A system for operating pneumatic capacity control system using air produced by turbo compressor itself

Abstract

The system invention relates to a system (100) comprising at least one turbo compressor (1) comprising air pressurization equipment, at least one suction guide vane or valve system (2) for adjusting the capacity of the air sucked in and for imparting an initial rotational motion to the air, at least one control valve (3) to discharge excess air out of the system (100) in case of sudden pressure fluctuations, at least one primary check valve (4) positioned on the outlet line to prevent compressed air from entering the system (100) in reverse in case of sudden pressure fluctuations, at least one block valve (5) to protect said primary check valve (4) from high pressure and sudden pressure fluctuation, at least one sensor (6) to read the outlet line pressure, at least one control unit (7) that controls all components and manages communication, at least one three-way valve (8) that sends and receives air in the actuator, at least one speed control unit (9) for adjusting the speed of air entering or leaving the pneumatic actuator.

Description

[0001] DESCRIPTION

[0002] A SYSTEM FOR OPERATING PNEUMATIC CAPACITY CONTROL SYSTEM USING AIR PRODUCED BY TURBO COMPRESSOR ITSELF

[0003] Technical Field

[0004] The invention relates to pneumatic capacity control systems used in turbo compressors. More specifically, the invention relates to a system for operating a pneumatic capacity control system using compressed air generated by the turbo compressor itself, without the need for an external source of compressed air (control air).

[0005] State of the Art

[0006] Turbo compressors are industrial machines widely used to produce compressed air in various industrial applications. These compressors are equipped with pneumatic capacity control systems to regulate air flow and pressure. Conventional pneumatic capacity control systems usually require an external source of compressed air. This situation makes the system dependent, especially in applications where access to external compressed air is unavailable or limited.

[0007] Turbo compressors generally have an electrically actuated guide vane or valve system that provides capacity control in the air suction line, a pneumatic relief valve, and a pneumatic outlet line block valve. Pneumatic valves require external compressed air. In applications where there is no access to external compressed air, the relief valve is also used with an electric actuator.

[0008] The suction vane or valve system has two tasks. The first effect is to increase the compressor efficiency by providing the first rotational effect of the inlet air in turbo compressors, and the second is to provide capacity control. Although the opening angles of these vanes are important, they are generally designed with electrical actuators and mechanical systems. In order to properly adjust the angle of the vanes, the electric actuators need to provide a sufficient amount of motion resolution. This resolution is limited by the motion accuracy of the gear system present in the electric actuators.In addition, electric actuators are unable operate under normal conditions in cases such as power outages and cannot fulfill the function to protect the compressor. One solution is to connect an external uninterruptible power source to the electric actuators so that they can operate during power outages. However, this leads to increased maintenance costs.

[0009] Relief and relief control valves are generally used with pneumatic actuators. The most important reason for this is that the motion sensitivity of pneumatic actuated valves depends only on the signal processing sensitivity, they can react very quickly, they contain no wearing parts such as gear wheels inside, and they can ensure the safety of the turbo compressor without the need for any intervention or energy source in case of power failure. However, pneumatic actuators require external compressed air. This prevents the commissioning of turbo compressors using pneumatic actuated systems in plants without access to compressed air, for example in newly commissioned plants. In the current situation, this means using another type of low-volume compressor alongside the turbo compressor. If the external compressed air source is damp or the compressed air supply decreases, causing the system to malfunction, the operation of the turbo compressor is adversely affected.

[0010] Another solution to the aforementioned external compressed air is the use of electric actuated systems instead of pneumatic actuated relief and relief control systems. However, there are many problems such as the gear systems in the mechanisms affecting the resolution, increasing the response times of the system, being susceptible to wear, as well as the need for additional investment during power outages.

[0011] The outlet block valve is an equipment with on-off function that protects the compressors against sudden pressure fluctuations in the line when they are not running. It is generally selected to be pneumatic. If it is selected to be pneumatic, external compressed air is also required for this valve. It is also possible to select it to be equipped with electric actuator to eliminate the need for external compressed air. The reduced motion sensitivity of the electric actuator does not pose a problem for this on-off equipment. However, it needs an uninterruptible power source to protect the compressor during power outages. This increases initial investment and maintenance costs.For the reasons listed, there is a need to develop a system that eliminates these disadvantages.

