Compressor Anti-Surge Control via Variable Operation Point
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Turbo compressors experience periodic fluid backflows known as surges, leading to mechanical vibrations and reduced performance, which existing control methods fail to prevent effectively.
Innovation Solution
A compressor system with a guide vane, drive unit, flow control valve, and control unit that calculates and compares operation points with anti-surge control lines to actively prevent surges by adjusting the flow control valve, allowing the operation point to remain above a first anti-surge control line or move along a pressure line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a surge control line is set with a fixed margin (e.g., 10%) from the surge line, then the compressor operation is simplified, but the surge prevention effectiveness is insufficient when operation points vary widely
Solution Approach 1:
The patent applies dynamics by making the anti-surge control line variable rather than fixed. The control line dynamically adjusts its position based on the current operation point of the compressor, ensuring that the surge margin adapts to different operating conditions. This resolves the contradiction by maintaining operational simplicity while improving surge prevention effectiveness through adaptive positioning of the control line.
Solution Approach 2:
The patent changes the parameter of the control line position from a fixed value to a variable that depends on the operation point. By calculating the anti-surge control line based on the current flow rate and pressure conditions, the system adapts to varying operating conditions, thereby maintaining reliable surge prevention across different scenarios without complicating the control logic.
2Device complexity
If a fixed surge control line is used, then the control system is simple, but it cannot adapt to varying operation points and may allow surges during transient conditions
Solution Approach 1:
The control system becomes dynamic by continuously adjusting the anti-surge control line position based on real-time operation point data. This allows the system to adapt to varying operating conditions including transients, while maintaining a relatively simple control structure that builds upon existing surge control concepts.
Solution Approach 2:
The system implements feedback by continuously monitoring the operation point (flow rate and pressure) and using this information to adjust the anti-surge control line position. This feedback mechanism enables adaptation to operation point variations without requiring a complex control system, as it builds on the existing surge control framework.
3Reliability
If the surge margin is kept large to ensure safety, then surge prevention is reliable, but the compressor operating range and efficiency are reduced
Solution Approach 1:
The patent changes the surge margin parameter from a fixed large value to a variable that adapts to the current operation point. By calculating the anti-surge control line based on real-time conditions, the system maintains adequate surge margins when needed while allowing the compressor to operate closer to the surge line during stable conditions, thereby expanding the operating range and improving efficiency without compromising reliability.
Data Source
AI summary
Provided is a compressor system including: a guide vane; a compressor compressing a fluid flowing from the guide vane; a drive unit connected to the compressor and driving the compressor; a guide flow path connecting the compressor and an external device; a branch flow path branching off from the guide flow path; a flow control valve opening and closing the branch flow path; a sensor unit measuring a current of the drive unit and a pressure of the guide flow path; and a control unit controlling at least one of the guide vane, the drive unit, and the flow control valve, calculating an operation point of the compressor, comparing the operation point of the compressor with a greater one of a first anti-surge control line and a second anti-surge control line and controlling the flow control valve according to the comparison.