Pitot Tube Valve Assembly for Early Compressor Surge Detection
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Solution Overview
Problem
Existing surge detection systems in fluid flow circuits are unreliable and often delayed, failing to detect surges promptly, which can lead to compressor unloading and component damage due to pressure waves and vibrations, and may induce artificial oscillations that degrade measurement accuracy.
Innovation Solution
A surge control system comprising a valve assembly with a pitot tube and pressure sensor integrated into a fluid conduit downstream of compressors, connected to a controller that analyzes pressure measurements over time to detect oscillations indicative of surge conditions, allowing for early and accurate identification and responsive action to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing pressure oscillation monitoring systems are used, then surge detection is provided, but the detection is delayed and reliability is reduced due to artificial oscillations induced by curved tubes
Solution Approach 1:
The patent extracts the problematic curved tube element from the detection system and replaces it with a straight tube Pitot static tube. This removal eliminates the source of artificial oscillations that degraded measurement accuracy and caused delayed surge detection, while preserving the essential function of pressure monitoring for surge detection.
Solution Approach 2:
The patent introduces a Pitot static tube as an intermediary measurement element that directly samples flow conditions without inducing artificial oscillations. This intermediary device provides accurate pressure and velocity data to the detection system, enabling reliable and timely surge detection without the harmful effects of curved tube designs.
2Measurement precision
If curved tube pressure monitoring systems are used, then pressure measurements are obtained, but measurement accuracy is degraded due to induced artificial oscillations
Solution Approach 1:
The patent removes the curved tube configuration that generates artificial oscillations and replaces it with a straight tube Pitot static tube design. This extraction eliminates the harmful oscillatory artifacts while maintaining the capability to measure pressure and infer flow velocity, thereby improving measurement accuracy.
Solution Approach 2:
The patent changes the geometric parameter of the pressure tube from curved to straight configuration. This parameter change fundamentally alters the flow interaction characteristics, eliminating the generation of artificial oscillations while preserving the measurement function, thus improving pressure measurement accuracy.
3Reliability
If traditional surge detection systems are used, then surge conditions are detected, but component damage may occur before detection due to delayed response
Solution Approach 1:
The patent implements preliminary detection of surge conditions by using a Pitot static tube that accurately measures pressure and flow velocity before surge fully develops. This preliminary action enables the control system to detect early signs of surge and take corrective action before pressure waves cause component damage, improving overall system reliability.
Solution Approach 2:
The patent establishes a feedback loop where the Pitot static tube continuously monitors pressure and flow conditions, and this information is fed back to the control system for real-time surge detection. This feedback mechanism enables timely detection and response to surge conditions, preventing component damage before it occurs.
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
The system enables quick and reliable detection of surge conditions, reducing the likelihood of component damage, extending operational lifetimes, and allowing for scheduled maintenance to prevent unscheduled downtime by accurately identifying surge modes and compressor issues.
Implementation Method 1
The valve assembly includes a valve body, a pitot tube integrated onto the valve body, and a pressure sensor device operably connected to the pitot tube
Data Source
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AI summary
A surge control system and method include a valve assembly located along a fluid conduit downstream of one or more compressors in a flow circuit, and configured to receive a fluid stream from the one or more compressors. The valve assembly includes a valve body, a pitot tube integrated onto the valve body, and a pressure sensor device operably connected to the pitot tube. A controller of the surge control system receives pressure measurements generated by the pressure sensor device. The pressure measurements represent pressure in the pitot tube over time. The controller analyzes at least one of (i) the pressure measurements or (ii) flow velocity values derived from the pressure measurements, and detects a surge condition in the flow circuit based on oscillations in the at least one of the pressure measurements or the flow velocity values.