100] After completing step 320, if there is a further increase in demand, the flow parameter value will decrease. At step 322, if it may be determined that the flow parameter has decreased to an eighth predetermined value, the first modulation valve 114 may be modulated to the fully closed position. The eight predetermined value may be less than the fifth, sixth, seventh predetermined values. In this fully closed position, the first modulation valve 114 no longer redirects gas from the suctionstabilization zone to the suction zone. The release valve may remain fully closed.

[0101] In the above examples, the first modulation valve and the release valve are explained to be opened and / or closed in a sequential manner. However, as will be understood, in other examples, the first modulation valve and the release valve may be opened and / or closed simultaneously depending on the demand of the plant. In other words, to match the capacity of the single stage compressor with the demand of the plant, the first modulation valve and the release valve may be opened and / or closed simultaneously. The controller 122 may continuously adjust the valves based on the flow parameters to maintain cut-in and cut-out parameter within the predetermined range. This ensures efficient compressor operation by preventing rapid cycling and maintaining stability based on flow parameter, which enhances system reliability and reduces energy consumption.

[0102] Figs. 4a and 4b illustrate a method 400 for flow stabilization of fluids, according to an example implementation of the present subject matter. Herein, the flow stabilization of a gas is explained with reference to a two-stage compressor 202. The order in which the method 400 is described is not intended to be construed as a limitation, and any number of the described method blocks may be combined in any order to implement the method 400, or an alternative method. Furthermore, the method 400 may be implemented by processor(s) or computing device(s) through any suitable hardware, non-transitory machine-readable instructions, or a combination thereof.

[0103] It may be understood that steps of the method 400 may be performed by programmed computing devices and may be executed based on instructions stored in a non-transitory computer readable medium. The non-transitory computer readable medium may include, for example, digital memories, magnetic storage media, such as magnetic disks and magnetictapes, hard drives, or optically readable digital data storage media. In an example, the method 400 may be performed by the controller 122. In particular, the method 400 may be performed by the processing unit.

[0104] Referring to Fig. 4a and Fig. 4b, at step 402, a flow parameter may be continuously monitored to determine the demand for the compressed gas in a facility, such as an industrial plant. For example, the flow parameter may be the line pressure, the flow rate, or another relevant indicator of the demand for the compressed gas.

[0105] At step 404, in response to the continuous determination of the demand for the compressed gas, it may be determined whether the demand for the compressed gas may be decreasing. At step 404, if it is determined that the demand for compressed gas may be decreasing, the method 400 may proceed to step 406. For example, the utility points, such as powering pneumatic tools and machinery may not be in use and only spray painting and coating applications are in used. Therefore, there will be a decrease in demand for the compressed gas. On the other hand, if it is determined that the demand for the compressed gas may be not decreasing, i.e., the demand for the compressed gas may be increasing, the method 400 may proceed to step 408. For example, the utility points, such as powering pneumatic tools and machinery may be back in use along with spray painting and coating applications. Therefore, there will be an increase in demand for the compressed gas.

[0106] At step 406, if it is determined that the flow parameter reaches an eleventh predetermined value, the first modulation valve 114 may be modulated from a closed position to an open position, with the degree of opening increasing in proportion to the rise in the flow parameter. The modulation of the first modulation valve 114 controls the flow of gas from the suction stabilization zone to the suction zone of the first working chamber 104, allowing the gas flow to increase incrementally in response to the increasing flow parameter. The modulated opening refers to adjustingthe valve opening in small increments, thereby precisely regulating the gas flow rate from the suction stabilization zones to the suction zones.

[0107] After completing step 406, if there is a further decrease in demand, the flow parameter value will increase. At step 410, when the flow parameter reaches a twelfth predetermined value, the first modulation valve 114 may be actuated to a fully open position. The twelfth predetermined value may be greater than the eleventh predetermined value. In this fully open position, the first modulation valve 114 redirect the gas from the suction stabilization zone to the suction zone of the first working chamber 104 at the maximum capacity of the valve. The capacity of the valve refers to the rate at which the fluid can flow through the valves.