[0012] Summary of the Invention

[0013] The object of the invention is to develop a system to enable the pneumatic capacity control system to be commissioned and operated with the air produced by the turbo compressor itself, without the need for external compressed air, and without reducing the control resolution and reliability of the capacity control system.

[0014] The advantages obtained with the invention are as follows.

[0015] - The precision of motion and control generated by electric actuated systems is not affected. The absence of additional mechanical components does not limit the control capability.

[0016] - Compared to systems with electric actuators, there is no need for additional uninterruptible power source investment. Pneumatic systems ensure the safety of the turbo compressor without any power source.

[0017] - The problem of increased response time caused by electric actuated systems is not encountered. Thanks to the fast response times of pneumatic systems, the turbo compressor can take action much more quickly. Sudden pressure fluctuations of the line are minimized.

[0018] - The wear problem experienced by electric actuators is not encountered in the system subject to the invention. Thanks to the simple designs of pneumatic systems, the wear on parts is minimized.

[0019] - The reliability issues associated with electric actuators in situations such as emergency shutdowns and power outages are eliminated. Pneumatically controlled systems ensure turbo compressor safety without any power source. There is no need for additional compressor investment for external compressed air. This reduces initial investment and maintenance costs and improves energy efficiency.Description of the Drawings

[0020] Fig. 1 : A representative schematic view showing how the system subject to the invention uses the compressed air generated by the turbo compressor to drive the pneumatic capacity control system.

[0021] Description of the References in the Drawings

[0022] For a better understanding of the invention, the description of the numbers in the figures is given below:

[0023] 100. System

[0024] 1. Turbo compressor

[0025] 2. Suction guide vane or valve system

[0026] 3. Control valve

[0027] 4. Primary check valve

[0028] 5. Block valve

[0029] 6. Sensor

[0030] 7. Control unit

[0031] 8. Three-way valve

[0032] 9. Speed control unit

[0033] 10. By-pass valve

[0034] 11. Secondary check valve

[0035] Detailed Description of the Invention

[0036] The system (100) subject to the invention, in a preferred embodiment of the invention, comprises at least one turbo compressor (1) comprising air pressurization equipment, at least one suction guide vane or valve system (2) with a pneumatic actuator for adjusting the capacity of the air sucked in from the inlet and for imparting an initial rotational motion to the air, at least one control valve (3) with pneumatic actuator to discharge excess air out of the system (100) in case of sudden pressure fluctuations, at least one primary check valve (4) positioned on the outlet line to prevent compressed air from entering the system (100) in reverse in case of sudden pressure fluctuations, at least one block valve (5) with a pneumatic actuator to protect said primary check valve (4) from high pressureand sudden pressure fluctuation, at least one sensor (6) to read the outlet line pressure, at least one control unit (7) that controls all components and manages communication, at least one three-way valve (8) that sends compressed air and receives air in the actuator, at least one speed control unit (9) for adjusting the speed of air entering or leaving the pneumatic actuator, at least one by-pass valve (10) to increase the air flow rate through the turbo compressor (1), and at least one secondary check valve (11) to prevent backflow of air sent into the actuators in case of sudden pressure fluctuations.

[0037] In the invention, spring return single acting or double acting piston type, single and pneumatic diaphragm acting, geared lever and sprocket or vane type actuators can be used as pneumatic actuators.

[0038] It is also possible to use another pneumatic actuated valve instead of said suction guide vane or valve system (2). In addition, although the absence of the block valve (5) does not prevent the operation of the system (100), it is preferred in the embodiment of the invention since it prolongs the initial start-up and the time required to produce the desired air flow rate, making the system (100) less efficient. However, it is also possible to operate the system (100) without the speed control unit (9). Instead of extra speed adjustment with some valves in the state of the art, speed control can be provided by sending a digital signal to the positioner inside the valve.

[0039] Said suction guide vane or valve system (2) increases the efficiency of said turbo compressor (1) by adjusting the capacity of the sucked air and imparting an initial rotational motion to the air.

