Process and device for monitoring and for controlling of a compressor
First Claim
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1. Process for controlling an axial compressor, said axial compressor comprising:
- a rotor,a housing,an inlet where, in operation, gas enters at a first pressure, andan outlet where, in operation, gas exits at a second pressure higher than said first pressure,said rotor being rotatably mounted within said housing for rotation about a rotational axis,said axial compressor further comprising at least one axial compressor stage, each said axial compressor stage comprising;
a row of rotor blades mounted on said rotor and being arranged one following the other in a circumferential direction with respect to said rotational axis, anda row of stator blades mounted on said housing and being arranged one following the other in a circumferential direction with respect to said rotational axis,each said axial compressor stage having, in operation, a turbulent fluid layer surrounding each said rotor in the region of said housing,each said axial compressor stage further having, in operation, a characteristic frequency defined as the product of the number of rotor blades mounted in said row of rotor blades and the rotational speed of said rotor,each said characteristic frequency having an associated frequency interval contiguous above and below said characteristic frequency,said process comprising the following steps;
controlling said axial compressor to a first load level and known rotational speed such that the first load level is sufficiently low in value to avoid the risk of surge and stall conditions in said axial compressor;
measuring the pressure fluctuations of at least one said turbulent fluid layer with a pressure sensing means responsive at the characteristic frequency for the known rotational speed and generating thereby at least one sensor signal;
deriving a plurality of frequency components within the frequency interval from each sensor signal, wherein one of the plurality of frequency components is derived at a frequency essentially equivalent to said characteristic frequency;
smoothing said plurality of frequency components into a frequency signal;
respective to the above steps, incrementally increasing the load on said axial compressor at said known rotational speed and performing the steps of measuringeach resultant sensor signal, deriving respective resultant frequency components, and smoothing said respective resultant frequency components into a respective resultant frequency signal at each resulting load increment until at least one first characteristic peak is defined in a respective resultant frequency signal, said first characteristic peak having a frequency range proximate to said frequency interval and a mean frequency essentially equal to said characteristic frequency, and each said first characteristic peak further having at least one first peak parameter respective to those portions of the respective resultant frequency signal which are not a part of any said first characteristic peak;
retaining the value of said first peak parameter;
respective to the above steps, further incrementally increasing the load on said axial compressor at said known rotational speed and performing the steps of measuring at least one resultant sensor signal, deriving respective resultant frequency components, and smoothing said respective resultant frequency components into a respective resultant frequency signal at the resulting load increment to define at least one second characteristic peak, said second characteristic peak having a frequency range proximate to said frequency interval and a mean frequency essentially equal to said characteristic frequency, and each said second characteristic peak further having at least one second peak parameter respective to that portion of the frequency signal which is not a part of any said second characteristic peak;
comparing the value of said second peak parameter with the value of said first peak parameter;
incrementally modifying the load on said axial compressor at said known rotational speed to a higher level if the value of said second peak parameter is greater than or equal to the value of said first peak parameter, and to a lower level if the value of said second peak parameter is less than the value of said first peak parameter, andrespective to the above steps, perpetually repeating the steps of measuring a subsequent sensor signal, deriving respective subsequent frequency components, smoothing said respective subsequent frequency components into a subsequent frequency signal, comparing a subsequent peak parameter value with its respective prior peak parameter value, retaining each peak parameter value as the prior peak parameter value for the subsequent comparing step, and incrementally modifying the load on said axial compressor on a periodic basis to, in each case, increase the load on said axial compressor at said known rotational speed to a higher level if the value of a peak parameter is greater than or equal to the value of its respective prior peak parameter, and decrease the load on said axial compressor to a lower level if the value of a peak parameter is less than the value of its respective prior peak parameter.
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Abstract
A process and a computer implemented system for controlling an axial compressor through measurement of pressure fluctuations of the turbulent fluid layer in the region of the compressor housing in at least one stage of the compressor by means of at least one pressure sensing device sensitive to differential pressure fluctuations affecting the blades at the characteristic frequency of the stage. The process and computer implemented system use a characteristic peak which emerges under load in a smoothed frequency signal derived from a transform of the pressure measurement to achieve optimal efficiency while, at the same time, avoiding destructive surge and stall conditions in the compressor.