[0108] At step 412, if it is determined that the flow parameter reaches a thirteenth predetermined value, the second modulation valve 214 may be modulated from a closed position to an open position, with the degree of opening increasing in proportion to the rise in the flow parameter. The modulation of the second modulation valve 214 controls the flow of gas from the suction stabilization zone to the suction zone of the second working chamber 204, allowing the gas flow to increase incrementally in response to the increasing flow parameter. The modulated opening refers to adjusting the valve opening in small increments, thereby precisely regulating the gas flow rate from the suction stabilization zones to the suction zones.

[0109] After completing step 412, if there is a further decrease in demand, the flow parameter value will increase. At step 414, when the flow parameter reaches a fourteenth predetermined value, the second modulation valve 214 may be actuated to a fully open position. The fourteenth predetermined value may be greater than the thirteen predetermined value. In this fully open position, the second modulation valve 214 redirect the gas from the suction stabilization zone to the suction zone of the second working chamber 204 at the maximum capacity of thevalve. The capacity of the valves refers to the rate at which the fluid can flow through the valves.

[0110] After completing step 414, if there is a further decrease in demand, the first and the second modulation valves 114, 214 may no longer be sufficient to control the pressure, as they are already redirecting gas from the suction stabilization zones to the suction zones at their maximum capacity. Accordingly, the flow parameter value will increase. At step 416, when the flow parameter reaches a fifteenth predetermined value, the release valve 118 may be opened. The fifteenth predetermined value may be greater than the eleventh to fourteenth predetermined values. The release valve allows the compressed gas to return to the suction zone. The first and the second modulation valves 114, 214 remains in the fully open position.

[0111] Since the release valve118 is open position, the compressed gas returns to the suction zone from the discharge zone. The releasing of the compressed gas through the release valve 118 may reduce the flow parameter value significantly. At step 418, if it is determined that the flow parameter has decreased to a sixteenth predetermined value, the release valve 118 is closed. The closing of the release valve 118 prevents further decrease in the flow parameter. In an example, the sixteenth predetermined value may be equal to the twelfth or fourteenth predetermined value.

[0112] At step 420, if it is determined that the flow parameter has increased to the cut-out threshold value, the release valve 118 may be opened. The release valve facilitates rapid unloading by quickly reducing the pressure of the reservoir, thereby minimizing energy consumption during the unload mode of the compressor 202.

[0113] At step 408, if it is determined that the flow parameter has decreased to a seventeenth predetermined value, the release valve 118 may be closed. In the closed position, the release valve 118 may not allow the compressed gas to return to the suction zone. In an example, theseventeenth predetermined value may at least one of: lesser than the fifteenth predetermined value and equal to the eleventh or thirteenth predetermined value.

[0114] Closing of the release valve 118 may increase the flow parameter significantly. At step 422, if it is determined that the flow parameter has increased to an eighteenth predetermined value, the second modulation valve 214 may be opened. In an example, the eighteenth predetermined value may at least one of: equal to the fifteenth predetermined value and greater than seventh predetermined value. The release valve continues to be in closed position.

[0115] At step 424, if it is determined that the flow parameter has decreased to a nineteenth predetermined value, the second modulation valve 214 may be modulated from the open position to the closed position in proportion to the decrease in the flow parameter. The gradual closing of the second modulation valve 214 reduces the gas flow from the suction stabilization zone to the suction zone of the second working chamber 204 in proportion to the decrease in the flow parameter. The modulated closing refers to adjusting the valve opening in small decrements to precisely control the gas flow rate from the suction stabilization zone to the suction zone. The release valve 118 continues to be in be closed. The nineteenth predetermined value may be equal to the seventeenth predetermined value.

[0116] After completing step 424, if there is a further increase in demand, the flow parameter value will decrease. At step 426, if it may be determined that the flow parameter has decreased to a twentieth predetermined value, the second modulation valve 214 may be modulated to the fully closed position. The twentieth predetermined value may be less than the nineteenth predetermined value. In the fully closed position, the second modulation valve 214 no longer redirects gas from the suction stabilization zone to the suction zone of the second working chamber. The release valve may remain fully closed.

[0117] Closing of the second modulation valve 214 may increase the flow parameter significantly. At step 428, if it is determined that the flow parameter has increased to a twenty-first predetermined value, the first modulation valve 114 may be opened. In an example, the twenty-first predetermined value may at least one of: equal to the eighteenth predetermined value and greater than twentieth predetermined value. The second modulation valve 214 and the release valve continue to be in closed position.

