Multistage Compressor Surge Protection Using Dynamic Valve Control
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Solution Overview
Problem
Existing coolant systems face efficiency losses due to surge conditions caused by back pressure from gaseous coolant injection, which existing bypass flowpath solutions fail to address effectively.
Innovation Solution
A multistage compressor system with surge detection sensors and a controllable valve connected to a controller that restricts gaseous coolant flow to later stages during surge conditions and opens it once the surge ceases, using a feedback loop to maintain optimal operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If gaseous coolant is injected into later stages of the compressor, then cooling efficiency is improved, but back pressure increases causing surge conditions
Solution Approach 1:
The patent applies dynamics by making the valve opening degree variable rather than fixed. The controller dynamically adjusts the opening degree of the valve connecting the economizer to later stages based on real-time surge detection sensor feedback, allowing the system to adapt to changing operating conditions and prevent surge while maintaining cooling efficiency.
Solution Approach 2:
The patent implements feedback control by using surge detection sensors to monitor compressor operation and automatically adjusting the valve opening degree in response to detected surge conditions. This closed-loop control system continuously monitors and adjusts the gaseous coolant injection to prevent surge while maintaining optimal cooling performance.
2Reliability
If a bypass flowpath is used to route gaseous coolant to the first stage inlet during surge, then surge is prevented, but system efficiency is reduced
Solution Approach 1:
The patent applies dynamics by dynamically adjusting the valve opening degree to the minimum necessary to prevent surge, rather than fully opening a bypass valve. This partial modulation approach prevents surge conditions while minimizing the diversion of gaseous coolant, thereby reducing efficiency losses compared to traditional bypass methods.
Solution Approach 2:
The patent changes the parameter of valve opening degree from a binary state (open/closed) to a continuous variable that can be precisely controlled. By adjusting this parameter to the minimum level needed for surge prevention, the system maintains higher efficiency while still preventing surge, avoiding the energy losses associated with full bypass valve opening.
3Productivity
If valve opening degree is increased to allow more gaseous coolant flow, then cooling performance is improved, but surge risk increases
Solution Approach 1:
The patent uses feedback control where surge detection sensors continuously monitor compressor operation and automatically adjust the valve opening degree. This real-time feedback allows the system to maximize gaseous coolant flow for cooling performance while automatically reducing flow when surge conditions are detected, preventing surge risk.
Solution Approach 2:
The patent applies preliminary action by proactively adjusting the valve opening degree in response to detected surge conditions before surge fully develops. The controller anticipates potential surge problems and reduces gaseous coolant injection accordingly, preventing the harmful effects of surge while maintaining optimal cooling performance.
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
Prevents surge conditions while minimizing efficiency losses by dynamically controlling gaseous coolant flow, ensuring stable operation and maintaining high system performance.
Implementation Method 1
a plurality of surge detection sensors
Implementation Method 2
restricting a flow through the controllable valve
Data Source
AI summary
A coolant system includes a multistage compressor having a plurality of surge detection sensors. A condenser is connected to an outlet of the multistage compressor. An economizer is connected to an outlet of the condenser and has a gaseous coolant outlet and a liquid coolant outlet. The liquid coolant outlet is connected to a cooler and the gaseous coolant outlet is connected to a second or later stage of the multistage compressor via a controllable valve. A controller is communicatively coupled to the surge detection sensors and the controllable valve. The controller includes a non-transitory medium storing instructions for causing the controller to detect an occurrence of a surge and restricting a flow through the controllable valve until the surge has ceased.