[0040] Said primary check valve (4) and said block valve (5) protect the turbo compressor (1 ) in case of sudden pressure fluctuations and / or emergency shutdowns. While performing said function, the block valve (5) reduces creep and fatigue effects by preventing the existing compressed air line from continuously applying force to the primary check valve when the compressor is not running, and protects the primary check valve (4) by preventing liquid or solid foreign materials that may come from the line from reaching the primary check valve (4) when the compressor is not running, and the primary check valve (4) which prevents the backflow of compressed air from entering the system (100) protects the turbo compressor (1).Said sensor (6) is a pressure sensor that reads the output line pressure and sends pressure information to said control unit (7). Said control unit (7) thus determines when the turbo compressor (1) supplies air and when it stops.

[0041] Said by-pass valve (10) is electrically actuated in the preferred embodiment of the invention.

[0042] In summary, the invention is realized by adding to the existing pneumatic capacity control system, preferably one electrically actuated by-pass valve (10) and preferably two secondary check valves (11).

[0043] The working principle of the system (100) subject to the invention is as follows:

[0044] - The turbo compressor (1) is operated in standby mode. In this case, the suction guide vane or valve system (2) is closed. By-pass valve (10) is closed. The relief or relief control valve (3) is fully open. The outlet block valve (5) is closed. Since there is no external compressed air, the control valve (3), suction guide vane or valve system (2) and outlet block valve (5) have no mobility.

[0045] - When compressed air is required, the by-pass valve (10) starts to be opened through the electric actuator. Since the outlet block valve (5) is closed, it prevents air from escaping from the outlet side. Air is only allowed to escape through the relief or relief control valve (3).

[0046] When the by-pass valve (10) is sufficiently open, the relief or relief control valve (3) is unable to discharge a sufficient volume of air. This increases the air pressure inside the turbo compressor (1).

[0047] - With increasing pressure, the relief or relief control valve (3) starts to close and traps the air inside the turbo compressor (1).

[0048] - When the air trapped in the turbo compressor (1 ) reaches the pressure required for the operation of the pneumatic actuators, it sends the air to the pneumatic actuators. In this case, the suction guide vane or valve system (2), the relief or relief control system (3), the outlet block valve (5) become mobile.

[0049] - With the creation of compressed air, the suction guide vane or valve system (2) starts to open and brings the turbo compressor (1) to the desired flow rate. - The by-pass valve (10) is closed when the suction guide vane or valve system (2) starts to operate.- The outlet block valve (5) opens to release the air and the turbo compressor (1) reaches the load state (producing air at the desired capacity).

[0050] - With the opening of the outlet block valve (5), a sudden pressure drop is observed in the air trapped in the turbo compressor (1). In order to prevent the pressure drop inside the turbo compressor (1) from affecting the system (100), a primary check valve (4) is installed on the suction guide vane or valve system (2) and outlet block valve (5). This prevents air from escaping.

[0051] - As long as there is sufficient pressure in the pressurized air line, these steps do not need to be repeated. The turbo compressor (1) operates according to normal operating procedures. In this way, continuous operation of the by-pass valve (10) is prevented and wear problems are not encountered.

[0052] The system (100) subject to the invention ensures that the turbo compressor (1) only operates in the absence of external compressed air during initial start-up or maintenance.

[0053] In case of power failure and emergency shutdown, the safety measures of the pneumatic capacity control system are activated. No additional controls or equipment are required for this situation. The fact that the by-pass valve (10) has no connection to safety measures prevents any doubts from arising in terms of reliability.

[0054] As shown in Figure 1, when the turbo compressor (1) is not running (no compressed air is being produced), the elements are in the following positions.

[0055] The turbo compressor (1) is not running.

[0056] - The suction guide vane or valve system (2) is completely closed. It returns to the closed position in the unpowered or depressurized state.

[0057] The relief or relief control valve (3) is fully open. It returns to the fully open position in the unpowered or depressurized state.

[0058] The primary check valve (4) is closed. It is a mechanical component.

[0059] - The outlet line block valve (5) is closed. It returns to the closed position in the unpowered or depressurized state.

[0060] - The pressure sensor (6) monitors the pressure of the line after the outlet line block valve (5) and communicates with the control unit (7).