[0118] At step 430, if it is determined that the flow parameter has decreased to a twenty-second predetermined value, the first modulation valve 114 may be modulated from the open position to the closed position in proportion to the decrease in the flow parameter. The gradual closing of the first modulation valve 114 reduces the gas flow from the suction stabilization zone to the suction zone of the first working chamber in proportion to the decrease in the flow parameter. The modulated closing refers to adjusting the valve opening in small decrements to precisely control the gas flow rate from the suction stabilization zone to the suction zone. The release valve continues to be in be closed.

[0119] After completing step 430, if there is a further increase in demand, the flow parameter value will decrease. At step 432, if it may be determined that the flow parameter has decreased to a twenty-third predetermined value, the first modulation valve114 may be modulated to the fully closed position. In this fully closed position, the first modulation valve 114 no longer redirects gas from the suction stabilization zone to the suction zone at its maximum capacity. The release valve and the second modulation valve 214 may remain fully closed.

[0120] In the above examples, the first modulation valve, the second modulation valve, and the release valve are explained to be opened and / or closed in a sequential manner. However, as will be understood, in other examples, the first modulation valve, the second modulation valve, and therelease valve may be opened and / or closed simultaneously depending on the demand of the plant. In other words, to match the capacity of the two- stage compressor with the demand of the plant, the first modulation valve, the second modulation valve, and the release valve may be opened and / or closed simultaneously.

[0121] Throughout this entire process, the controller 122 continuously adjusts the valves based on these flow parameters to maintain cut-in and cut-out parameter within the predetermined range. This method ensures efficient compressor operation by preventing rapid cycling and maintaining stability based on flow parameter, which enhances system reliability and reduces energy consumption.Examples:Example I

[0122] The method for flow stabilization of fluids, according to an example implementation of the present subject matter in a single-stage fluid handling system, such as a compressor, will be illustrated with reference to Table I illustrated in Fig. 5a.

[0123] The flow parameter may be line pressure, and the compressor system may be designed to operate between a cut-in pressure of 6.5 bar and a cut-out pressure of 7.5 bar. The controller may control the two valves: the first modulation valve 114 and the release valve. As illustrated in the left hand side of the table I in Fig. 5a, when demand decreases and the line pressure begins to rise (from bottom to top of the table), the controller responds accordingly to control the valves. As the pressure reaches a first predetermined value, for example, 7.0 bar, the controller signals the first modulation valve 114 to start modulating from closed position towards open position in proportion to increase in the line pressure. If demand for the compressed gas continues to decrease and the line pressure increases, the first modulation valve 114 continues to modulate proportionally. Whenpressure reaches the second predetermined value, for example, 7.1 bar, the first modulation valve 114 becomes fully opened. If demand for the compressed gas continues to decrease and the line pressure increases, the line pressure may reach a third predetermined value, i.e. , 7.4 bar. When the line pressure reached 7.4 bar, the release valve may be opened. The opening of the release valve may decrease the pressure significantly because the compressed gas is redirected back from the discharge zone to suction zone. Therefore, when the line pressure drops to a fourth predetermined value, i.e., 7.1 bar, the release valve may be closed. The closing of the release valve may prevent the further decreasing of the line pressure. Still if the line pressure reaches the cut-out threshold of 7.5 bar, the release valve may be opened to quickly release pressure to reduce the energy consumption during the unload mode of the compressor.

[0124] Conversely, as illustrated in the right hand side of the table I in Fig. 5a, when demand increases and the line pressure begins to fall (from top to bottom of the table), the controller responds accordingly to control the valves. As pressure drops to a fifth predetermined value, for example, 7.0 bar, the release valve is closed. The closing of the release valve may increase the line pressure. When the line pressure increases to sixth predetermined value, for example, 7.4 bar, the first modulation valve is opened. When the first modulation valve 114 is opened, the line pressure may drop. When the line pressure increases to seventh predetermined value, for example, 7.0 bar, the first modulation valve 114 begins modulating from fully open towards close position in proportion to decrease in line pressure. If demand continues to increase, the first modulation valve 114 continues to modulate proportionally. When pressure returns to an eighth predetermined value, i.e., 6.9 bar in an example the first modulation valve 114 becomes fully closed.

