Chiller Compressor Surge Detection Using Multi-Parameter Monitoring
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Solution Overview
Problem
Chiller systems face issues with compressor surge due to high compression ratios, leading to unstable refrigerant flow and frequent damage, necessitating a method to prevent and accurately detect surge for efficient operation and reduced maintenance costs.
Innovation Solution
A chiller system equipped with sensors and a controller using machine learning to predict and detect surge, adjusting refrigerant flow and compressor speed, and updating the compressor map to optimize operation, thereby preventing surge and extending component life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the compressor operates with high compression ratio, then the cooling capacity is improved, but surge occurs causing unstable refrigerant flow and compressor damage
Solution Approach 1:
The system performs preliminary detection of surge conditions by monitoring compressor operating parameters (pressure ratio, refrigerant flow rate, rotational speed) and compares them against pre-stored surge map data. When surge is predicted before it occurs, the control system takes preventive action by adjusting the expansion valve opening degree or compressor rotational speed to move the operating point away from the surge region, thereby preventing compressor damage while maintaining high compression ratio operation
Solution Approach 2:
The system continuously monitors compressor operating parameters (suction pressure, discharge pressure, refrigerant flow rate, rotational speed) and feeds this information back to the control unit. The control unit compares real-time parameters with surge map thresholds and dynamically adjusts the expansion valve or compressor speed to maintain operation outside the surge region, creating a closed-loop feedback control system that prevents surge while optimizing cooling capacity
2Device complexity
If traditional surge detection methods are used, then the detection process is simple, but the detection accuracy is insufficient leading to late surge identification
Solution Approach 1:
The system transitions from single-parameter surge detection to multi-dimensional detection by simultaneously monitoring multiple parameters (pressure ratio, refrigerant flow rate, rotational speed, expansion valve opening degree) and comparing them against a multi-dimensional surge map. This dimensional expansion enables more accurate surge prediction by considering the interrelationships between parameters rather than relying on single-threshold detection
Solution Approach 2:
The system stores surge map data that defines surge thresholds as functions of multiple varying parameters (rotational speed, refrigerant flow rate, pressure ratio). Instead of using fixed thresholds, the system dynamically determines surge boundaries based on the current combination of operating parameters, enabling accurate surge detection across different operating conditions while maintaining a relatively simple detection architecture
3Ease of manufacture
If maintenance is performed at predetermined cycle, then the maintenance schedule is simple, but unnecessary maintenance costs are incurred
Solution Approach 1:
The system performs self-diagnosis by continuously monitoring compressor operating parameters and comparing them against surge map thresholds. When surge conditions are detected or predicted, the system automatically generates maintenance alerts and tracks surge occurrence frequency. This enables condition-based maintenance scheduling where maintenance is performed only when actually needed based on real system state, eliminating unnecessary routine maintenance while ensuring timely intervention when surge problems occur
Data Source
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AI summary
A chiller system according to an aspect of the present disclosure includes: a compressor configured to compress a refrigerant by rotation; a condenser configured to condense the refrigerant compressed by the compressor; an expander configured to expand the condensed refrigerant; an evaporator configured to evaporate the expanded refrigerant; a sensor unit including a plurality of temperature sensors, a speed sensor for sensing a rotational speed of the compressor, and a current sensor for sensing a current of the compressor; and a controller configured to determine whether to enter into a surge detection logic based on a volatility of data sensed by the sensor unit, and configured to perform surge detection.