Dynamic Compressor Surge Detection Using Electrical Signals
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Solution Overview
Problem
Existing compressor surge detection and monitoring methods for electrically-driven compressors are limited by the need for intrusive and expensive sensors, lack of generality, and complexity, particularly in variable speed operations, and do not effectively utilize electrical signals for accurate surge margin estimation and precursor detection.
Innovation Solution
A new compressor map representation based on electrical signals, using pseudo-dimensional parameters derived from the electrical machine, allows for surge margin estimation and precursor detection without requiring mass flow meters or vibro-acoustic sensors, utilizing fast variable speed drivers to accurately measure torque and rotational speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mass flow meters and vibro-acoustic sensors are used for surge detection, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces mechanical and acoustic sensing systems with electrical signal analysis. Instead of using mass flow meters and vibro-acoustic sensors, the invention extracts surge information from electrical signals (current, voltage, power) already present in the compressor drive system, substituting physical measurement hardware with electrical signal processing
Solution Approach 2:
The compressor drive system's electrical signals serve dual purposes: both controlling the compressor operation and providing surge detection information. The existing electrical signals are analyzed to extract surge margin and precursor data, eliminating the need for separate dedicated sensors
2Measurement precision
If intrusive sensors are installed to monitor compressor performance, then measurement precision is improved, but reliability decreases due to additional failure points
Solution Approach 1:
The invention replaces physical intrusive sensors with electrical signal analysis of the drive system. By using electrical signals (current, voltage, power) that are already part of the control system, the solution avoids adding mechanical sensors that could fail or be damaged
Solution Approach 2:
The patent uses electrical signals as an intermediary carrier of compressor state information. Instead of directly measuring physical parameters with sensors, the electrical signals serve as a mediator that encodes surge margin and precursor information, providing a non-contact measurement approach
3Adaptability or versatility
If general compressor maps are used for surge margin estimation, then adaptability is improved, but measurement precision deteriorates due to pseudo-dimensional parameters
Solution Approach 1:
The patent transforms the parameters used in compressor maps from traditional mechanical/fluid parameters to electrical parameters. By expressing compressor state in terms of electrical signals (current, voltage, power, frequency), the invention maintains generality across different compressor types while improving measurement precision through direct electrical measurement
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
Provides accurate and reliable surge margin estimation and detection with reduced complexity and cost, enhancing system robustness and redundancy by using electrical signals as sensors, applicable to compressors with or without Inlet Guide Vanes, and avoiding the need for additional sensors.
Implementation Method 1
compressors mechanically connected to electrical machines, preferably dynamic compressors of radial or axial type
Data Source
AI summary
In one embodiment, a method and a system for determining the operating state of a dynamic compressor that is mechanically connected to an electrical machine and that is equipped with a rotor that exchanges energy with a known fluid by rotating at a speed and with a driving mechanical torque, and in particular for determining the operating point of the dynamic compressor and the distance of the operating point from a surge limit curve, which delimits a stable operation zone from an unstable operation zone of the dynamic compressor.