[0125] Throughout this process, the controller continuously adjusts both valves based on the line pressure to maintain stability within the 6.5-7.5 bar range. This method allows the system to handle demand fluctuations between 0-100% of the compressor's total capacity while preventing cyclic cut-in and cut-out, thereby enhancing system efficiency and reliability.

[0126] The method for flow stabilization of fluids, according to an example implementation of the present subject matter in a two-stage fluid handling system, such as a compressor, will be illustrated with reference to Table II in Fig. 5b.

[0127] The flow parameter may be line pressure, and the compressor system may be designed to operate between a cut-in pressure of 6.5 bar and a cut-out pressure of 7.5 bar. The controller may control the three valves: the first modulation valve 114, the second modulation valve 214, and the release valve. As illustrated in the left hand side of the table II in Fig. 5b, when demand decreases and the line pressure begins to rise (from bottom to top of the table), the controller responds accordingly to control the valves.

[0128] As the pressure reaches the eleventh predetermined value, for example, 7.0 bar, the controller signals the first modulation valve 114 to start modulating from closed position towards open position. If demand for the compressed gas continues to decrease and the line pressure increases, the first modulation valve 114 continues to modulate proportionally. When pressure reaches the twelfth predetermined value, for example, 7.1 bar, the first modulation valve 114 becomes fully opened. As the pressure reaches the thirteen predetermined value, for example, 7.0 bar, the controller signals the second modulation valve 214 to start modulating from closed position towards open position. If demand for the compressed gas continues to decrease and the line pressure increases, the first modulation valve 114 continues to modulate proportionally. When pressure reaches the fourteenth predetermined value, for example, 7.1 bar, the second modulation valve 214 becomes fully opened. If demand for the compressed gas continues to decrease and the line pressure increases to fifteenthpredetermined value, the release valve may be opened. The opening of the release valve may decrease the pressure significantly because the compressed gas is redirected back from the discharge zone to suction zone. Therefore, when the line pressure drops to a sixteenth predetermined value, i.e. , 7.1 bar, the release valve may be closed. Still if pressure reaches the cut-out threshold of 7.5 bar, the release may be opened to quickly release pressure to reduce the energy consumption during the unload mode of the compressor.

[0129] Conversely, as illustrated in the right hand side of the table II in Fig. 5b, when demand increases and the line pressure begins to fall (from top to bottom of the table), the controller responds accordingly to control the valves. As pressure drops to a seventeenth predetermined value, for example, 7.0 bar, the release valve 118 is closed. The closing of the release valve may increase the line pressure. When the line pressure increases to eighteenth predetermined value, for example, 7.4 bar, the second modulation valve 214 is opened. If the demand increase and when the pressure reaches nineteenth predetermined value, for example, 7.0 bar, the second modulation valve 214 is modulated from fully open towards closed position. The release valve may remain closed. If demand continues to increase, the second modulation valve 214 continues to modulate proportionally. When pressure returns to a twentieth predetermined value, i.e., 6.9 bar, the second modulation valve 214 becomes fully closed. The closing of the second modulation valve 214 may increase the line pressure. When the line pressure increases to twenty-first predetermined value, for example, 7.4 bar, the first modulation valve 114 is opened. If the demand increase and when the pressure reaches twenty-second predetermined value, for example, 6.9 bar, the first modulation valve 114 is modulated from fully open towards closed position. The release valve and the second modulation valve 214 may remain closed. If demand continues to increase, the first modulation valve 114 continues to modulate proportionally. Whenpressure returns to a twenty-third predetermined value, i.e. , 6.8 bar, the first modulation valve 114 is fully closed.

[0130] Throughout this process, the controller continuously adjusts both valves based on the line pressure to maintain stability within the 6.5- 7.5 bar range. This method allows the system to handle demand fluctuations between 0-100% of the compressor's total capacity while preventing cyclic cut-in and cut-out, thereby enhancing system efficiency and reliability.

