Recycle Valve Control for Compressor Surge During Voltage Dips
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Solution Overview
Problem
Centrifugal gas compressors are prone to instability and surge due to changes in operating conditions, such as flow rate or pressure, leading to mechanical damage, vibrations, and overheating, and existing surge control systems, particularly those using pneumatic actuators, are slow to respond to voltage dips, causing unnecessary compressor trips and production losses.
Innovation Solution
A gas compression system utilizing an electric motor drive actuator for the recycle valve, which enables fast and accurate valve positioning, and a control unit that monitors input voltage to quickly respond to voltage dips by opening or closing the valve, thereby preventing surge and reducing compressor trips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If pneumatic actuators are used for surge control, then the system is simple and reliable, but the response speed to voltage dips is slow causing unnecessary compressor trips
Solution Approach 1:
The patent replaces pneumatic actuators with an electric motor drive system for actuating the recycle valve. This substitution enables faster and more precise control response to voltage dips and surge conditions, eliminating the inherent delays of pneumatic systems while maintaining reliability through electronic control.
2Reliability
If the recycle valve opens quickly to prevent surge, then compressor protection is improved, but mechanical damage from rapid valve action may increase
Solution Approach 1:
The patent employs dynamic control of the recycle valve through electric motor actuation, allowing the valve to open and close smoothly under controlled conditions. The system adjusts valve position dynamically based on real-time compressor operating parameters, preventing surge while minimizing mechanical shock and stress on valve components.
Solution Approach 2:
The control system continuously monitors compressor operating parameters such as flow rate, pressure, and power consumption, and uses this feedback to modulate the recycle valve position. This closed-loop control ensures the valve responds appropriately to surge conditions while avoiding excessive mechanical stress through precise, adaptive positioning.
3Productivity
If the compressor operates close to the surge limit to maximize productivity, then gas compression output is improved, but the risk of surge and mechanical damage increases
Solution Approach 1:
The patent implements preliminary surge prevention by continuously monitoring compressor operating parameters and activating the recycle valve before actual surge conditions occur. The control system detects approaching surge limits through power consumption patterns and flow rate changes, opening the recycle valve proactively to maintain stable operation while maximizing productivity.
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 solution provides rapid and precise control of the recycle valve, effectively preventing compressor surge during voltage dips, reducing unnecessary trips, and maintaining stable operation, thus minimizing mechanical damage and production losses.
Implementation Method 1
an electric motor driving the compressor, a compressor motor drive unit producing current to said motor
Data Source
Figure 1~3
Figure 4~6
Figure 7a~8
AI summary
A gas compression system comprising a compressor (1) for compressing a gas fed to the compressor, an electric motor (4) driving the compressor, a compressor motor drive unit (5) producing current to said motor, a pipe (20) for feeding back gas from the outlet of the compressor to the inlet of the compressor, a recycle valve (22) controlling the gas flow in the pipe, an actuator (25) for actuating the recycle valve, and a control unit (24) generating a control signal to said actuator for controlling the opening and closing of the recycle valve. The actuator comprises an electric motor (26) controlling the opening and closing of the recycle valve. The gas compression system further comprises measuring equipment (32) for measuring the input voltage to the compressor motor drive unit, and the control unit is adapted to determine whether there is a risk of surge of the compressor based on the measured input voltage to the compressor motor drive unit, and to generate a control signal for opening the recycle valve if it is determined that there is a risk of surge of the compressor.