Compressor Surge Prevention via Active Isolation Valve Control

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Solution Overview

Problem

Compressor operations are limited by choke and surge parameters, restricting the efficient operating range and potentially leading to instability, vibrations, and component damage.

Innovation Solution

An actively controlled valve is used to restrict flow into the condenser in response to surge events or precursors, adjusting its state via a feedback loop to maintain the compressor operating point below the surge line, thereby preventing surge and extending the operating range.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the compressor operates at higher load to increase productivity, then the output increases, but the risk of surge events increases causing instability and potential damage

Engineering Contradiction:

Improvecompressor outputVSAvoidcompressor stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system detects surge precursors (changes in discharge pressure, suction pressure, or flow rate) and takes preliminary action by restricting the isolation valve before the actual surge event occurs. This preventive approach allows the compressor to operate closer to the surge line without actually entering the surge region, thereby increasing productivity while maintaining reliability.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors compressor parameters (discharge pressure, suction pressure, flow rate) and uses feedback control to dynamically adjust the isolation valve position. When surge precursors are detected, the feedback loop restricts the valve to prevent surge; when surge-free conditions are confirmed, the valve gradually opens to maximize output. This feedback mechanism resolves the contradiction by enabling high productivity operation while maintaining stability through real-time adjustments.

Inventive Principle:

Principle #23Feedback

2Reliability

If the isolation valve is restricted to prevent surge, then compressor stability improves, but the operating range and productivity decrease

Engineering Contradiction:

Improvecompressor stabilityVSAvoidcompressor operating range

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system dynamically adjusts the isolation valve position based on real-time compressor conditions rather than maintaining a fixed restricted position. The valve opens gradually when surge-free conditions are confirmed for a predetermined time period, allowing the operating range to expand. This dynamic approach resolves the contradiction by adapting the restriction level to current operating conditions, maximizing productivity while maintaining stability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system implements a predetermined time period delay before fully opening the valve after surge prevention. This preliminary waiting period ensures stability is maintained while allowing the system to safely expand its operating range. The gradual valve opening approach prevents sudden transitions that could cause instability, thereby resolving the contradiction between stability and operating range.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If the compressor operates closer to the surge line to extend operating range, then productivity increases, but the risk of surge events and harmful effects increases

Engineering Contradiction:

Improvecompressor operating rangeVSAvoidsurge event damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The system applies preliminary anti-action by detecting surge precursors and restricting the isolation valve before the harmful surge effect can occur. The feedback control system continuously monitors parameters and takes counteracting action (valve restriction) when precursors are detected, preventing the harmful surge phenomenon while allowing operation close to the surge line. This resolves the contradiction by neutralizing the harmful effect before it can manifest.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The feedback control system continuously monitors compressor parameters and dynamically adjusts the isolation valve to prevent harmful surge effects. When surge precursors are detected, the feedback loop immediately restricts the valve; when conditions are safe, it gradually opens the valve to expand operating range. This feedback mechanism resolves the contradiction by enabling high productivity operation while preventing harmful effects through real-time control adjustments.

Inventive Principle:

Principle #23Feedback

Data Source

PatentEP3969758B1Method and system for compressor operating range extension via active valve control

Publication Date: 2025.07.02 CARRIER CORP

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AI summary

An exemplary compressor system includes a compressor having a fluid inlet and a fluid outlet. An isolation valve connects the fluid outlet of the compressor to a condenser. A controller is communicatively coupled to the isolation valve and the compressor. The controller includes a memory storing instructions configured to cause the controller to detect one of a surge event and a surge event precursor and restrict an opening in the isolation valve in response.