[0131] The present invention offers numerous advantages that significantly enhance the performance, efficiency, and longevity of the compressor systems. By dynamically adjusting capacity of the compressor to match demand of the plant, it optimizes energy consumption and reduces unnecessary usage during low-demand periods, leading to substantial cost savings over time. The techniques ensures stable operation even under fluctuating demand conditions, preventing frequent cut-in and cut-out cycles that typically cause wear and tear on components. This stability, combined with reduced stress on critical parts, extends lifespan of the equipment. The present subject matter allow to adjust to a wide range of demand scenarios, ensuring optimal performance across varying operational conditions. By utilizing a strategically chosen suction zone, the present subject matter reduces the overall compression ratio, minimizing energy loss and improving efficiency. The integration of modulation valves and release valve ensure a continuous balance between capacity of the compressor and demand for the compressed gas, enhancing system reliability and uptime. Notably, this approach is applicable not only to the compressor systems but also to vacuum systems and blower systems, offering versatility across different industrial applications. The modulation valves reduce stress on kinematic parts, preventing premature wear. Furthermore, the automated operation simplifies control, allowing for optimal capacity control without complex manual adjustments. Ultimately, the dynamic adjustment based on real-time demand ensures operation within a narrow pressure band,providing more precise control over gas supply and improving overall process performance.

[0132] Various experiments were conducted with various capacities requirements in various plants under various pressure and demand requirement conditions experimental conditions. Figs. 5a and 5b represents charts corresponding to experiments that illustrate the results and performance of the FHS under various conditions.

[0133] Fig. 6a represents a chart 600 comparing power consumption and load counts for various usage patterns for both the conventional technique and the present technique disclosed in the present application. Five distinct usage patterns were tested, and the results show significant differences in load counts between the two techniques. For the present technique, four of the usage patterns showed no load counts, while the remaining pattern had 8 load counts. In contrast, the conventional technique consistently showed load counts ranging from a minimum of 20 up to 125 across all five usage patterns. Tests reveal that the present technique provides substantial benefits in terms of reduced load counts when compared to standard machines, across all tested usage patterns. The present technique also offers energy savings, offering at least around 4-6% of energy savings. The degree of energy efficiency varies depending on the specific usage scenario. These results highlight the benefits of the present technique.

[0134] Fig. 6b illustrates graphs comparing the load counts and the number of hours the fluid handling machine was operated, for both conventional and present techniques through two different usage patterns.

[0135] Graph 602 illustrates a first usage pattern where the conventional technique showed a total of 452 load counts over 18 hours of operation, resulting in an average load count of 25 counts per hour. In contrast, the present technique in this scenario recorded zero load counts.

[0136] Similarly, graph 604 depicts another usage pattern, where the conventional technique registered 628 load counts over 24 hours of operation, with an average load count of 26 counts per hour. Again, the present technique recorded zero load counts for this usage pattern as well.

[0137] These comparisons further highlight the significant advantage of the present technique, which achieved zero load counts across both usage patterns, indicating a more efficient operation. The conventional technique, on the other hand, exhibited substantial load counts, which may be indicative of higher energy consumption or operational strain. This underscores the efficiency of the present technique in reducing load counts, regardless of the specific usage scenario, offering a notable improvement in performance over conventional methods.

[0138] The features of the flow stabilization in fluid handling system:

[0139] Dynamic Capacity Adjustment: The ability to dynamically adjust the fluid handling system’s capacity in real-time based on the plant’s demand, utilizing a progressively opening and closing valve (first and second modulation valve), ensures optimal capacity management and energy efficiency across varying demand levels.

[0140] Suction and Suction Stabilization Zone Integration: The identification and connection of the suction and suction stabilization zones through the first and the second modulation valves ensures smooth and efficient operation, with the system maintaining flow parameter, for example, line pressure within a defined band, minimizing energy loss and optimizing compressor performance.

[0141] Use of Release Valve for Low Demand: The introduction of an on / off valve (the release valve) between the discharge and suction zones, activated by flow parameter, for example, the line pressure, to maintain balance when demand is below 70%, reduces energy losses and helps manage the fluid handling system's capacity efficiently.

[0142] Multi-Stage Application: The integration of this balancing method into all stages of a multi-stage fluid handling system allows for managing capacity and demand efficiently even at lower capacity levels, optimizing all the stages.

