Turbomachinery Actuator Force Monitoring for Compressor Diagnostics
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Solution Overview
Problem
Detecting and predicting conditions in turbomachinery, such as compressor surges and stalls, is costly and inefficient due to the difficulty in placing sensors throughout the system, necessitating the derivation of conditions from measurements of forces on inlet guide vanes and variable stator vane actuation systems.
Innovation Solution
A system comprising actuators, positioners, and a controller that monitor and adjust the pitch of inlet guide vanes and variable stator vanes, using sensors to derive operating conditions by analyzing dynamic and static forces, and communicating via a communication bus to provide real-time and historical trending data for predictive and diagnostic purposes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are placed throughout the turbomachinery system to directly detect conditions, then measurement precision and reliability improve, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent uses actuator positioners as intermediary components to indirectly measure compressor conditions. Instead of placing sensors throughout the system, the positioners that control inlet guide vanes and variable stator vanes serve dual purposes: controlling vane positions and detecting operating conditions through their force measurements. This intermediary approach provides diagnostic information without requiring direct sensor placement in the compressor flow path.
Solution Approach 2:
The positioner components are designed to perform multiple functions: they control the pitch of inlet guide vanes and variable stator vanes, and simultaneously serve as measurement devices for detecting compressor operating conditions. By making these existing control components multi-functional, the system avoids adding separate sensor systems while maintaining measurement capabilities.
2Reliability
If comprehensive sensor coverage is implemented for predictive maintenance, then reliability improves, but loss of time for installation and maintenance increases
Solution Approach 1:
The existing actuation system components (positioners, actuators, controllers) perform self-diagnosis by monitoring their own operational parameters. The positioners automatically detect abnormal forces and communicate condition data to the controller, enabling the system to monitor its own health without external sensor installations. This self-service capability eliminates installation time while maintaining continuous monitoring.
Solution Approach 2:
The system establishes baseline force measurements during normal operation before fault conditions develop. By continuously comparing current force readings against these pre-established baselines, the system can detect deviations indicating developing faults. This preliminary characterization of normal operation enables early warning before actual failures occur, maintaining reliability without requiring additional installation time.
3Loss of information
If detailed force measurements are taken from actuators, then diagnostic information quality improves, but use of energy increases
Solution Approach 1:
The controller receives force measurement feedback from positioners and uses this information to adjust actuator commands and predict compressor conditions. The feedback loop allows the system to maintain high diagnostic quality by continuously refining its understanding of compressor state based on measured forces, while optimizing energy use through intelligent control algorithms that process only necessary data.
Solution Approach 2:
The system measures forces at key actuator locations (inlet guide vane actuators and variable stator vane actuators) rather than attempting to measure all parameters throughout the entire compressor. This partial measurement approach captures sufficient diagnostic information about compressor operating conditions, surge margins, and potential faults without the excessive energy consumption that would result from comprehensive multi-point measurements.
Data Source
AI summary
Systems and methods include actuation system of turbomachinery that include an actuator configured to control pitch of vanes of the turbomachinery and a positioner configured to position the actuator to control the pitch. The actuation system also includes a controller system communicably coupled to the positioner. The controller system is configured to drive the positioner based at least in part on a set point of the turbomachinery and obtain data from the positioner indicating an amount of force used for a target pitch. Using the data, the controlling system derives an operating condition for the turbomachinery and controls the turbomachinery based at least in part on the operating condition of the turbomachinery.