Compressor Surging Control via Proportional Coefficient
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Solution Overview
Problem
Current methods for detecting and handling surging in centrifugal compressors are inefficient, leading to reduced efficiency and potential damage due to inaccurate detection and delayed response, especially when surging is minor.
Innovation Solution
A control device and method that includes a variation command unit, proportional coefficient calculation unit, and control unit to change command values affecting the compressor's operating state, calculating a proportional coefficient based on the compressor's state, and performing control to avoid or suppress surging by adjusting the circulation flow regulation valve.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If circulation flow rate is increased to avoid surging, then surging is prevented, but compressor efficiency is reduced due to work loss
Solution Approach 1:
The system performs preliminary detection of surging occurrence before it fully develops, using the proportional coefficient to identify early signs of surging. This allows the circulation flow rate to be increased just enough to prevent surging, rather than maintaining a constantly high circulation flow rate, thereby minimizing energy loss while ensuring reliability.
Solution Approach 2:
The system continuously monitors the proportional coefficient as feedback on compressor operation state. When the proportional coefficient indicates surging occurrence, the circulation flow rate is adjusted. This feedback mechanism enables precise control that prevents surging only when necessary, avoiding unnecessary energy loss from excessive circulation flow.
2Reliability
If conventional surging detection methods are used based on flow rate and discharge pressure, then surging can be detected, but detection accuracy is insufficient leading to delayed response
Solution Approach 1:
The system replaces conventional mechanical measurement methods (flow rate meters, pressure sensors) with a computational approach using the proportional coefficient. This substitution enables more precise detection of surging occurrence by analyzing the relationship between command values and actual operation values, achieving higher measurement precision without additional mechanical sensors.
Solution Approach 2:
The proportional coefficient acts as an intermediary parameter that bridges the gap between command values and actual operation values. By monitoring changes in this intermediary parameter, the system can detect surging occurrence more accurately and respond faster than by directly monitoring flow rate or pressure alone.
3Reliability
If circulation flow regulation valve is opened early to prevent surging, then surging is avoided, but unnecessary circulation flow increases causing energy loss
Solution Approach 1:
The system takes preliminary action by detecting surging occurrence at an early stage using the proportional coefficient, before the compressor operation fully enters the surging region. This allows for minimal necessary adjustment of circulation flow rate, avoiding both premature action and complete failure to act.
Solution Approach 2:
The system dynamically adjusts the circulation flow rate based on real-time detection of surging occurrence through the proportional coefficient. Rather than maintaining a fixed or overly conservative circulation flow rate, the system adapts the circulation flow dynamically, opening the regulation valve only when and to the extent necessary, thereby maintaining compressor efficiency while ensuring surging avoidance.
Data Source
AI summary
A control device includes: a variation command unit that changes a command value, which is a command value sent to a system including a compressor, affecting an operating state of the compressor; a proportional coefficient calculation unit that calculates a proportional coefficient of a variation in a parameter, which indicates a state of the compressor or an electric motor that drives the compressor when the system is operated based on the command value, with respect to the command value; and a control unit that performs control for avoiding or suppressing surging in the compressor, based on a value of the proportional coefficient.