[0143] Minimization of Compression Ratio: By carefully selecting a suction zone that raises suction pressure and reduces the compression ratio, the energy loss typically associated with bringing compressed gas back to the suction stage is reduced. This approach lowers overall energy consumption while maintaining efficiency.

[0144] Cross-Applicability: The present application extends the benefits of dynamic capacity balancing beyond compressor systems to blower systems and vacuum systems marking a new way of optimizing multiple types of fluid-handling systems.

[0145] Intelligent Valve Logic: The logic behind the operation of the first and the second modulation valve and the release valve ensures a highly adaptive and responsive fluid handling system that balances capacity and demand while maintaining efficiency, a feature that sets this approach apart from traditional fixed-capacity systems.

[0146] Energy Loss Minimization with Strategic Airflow Control: The intelligent control of gas flow between the suction and discharge zones ensures minimal energy loss, even when the gas is redirected back to the suction zone, making the system more energy-efficient than conventional methods.

[0147] Although the present subject matter has been described with reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the subject matter, will become apparent to persons skilled in the art upon reference to the description of the subject matter.

Claims

AMENDED CLAIMS received by the International Bureau on 26 May 2026 (26.05.2026).We Claim:

1. A fluid handling system comprising: a working chamber having an element driven within the working chamber to handle fluid, wherein during each cycle of operation of the working chamber, fluid is drawn into and expelled from the working chamber, and wherein each cycle comprises: a suction phase wherein the fluid is drawn into the working chamber while volume of the working chamber is increasing and pressure of the fluid is fluctuating, a zone of the working chamber where the suction phase is to occur corresponds to a suction zone; and a suction stabilization phase where volume of the working chamber remains substantially constant and pressure of the fluid stabilizes, a zone of the working chamber where the suction stabilization phase is to occur corresponds to a suction stabilization zone; a modulation valve progressively adjustable to redirect at least a portion of the fluid from the suction stabilization zone to the suction zone; and a controller being operably connected to the modulation valve, wherein the controller is to: monitor a flow parameter indicative of demand for the fluid; and cause the modulation valve to redirect at least a portion of the fluid flow from the suction stabilization zone to the suction zone based on the flow parameter to maintain the flow parameter within a predetermined operating range to prevent cyclic unloading and reloading of the fluid handling system, wherein the fluid handling system is a rotary type fluid handling system.

2. The fluid handling system as claimed in claim 1 , wherein each cycle comprises: a discharge phase occurs where the handled fluid is expelled from the working chamber into a discharge zone, the fluid handling system comprising: a release valve to selectively redirect at least a portion of the fluid from the discharge zone to the suction zone.

3. The fluid handling system as claimed in claim 2, wherein the release valve is an on / off valve, and the controller is to: cause the release valve to be actuated between an open state and a closed state based on the flow parameter, wherein in the open state, the release valve is to redirect at least a portion of the handled fluid from the discharge zone to the suction zone, and in the closed state, the release valve is to prevent fluid flow from the discharge zone to the suction zone.

4. The fluid handling system as claimed in claim 1 , wherein the flow parameter is at least one of pressure and flow rate of the handled fluid at a discharge side.

5. The fluid handling system as claimed in claim 1 , wherein the controller is to: determine that demand for the handled fluid has decreased based on the flow parameter; and in response to determination that demand for the handled fluid has decreased:cause the modulation valve to be opened in proportion to the decrease in demand.

6. The fluid handling system as claimed in claim 5, wherein the fluid handling system comprises a release valve to selectively redirect at least a portion of the fluid from a discharge zone downstream of the working chamber to the suction zone, and wherein the controller is to: cause the modulation valve to be opened until the modulation valve reaches a fully open position; determine that demand continues to decrease after the modulation valve has reached the fully open position; and in response to determination that the demand continues to decrease, cause the release valve to be actuated to an open state to redirect at least a portion of the fluid from the discharge zone to the suction zone.

7. The fluid handling system as claimed in claim 1 , wherein the fluid handling system comprises a release valve to selectively redirect at least a portion of the fluid from a discharge zone downstream of the working chamber to the suction zone, and wherein the controller is to: determine that demand for handled fluid has increased based on the flow parameter; and in response to determination that demand has increased, cause the release valve to be actuated to a closed state to prevent fluid flow from the discharge zone to the suction zone.

