Turbocompressor Surge Control via Speed Reduction and Non-Return Valve
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Solution Overview
Problem
Existing turbocompressor control methods face instability and energy loss issues during low flow rates, leading to surge conditions that can damage the machine and result in significant mechanical forces and energy wastage.
Innovation Solution
A method involving a non-return valve and sudden reduction of turbocompressor rotational speed to minimum, with simultaneous diversion of compressed gas to prevent backflow, allowing for efficient operation with reduced power consumption and minimal energy loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the flow rate is reduced below the minimum value defined by the surge control curve, then the energy consumption is reduced, but the compressor becomes unstable and suffers from surge
Solution Approach 1:
The patent applies periodic action by alternately opening and closing the exhaust valve in controlled cycles. When the flow rate drops below the surge control curve, the exhaust valve is periodically opened to blow off compressed gas, creating a cyclic operation that maintains average flow rate below the minimum while preventing continuous surge conditions. This periodic intervention allows the compressor to operate in a controlled manner that reduces energy consumption without compromising stability.
Solution Approach 2:
The patent changes the operational parameters by dynamically adjusting the exhaust valve opening/closing timing and duration based on the actual flow rate and pressure conditions. This parameter adjustment allows the system to maintain stable operation at reduced flow rates by adapting the surge prevention strategy to real-time operating conditions, enabling energy-efficient operation below the traditional minimum flow rate threshold.
2Stability of the object's composition
If an exhaust valve is opened to blow off compressed gas and prevent surge, then compressor stability is maintained, but energy is lost due to discharge of compressed gas
Solution Approach 1:
The patent applies partial action by opening the exhaust valve only when absolutely necessary to prevent surge, rather than keeping it continuously open. The valve is opened in controlled, intermittent cycles only when the flow rate drops below the surge control curve, allowing the system to maintain stability while minimizing the amount of compressed gas discharged and thus reducing energy loss compared to continuous discharge methods.
Solution Approach 2:
The patent recovers energy by closing the exhaust valve after the necessary surge prevention action is completed, allowing the compressor to supply flow rate to the process again. This cyclical opening and closing of the exhaust valve minimizes the duration of gas discharge, thereby reducing energy loss while still maintaining compressor stability during low flow rate conditions.
3Stability of the object's composition
If the compressor operates at design rotational speed to maintain flow rate, then surge is prevented, but power consumption is high
Solution Approach 1:
The patent applies dynamics by allowing the compressor to operate at variable rotational speeds rather than fixed design speed. The control system dynamically adjusts the rotational speed based on the required flow rate and surge control requirements, enabling the compressor to run at lower speeds when possible to reduce power consumption while maintaining surge prevention through coordinated exhaust valve control.
Solution Approach 2:
The patent changes the operational parameters by dynamically adjusting both the rotational speed and exhaust valve positioning based on real-time flow rate and pressure conditions. This parameter optimization allows the compressor to operate at reduced power consumption levels while maintaining surge prevention through coordinated control of speed and valve timing.
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 enables stable operation at low flow rates with reduced mechanical load and energy consumption, minimizing damage risks and energy losses, while maintaining readiness for quick return to normal operation.
Implementation Method 1
a non-return valve (6) which is closed when the rotational speed is very suddenly reduced
Implementation Method 2
The gas is hereby compressed thanks to the balance of the centrifugal forces and the transformation of kinetic energy into pressure
Data Source
Figure 1~2
AI summary
Method for controlling a turbocompressor, whereby a compressed air line (5) is connected to this turbocompressor (1) with a non-return valve (6) provided therein, characterised in that, when one or several process parameters exceed a predetermined limit, the rotational speed of the turbocompressor (1) will be reduced very suddenly to a predetermined minimum rotational speed and the above-mentioned non-return valve (6) will be closed and in that, after the above-mentioned reduction of the rotational speed, when one or several gear-down conditions are fulfilled, the rotational speed of the compressor (1) will be increased again and the non-return valve (6) will be opened.