[0061] - The control unit (7) sends an open or close signal to the three-way valves (8) and by-pass valve (10) according to the value measured by the pressure sensor (6).Three-way valves (8) direct the compressed air flow. In open condition, it sends pressurized air to the actuators, and in closed condition, it allows the air to be discharged from the actuator to the outside.

[0062] - The speed control unit (9) is used to control the compressed air speed. It adjusts the movement speed of the actuator.

[0063] - The by-pass valve (10) operates as an open-close valve with an electric actuator.

[0064] In case of power failure, it maintains its position and does not move.

[0065] The secondary check valve (11) allows air to flow in only one direction. It is a mechanical component.

[0066] When said turbo compressor (1) starts up and starts producing air,

[0067] - The pressure sensor (6) reads the outlet line pressure and transmits it to the control unit (7).

[0068] - The control unit (7) controls the outlet line pressure. It decides whether the outlet line pressure is sufficient for the actuators to operate.

[0069] If the outlet line pressure is not sufficient, the control unit (7);

[0070] • Sends an open command to the by-pass valve (10). Opening the by-pass valve (10) increases the air intake into the turbo compressor (1). The air passing through the turbo compressor (1) is discharged through the air relief or air relief control valve (3).

[0071] • When the by-pass valve (10) starts to open sufficiently, the control valve (3) becomes insufficient. Air that cannot be expelled sufficiently causes a pressure increase for the turbo compressor (1).

[0072] • With the pressure increase, the control unit (7) sends ON signal to the three-way valves (8). With this signal:

[0073] - The control valve (3) closes.

[0074] - The suction guide vane or valve system (2) starts to open.

[0075] - The outlet line block valve (5) completely opens.

[0076] - Secondary check valves (11) prevent the backflow of air sent to the actuators.

[0077] Upon activation of the suction guide vane or valve system (2), the control unit (7) sends a close signal to the by-pass valve (10).When the outlet line pressure is sufficient,

[0078] • The control unit (7) sends ON signal to the three-way valves (8). Therefore, - The control valve (3) closes.

[0079] - The suction guide vane or valve system (2) starts to open.

[0080] - The outlet line block valve (5) completely opens.

[0081] Secondary check valves (11) prevent the backflow of air sent to the actuators.

[0082] By-pass valve (10) remains in closed position.

[0083] Thanks to the system (100) subject to the invention, the turbo compressor (1) can be commissioned with its own generated air or can be operated with its own generated air after maintenance, even if there is no external compressed air during maintenance. This increases the reliability and availability of the system (100).

[0084] The invention is not limited to the above descriptions and the person skilled in the art can readily present other different embodiments of the invention. These should be considered within the protection scope of the invention claimed by the claims.

Claims

CLAIMS1 . A system (100) for operating a pneumatic capacity control system using the air produced by the turbo compressor itself, without the need for an external source of compressed air, characterized in that it comprises at least one turbo compressor (1) comprising air pressurization equipment, at least one control valve (3) with pneumatic actuator to discharge excess air out of the system (100) in case of sudden pressure fluctuations, at least one primary check valve (4) positioned on the outlet line to prevent compressed air from entering the system (100) in reverse in case of sudden pressure fluctuations, at least one sensor (6) to read the outlet line pressure, at least one control unit (7) that controls all components and manages communication, at least one three-way valve (8) that sends compressed air and receives air in the actuator, at least one by-pass valve (10) to increase the air flow rate through the turbo compressor (1), and at least one secondary check valve (11 ) to prevent backflow of air sent into the actuators in case of sudden pressure fluctuations.

2. The system (100) according to claim 1 , characterized in that said by-pass valve (10) is electrically actuated.

3. The system (100) according to claim 1 , characterized in that it comprises at least one suction guide vane or valve system (2) with a pneumatic actuator for adjusting the capacity of the air sucked in from the inlet and for imparting an initial rotational motion to the air.

4. The system (100) according to claim 1 , characterized in that it comprises at least one block valve (5) with a pneumatic actuator to protect said primary check valve (4) from high pressure and sudden pressure fluctuation.

5. The system (100) according to claim 1 , characterized in that it comprises at least one speed control unit (9) for adjusting the speed of air entering or leaving the pneumatic actuator.

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