8. The fluid handling system as claimed in claim 7, wherein upon actuating the release valve to the closed state, the controller is to:determine that demand for handled fluid has increased based on the flow parameter; and in response to determining that demand for the handled fluid has increased: cause the modulation valve to be closed in proportion to the increase in demand.

9. The fluid handling system as claimed in claim 1 , comprising: a second working chamber having an element driven within the second working chamber to handle the fluid discharged from the working chamber, wherein during each cycle of operation of the second working chamber, fluid is drawn into the second working chamber from the working chamber and expelled from the second working chamber, and wherein each cycle comprises: a suction phase where fluid is drawn into the second working chamber while a volume of the second working chamber is increasing and pressure of the fluid in the second working chamber is fluctuating, a zone of the second working chamber where the suction phase is to occur corresponds to a second suction zone, and a suction stabilization phase where the volume of the second working chamber remains substantially constant and pressure of the fluid in the second working chamber stabilizes, a zone of the second working chamber where the suction stabilization phase is to occur corresponds to a second suction stabilization zone; a second modulation valve progressively adjustable to redirect at least a portion of the fluid from the second suction stabilization zone to the second suction zone; and wherein the controller being operably connected to the second modulation valve and is to cause the second modulation valve toredirect at least a portion of the fluid flow from the second suction stabilization zone to the second suction zone based on the flow parameter to maintain the flow parameter within a predetermined operating range to prevent cyclic unloading and reloading of the fluid handling system.

10. The fluid handling system as claimed in claim 1 , wherein the fluid handling system is at least one of a compressor system, a vacuum system, and a blower system.

11. A method for stabilizing flow in a fluid handling system comprising a working chamber having an element driven within the working chamber to handle fluid, the method comprising: operating the working chamber through a plurality of cycles, wherein during each cycle of operation of the working chamber, fluid is drawn into and expelled from the working chamber, and wherein each cycle comprises: a suction phase wherein the fluid is drawn into the working chamber while volume of the working chamber is increasing and pressure of the fluid is fluctuating, a zone of the working chamber where the suction phase is to occur corresponds to a suction zone; and a suction stabilization phase where volume of the working chamber remains substantially constant and pressure of the fluid stabilizes, a zone of the working chamber where the suction stabilization phase is to occur corresponds to a suction stabilization zone; monitoring a flow parameter indicative of demand for the fluid; and progressively adjusting a modulation valve to redirect at least a portion of the fluid from the suction stabilization zone to the suctionzone, based on the flow parameter to maintain the flow parameter within a predetermined operating range to prevent cyclic unloading and reloading of the system, wherein the fluid handling system is a rotary type fluid handling system.

12. The method as claimed in claim 11 , wherein each cycle comprises: a discharge phase occurs where the handled fluid is expelled from the working chamber into a discharge zone, the method comprising: actuating a release valve connecting the discharge zone to the suction zone of the working chamber.

13. The method as claimed in claim 12, wherein actuating the release valve comprises actuating the release valve between an open state and a closed state to redirect at least a portion of the handled fluid from the discharge zone to the suction zone based on the flow parameter.

14. The method as claimed in claim 11 , comprising: determining that demand for handled fluid has decreased based on the flow parameter; in response to determining that demand for the handled fluid has decreased: opening the modulation valve in proportion to the decrease in demand.

15. The method as claimed in claim 14, comprising: opening the modulation valve until the modulation valve reaches a fully open position; determining that demand continues to decrease after the modulation valve has reached the fully open position; andin response to determining that the demand continues to decrease, actuating, a release valve connecting a discharge zone downstream of the working chamber to the suction zone, to an open state to redirect at least a portion of the fluid from the discharge zone to the suction zone.

16. The method as claimed in claim 11 , comprising: determining that demand for the handled fluid has increased based on the flow parameter; and in response to determining that demand has increased, actuating, a release valve connecting a discharge zone downstream of the working chamber to the suction zone, to a closed state to prevent fluid flow from the discharge zone to the suction zone.

17. The method as claimed in claim 16, wherein after actuating the release valve to the closed state, the method comprises determining that demand for handled fluid continues to increase based on the flow parameter; and closing the modulation valve in proportion to the increase in demand.

