Compressor Surge Detection Using Vibration Sensors
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Solution Overview
Problem
Existing methods for preventing compressor surges in turbomachines fail to reliably account for aging or damage, leading to potential mechanical damage and shutdowns, especially as the turbomachine's mileage increases, and existing sensors have limited service life at high temperatures.
Innovation Solution
Monitoring parameters associated with the rotational sound of the compressor, including oscillation amplitude and frequency, using durable vibration sensors like piezoelectric accelerometers attached to the shaft and housing, to predictively detect impending surges and trigger counteractive measures such as reducing turbine outlet temperature and fuel flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If pressure sensors and microphones are used to detect surge conditions, then surge detection capability is improved, but sensor service life is reduced due to limited durability at high ambient temperatures
Solution Approach 1:
The patent replaces acoustic sensors (microphones) and pressure sensors with vibration sensors that detect mechanical vibrations from rotating stall. This substitution uses mechanical vibration detection instead of acoustic or pressure measurement, enabling sensors to operate reliably in high-temperature environments where acoustic sensors would fail, thus extending service life while maintaining surge detection capability
Solution Approach 2:
The patent introduces vibration signals as an intermediary parameter to indirectly detect surge conditions. Instead of directly measuring pressure or acoustic signals near the hot compressor inlet, the system measures vibrations on the cooler shaft or housing, which are correlated with rotating stall but exposed to more favorable thermal conditions, thereby extending sensor life
2Strength
If compressor surge prevention methods are used, then mechanical damage from surge is prevented, but reliability deteriorates as turbomachine mileage increases due to aging and contamination
Solution Approach 1:
The patent implements preliminary detection of rotating stall through vibration monitoring before the compressor reaches dangerous surge conditions. By detecting the characteristic vibrations of developing rotating stall early in its evolution, the system can trigger preventive actions (such as opening inlet guide vanes or reducing fuel flow) before surge occurs, maintaining reliable protection even as the turbomachine ages and contamination accumulates
Solution Approach 2:
The patent establishes a feedback loop where vibration sensors continuously monitor compressor operation, compare measured vibrations against surge prediction models, and automatically adjust operating parameters to maintain safe distances from the surge line. This closed-loop control adapts to changing compressor characteristics over time due to aging and contamination, maintaining reliable surge prevention throughout the turbomachine's operational life
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for early detection of surge approaches and rotating stall, preventing mechanical damage and shutdowns by using sensors less sensitive to harsh conditions, thereby extending service life and ensuring reliable operation even at high mileage.
Implementation Method 1
a parameter assigned to the rotational sound of the compressor... oscillation amplitude and frequency... using durable vibration sensors like piezoelectric accelerometers
Implementation Method 2
using durable vibration sensors like piezoelectric accelerometers attached to the shaft and housing
Data Source
AI summary
The invention relates to a method for avoiding pump surges in a compressor (2), wherein a plurality of parameters of the compressor (2) are monitored during operation and a desired value range for the plurality of parameters is predetermined, wherein a reaction (24, 26, 28) that counteracts the pump surge is triggered if a number of parameters from the desired value range are exceeded or fallen below. According to the invention, the method also reliably prevents pumping of the compressor during a comparatively high running performance. For said purpose, the plurality of parameters comprises a parameter assigned to the rotational noise of the compressor (2).