Multi-Stage Compressor Malfunction Detection via Flow Comparison
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Solution Overview
Problem
Multi-stage compressors face challenges in detecting malfunctions, particularly when flow rate meters are in an abnormal state, leading to incorrect gas flow rate measurements and potential surge states, and existing redundancy-based methods are costly.
Innovation Solution
A system that compares suction flow rates measured by a first sensor with downstream flow rates measured by a second sensor, with corrections for temperature, pressure, and molecular weight, and includes a third sensor to measure drainage, allowing for malfunction detection without redundant measuring instruments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a flow rate meter is used to measure gas flow rate in a multi-stage compressor, then the gas flow rate can be measured for control purposes, but the measurement becomes unreliable when the flow rate meter is in an abnormal state, leading to incorrect measurements and potential surge states
Solution Approach 1:
The control unit continuously compares the suction flow rate measured by the first flow rate meter with the downstream flow rate measured by the second flow rate meter, creating a feedback mechanism that detects measurement discrepancies and identifies malfunctioning sensors, thereby maintaining reliable measurements even when one sensor becomes abnormal
Solution Approach 2:
The patent introduces a comparison mechanism as an intermediary that mediates between the two flow rate measurements. This intermediary detects inconsistencies and triggers appropriate responses, allowing the system to identify sensor malfunctions without requiring redundant measurement systems
2Reliability
If redundancy-based methods are used to detect malfunction of measuring instruments, then malfunction detection capability is improved, but the cost increases
Solution Approach 1:
The existing flow rate measurement system serves dual purposes: both for process control and for malfunction detection. By comparing measurements from the first and second flow rate meters, the system self-diagnoses sensor malfunctions without requiring additional redundant measuring instruments, thereby maintaining high reliability while avoiding increased costs
3Ease of operation
If the suction flow rate is corrected based on erroneously measured gas flow rate, then the control system attempts to maintain proper operation, but the compressor enters a surge state
Solution Approach 1:
The control unit performs preliminary detection by comparing flow rate measurements before applying corrections. When a discrepancy indicating sensor malfunction is detected, the system takes preliminary action to identify and address the malfunction, preventing erroneous corrections that would lead to surge states
Data Source
AI summary
A multi-stage compressor system is a system of a multi-stage compressor in which compressors are connected in series in a plurality of stages includes a control unit. The control unit determines whether a malfunction is present in the system by comparing a suction flow rate of a first-stage compressor measured by a first sensor with a downstream flow rate from an outlet of the multi-stage compressor measured by a second sensor.