18. A compressor system comprising: a plurality of working chambers arranged in series, each working chamber having a compressor element driven within the working chamber to compress gas, wherein during each cycle of each working chamber a quantity of gas is drawn into and expelled from the working chamber, and wherein each cycle comprises: a suction phase wherein the gas is drawn into the working chamber while volume of the working chamber is increasing and pressure of the gas is fluctuating, a zone of theworking chamber where the suction phase is to occur corresponds to a suction zone; and a suction stabilization phase where volume of the working chamber remains substantially constant and pressure of the gas stabilizes, a zone of the working chamber where the suction stabilization phase is to occur corresponds to a suction stabilization zone; a plurality of modulation valves, each modulation valve progressively adjustable to redirect at least a portion of the gas from the suction stabilization zone to the suction zone of each of the working chamber; and a controller operably connected to the plurality of modulation valves, wherein the controller is to: monitor a flow parameter indicative of demand for compressed gas; and cause each of the plurality of modulation valves to be adjusted based on the flow parameter to maintain the flow parameter within a predetermined operating range to prevent cyclic unloading and reloading of the compressor system, wherein the compressor system is a rotary type compressor system.

19. The compressor system as claimed in claim 18, wherein each cycle comprises: a discharge phase occurs where the gas is expelled from the working chamber into a discharge zone, the compressor system comprising: a release valve to selectively redirect at least a portion of the gas from the discharge zone to the suction zone.

20. The compressor system as claimed in claim 19, wherein the release valve is an on / off valve and the controller is to cause the release valve to be actuated between an open state and a closed state based on the flow parameter, wherein in the open state, the release valve is to redirect at least a portion of the compressed gas from the discharge zone to the suction zone of a first working chamber, and wherein in the closed state, the release valve prevents gas flow from the discharge zone to the suction zone of the first working chamber.

21. The compressor system as claimed in claim 18, wherein the flow parameter is at least one of line pressure and flow rate of the compressed gas.

22. The compressor system as claimed in claim 18, wherein the controller is to: determine that demand for compressed gas has decreased based on the flow parameter; and sequentially cause the plurality of modulation valves to be opened in proportion to the decrease in demand, wherein the plurality of modulation valves are sequentially opened based on their position in the series from the first working chamber to the final working chamber, and wherein a subsequent modulation valve in the series begins opening after a preceding modulation valve in the series reaches a fully open position.

23. The compressor system as claimed in claim 22, wherein the compressor system comprises a release valve to selectively redirect at least a portion of the compressed gas from a discharge zone downstream of thefinal working chamber to the suction zone of the first working chamber, and wherein the controller is to: determine that demand continues to decrease after all of the plurality of modulation valves have reached a fully open position; and in response to determining that demand for the gas has decreased, cause the release valve to be actuated to an open state to redirect at least a portion of the compressed gas from the discharge zone to the suction zone of the first working chamber.

24. The compressor system as claimed in claim 18, wherein the compressor system comprises a release valve to selectively redirect at least a portion of the compressed gas from a discharge zone downstream of the final working chamber to the suction zone of the first working chamber, and wherein the controller is to: determine that demand for compressed gas has increased based on the flow parameter; and in response to determining that demand for the gas has increased: cause the release valve to be actuated to a closed state to prevent gas flow from the discharge zone to the suction zone of the first working chamber.

25. The compressor system as claimed in claim 24, wherein after actuating the release valve to the closed state, the controller is to: sequentially cause the plurality of modulation valves to be closed in proportion to the increase in demand, wherein the plurality of modulation valves are sequentially closed based on their position in the series from the final working chamber to the first working chamber, and wherein a preceding modulation valve in the series begins closing after a subsequent modulation valve in the series reaches a fully closed position.STATEMENT UNDER ARTICLE 19The Applicant has amended independent claims 1 and 11 to specify that the fluid handling system is a rotary type fluid handling system. The following wherein clause has been added to the independent claims 1 and 11 :"wherein the fluid handling system is a rotary type fluid handling system. "The Applicant has added the following similar wherein clause to the independent claim 18:"wherein the compressor system is a rotary type compressor system. "

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