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Citations
36 Claims
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1. Process for controlling an axial compressor, said axial compressor comprising:
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a rotor, a housing, an inlet where, in operation, gas enters at a first pressure, and an outlet where, in operation, gas exits at a second pressure higher than said first pressure, said rotor being rotatably mounted within said housing for rotation about a rotational axis, said axial compressor further comprising at least one axial compressor stage, each said axial compressor stage comprising; a row of rotor blades mounted on said rotor and being arranged one following the other in a circumferential direction with respect to said rotational axis, and a row of stator blades mounted on said housing and being arranged one following the other in a circumferential direction with respect to said rotational axis, each said axial compressor stage having, in operation, a turbulent fluid layer surrounding each said rotor in the region of said housing, each said axial compressor stage further having, in operation, a characteristic frequency defined as the product of the number of rotor blades mounted in said row of rotor blades and the rotational speed of said rotor, each said characteristic frequency having an associated frequency interval contiguous above and below said characteristic frequency, said process comprising the following steps; controlling said axial compressor to a first load level and known rotational speed such that the first load level is sufficiently low in value to avoid the risk of surge and stall conditions in said axial compressor; measuring the pressure fluctuations of at least one said turbulent fluid layer with a pressure sensing means responsive at the characteristic frequency for the known rotational speed and generating thereby at least one sensor signal; deriving a plurality of frequency components within the frequency interval from each sensor signal, wherein one of the plurality of frequency components is derived at a frequency essentially equivalent to said characteristic frequency; smoothing said plurality of frequency components into a frequency signal; respective to the above steps, incrementally increasing the load on said axial compressor at said known rotational speed and performing the steps of measuring each resultant sensor signal, deriving respective resultant frequency components, and smoothing said respective resultant frequency components into a respective resultant frequency signal at each resulting load increment until at least one first characteristic peak is defined in a respective resultant frequency signal, said first characteristic peak having a frequency range proximate to said frequency interval and a mean frequency essentially equal to said characteristic frequency, and each said first characteristic peak further having at least one first peak parameter respective to those portions of the respective resultant frequency signal which are not a part of any said first characteristic peak; retaining the value of said first peak parameter;
respective to the above steps, further incrementally increasing the load on said axial compressor at said known rotational speed and performing the steps of measuring at least one resultant sensor signal, deriving respective resultant frequency components, and smoothing said respective resultant frequency components into a respective resultant frequency signal at the resulting load increment to define at least one second characteristic peak, said second characteristic peak having a frequency range proximate to said frequency interval and a mean frequency essentially equal to said characteristic frequency, and each said second characteristic peak further having at least one second peak parameter respective to that portion of the frequency signal which is not a part of any said second characteristic peak;comparing the value of said second peak parameter with the value of said first peak parameter;
incrementally modifying the load on said axial compressor at said known rotational speed to a higher level if the value of said second peak parameter is greater than or equal to the value of said first peak parameter, and to a lower level if the value of said second peak parameter is less than the value of said first peak parameter, andrespective to the above steps, perpetually repeating the steps of measuring a subsequent sensor signal, deriving respective subsequent frequency components, smoothing said respective subsequent frequency components into a subsequent frequency signal, comparing a subsequent peak parameter value with its respective prior peak parameter value, retaining each peak parameter value as the prior peak parameter value for the subsequent comparing step, and incrementally modifying the load on said axial compressor on a periodic basis to, in each case, increase the load on said axial compressor at said known rotational speed to a higher level if the value of a peak parameter is greater than or equal to the value of its respective prior peak parameter, and decrease the load on said axial compressor to a lower level if the value of a peak parameter is less than the value of its respective prior peak parameter. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
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21. Process for controlling an axial compressor, said axial compressor comprising:
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a rotor, a housing, an inlet where, in operation, gas enters at a first pressure, and an outlet where, in operation, gas exits at a second pressure higher than said first pressure, said rotor being rotatably mounted within said housing for rotation about a rotational axis, said axial compressor further comprising at least one axial compressor stage, each said axial compressor stage comprising; a row of rotor blades mounted on said rotor and being arranged one following the other in a circumferential direction with respect to said rotational axis, and a row of stator blades mounted on said housing and being arranged one following the other in a circumferential direction with respect to said rotational axis, each said axial compressor stage having, in operation, a turbulent fluid layer surrounding each said rotor in the region of said housing, each said axial compressor stage further having, in operation, a characteristic frequency defined as the