Chiller Surge Map Control for Energy-Efficient Compressor Operation

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Solution Overview

Problem

Chiller control systems face challenges in achieving energy efficiency while avoiding surge conditions, which can cause damage to compressor and system components due to unpredictable variations in load conditions, temperature, pressure, and other factors.

Innovation Solution

A computerized method and controller system that creates a surge map by plotting detected surge events in a two-dimensional coordinate system with non-axis representations, such as color, to predict and prevent surge conditions by adjusting chiller setpoints and controlling variables like prerotation vane position and variable speed drive frequency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If chiller control variables are adjusted to reduce power consumption, then energy efficiency is improved, but surge conditions may occur causing system damage

Engineering Contradiction:

Improvepower consumptionVSAvoidsurge condition avoidance

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The system performs preliminary actions by detecting surge conditions through monitoring chiller operating parameters and predicting potential surge events before they occur. The controller proactively adjusts control variables to prevent surge conditions, allowing the chiller to operate at lower power consumption levels while maintaining reliability through advance intervention rather than reactive response.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements continuous feedback by monitoring chiller operating parameters, comparing actual performance against surge prediction models, and dynamically adjusting control variables. This closed-loop feedback mechanism enables the system to optimize power consumption while preventing surge conditions, as the controller receives real-time information about chiller state and makes corrective adjustments to maintain safe operating boundaries.

Inventive Principle:

Principle #23Feedback

2Use of energy by moving object

If chiller control variables are adjusted to improve energy efficiency, then power consumption is reduced, but control difficulty increases due to unpredictable load and temperature variations

Engineering Contradiction:

Improvepower consumptionVSAvoidcontrol difficulty

Core Design Contradiction:

Use of energy by moving objectVSEase of operation

Solution Approach 1:

The chiller control system performs self-service by automatically detecting its own operating state, predicting surge conditions, and adjusting its control variables without external intervention. The controller monitors parameters such as load conditions, temperature, and pressure, then autonomously modifies control settings to prevent surge while optimizing energy efficiency, eliminating the need for complex manual control operations.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system replaces complex mechanical control mechanisms with electronic sensing and computational prediction. Instead of relying on mechanical feedback devices and manual adjustment mechanisms, the system uses electronic sensors to detect operating parameters, computational algorithms to predict surge conditions, and electronic actuators to adjust control variables, significantly simplifying the control process while improving energy efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If surge detection and mapping systems are implemented, then surge prediction capability is improved, but device complexity increases

Engineering Contradiction:

Improvesurge prediction capabilityVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The controller performs multiple functions using a single integrated system: it monitors chiller operating parameters, detects surge conditions, predicts potential surge events, displays surge maps, and adjusts control variables. By combining these functions into one multi-functional controller rather than separate dedicated devices for each task, the system achieves improved surge prediction capability while minimizing the increase in overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system uses color-coded visual representation in the surge map display to convey complex surge prediction information in an intuitive manner. Different colors represent different surge risk levels or operating conditions, allowing operators to quickly understand chiller status without interpreting complex numerical data. This visual encoding simplifies the user interface while providing comprehensive surge prediction capabilities.

Inventive Principle:

Principle #32Color changes

Data Source

PatentUS9097447B2Methods and controllers for providing a surge map for the monitoring and control of chillers

Publication Date: 2015.08.04 TYCO FIRE & SECURITY GMBH

AI summary

A controller for a chiller includes processing electronics configured to detect a plurality of surge events. The processing electronics create a surge map by calculating and plotting a point for each detected surge event in an at least two dimensional coordinate system. The surge map is displayed through the use of an electronic display system. The surge map describes at least three conditions of the chiller when the surge event was detected through the use of axis and non-axis representations. The processing electronics are further configured to control at least one setpoint for the chiller using the calculated surge map.