Compressor Surge Detection Using Pressure Evolution Analysis
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Solution Overview
Problem
Conventional centrifugal compressor systems rely solely on the first derivative of discharge pressure for surge detection, which is inadequate for recognizing complex surge patterns, and lack effective recovery mechanisms, leading to potential catastrophic failures due to repeated surges.
Innovation Solution
A fluid transport system with a controller that detects surge events based on the evolution of discharge pressure, including its rate and rate of change, and relocates the surge margin using recorded surge parameter values to prevent recurrence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional surge detection based on first derivative of discharge pressure is used, then the detection system is simple, but the detection accuracy is insufficient for complex surge patterns
Solution Approach 1:
The patent transitions from detecting only the first derivative of discharge pressure to analyzing multiple dimensions of pressure evolution including the pressure signal itself, its first derivative, and second derivative. This multi-dimensional analysis enables accurate detection of complex surge patterns while maintaining computational efficiency through systematic processing of these variables.
Solution Approach 2:
The detection system segments the surge detection process into distinct analytical components: monitoring discharge pressure, calculating its first derivative, calculating the second derivative, and evaluating multiple features independently. This segmentation allows each component to be optimized separately while collectively achieving high detection accuracy for complex surge patterns.
2Reliability
If conventional surge detection only trips the system, then the control mechanism is simple, but the system lacks effective recovery mechanisms leading to potential catastrophic failures
Solution Approach 1:
The patent implements a feedback-based surge margin relocation mechanism that uses recorded surge parameter values to proactively adjust the surge margin and prevent recurrence. The system continuously monitors surge events, learns from them by recording parameter values, and automatically relocates the surge margin to maintain system reliability and prevent catastrophic failures.
Solution Approach 2:
The system performs preliminary actions by recording surge parameter values during detected surge events and using this information to proactively relocate the surge margin before another surge can occur. This preventive approach enhances reliability by addressing potential surge conditions before they develop into catastrophic failures.
3Reliability
If surge margin is not relocated after surge events, then the system operation is simple, but repeated surges may result in catastrophic failures
Solution Approach 1:
The system performs self-service by automatically detecting surge events, recording the associated parameter values, and autonomously relocating the surge margin without requiring external intervention. This automated self-adjustment mechanism protects the compressor from repeated surges and catastrophic failures while maintaining simple operational procedures.
Data Source
AI summary
Methods, systems and controllers for detecting a surge event based on pattern of evolution of a discharge pressure of a compressor, and for relocating a surge margin relative to a surge parameter value recorded at the beginning of the surge event are provided. A controller has an interface configured to receive values of the discharge pressure from a compressor, and to output signals and alarms, a surge event detection unit connected to the interface and configured to detect a surge event in the compressor based on evolutions of the discharge pressure, a rate of the discharge pressure and a rate change of the rate, and a surge margin relocation unit connected to the surge event detection unit and the interface, and configured to relocate a surge margin relative to a surge parameter value recorded at a beginning of the surge event.