product of the number of rotor blades mounted in said row of rotor blades and the rotational speed of said rotor, each said characteristic frequency having an associated frequency interval contiguous above and below said characteristic frequency, said axial compressor further having an associated stability control target value, said process comprising the following steps; selecting a control set of a plurality of axial compressor stages; identifying a sensor signal control parameter respective to both said control set and said stability control target value; controlling said axial compressor to a first load level and known rotational speed such that the first load level is sufficiently low in value to avoid the risk of surge and stall conditions in said axial compressor; measuring the pressure fluctuations of each said turbulent fluid layer respective to the control set with a pressure sensing means responsive at the characteristic frequency for the known rotational speed and generating thereby a sensor signal respective to each turbulent fluid layer; deriving a plurality of frequency components within the frequency interval from each sensor signal in the control set, wherein one of the plurality of frequency components is derived at a frequency essentially equivalent to the characteristic frequency; smoothing each said plurality of frequency components into a respective frequency signal; respective to the above steps, incrementally increasing the load on said axial compressor at said known rotational speed and performing the steps of measuring each resultant sensor signal, deriving respective resultant frequency components, and smoothing said respective resultant frequency components into a respective resultant frequency signal at each resulting load increment until at least one first characteristic peak is defined in at least one respective resultant frequency signal, said first characteristic peak having a frequency range proximate to said frequency interval and a mean frequency essentially equal to said characteristic frequency, and said first characteristic peak further having at least one first peak parameter respective to those portions of the respective resultant frequency signal which are not a part of said first characteristic peak; combining each first peak parameter value from each defined characteristic peak into a characteristic peak stability measurement respective to said sensor signal control parameter; using the value of said characteristic peak stability measurement to define an increment of load change at said known rotational speed such that the difference between said characteristic peak stability measurement and said stability control target value will diminish; using the increment of load change value to diminish the difference between said characteristic peak stability measurement and said stability control target value; and respective to the above steps, perpetually repeating the steps of measuring a plurality of subsequent sensor signals, deriving respective subsequent frequency components, smoothing said respective subsequent frequency components into subsequent frequency signals, combining each respective subsequently derived peak parameter value from each respective subsequent characteristic peak into a subsequent characteristic peak stability measurement, and using the value of said subsequent characteristic peak stability measurement to control said axial compressor at said known rotational speed to achieve said stability control target value. - View Dependent Claims (22, 23, 24)
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25. Computer implemented system for controlling an axial compressor, said axial compressor comprising:
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a rotor, a housing, an inlet where, in operation, gas enters at a first pressure, and an outlet where, in operation, gas exits at a second pressure higher than said first pressure, said rotor being rotatably mounted within said housing for rotation about a rotational axis, said axial compressor further comprising at least one axial compressor stage, each said axial compressor stage comprising; a row of rotor blades mounted on said rotor and being arranged one following the other in a circumferential direction with respect to said rotational axis, and a row of stator blades mounted on said housing and being arranged one following the other in a circumferential direction with respect to said rotational axis, each said axial compressor stage having, in operation, a turbulent fluid layer surrounding each said rotor in the region of said housing, each said axial compressor stage further having, in operation, a characteristic frequency defined as the product of the number of rotor blades mounted in said row of rotor blades and the rotational speed of said rotor, each said characteristic frequency having an associated frequency interval contiguous above and below said characteristic frequency, said computer implemented system comprising; a compressor control unit for controlling said axial compressor to a first load level and known rotational speed such that the first load level is sufficiently low in value to avoid the risk of surge and stall conditions in said axial compressor and for subsequently increasing, decreasing, and modifying the load on said axial compressor; pressure sensing means responsive at said characteristic frequency for measuring the pressure fluctuations of at least one said turbulent fluid layer and generating thereby at least one sensor signal; and an evaluation unit for; deriving a plurality of frequency components within the frequency interval from each sensor signal, wherein one of the plurality of frequency components is derived at a frequency essentially equivalent to said characteristic frequency, smoothing said plurality of frequency components into a frequency signal, prompting said compressor control unit to incrementally increase the load on said axial compressor at said known rotational speed, deriving respective resultant frequency components from each resultant sensor signal, and smoothing said respective resultant frequency components into a respective resultant frequency signal at each resulting load increment respective to the above operations until at least one first characteristic peak is defined in a respective resultant frequency signal, said first characteristic peak having a frequency range proximate to said frequency interval and a mean frequency essentially equal to said characteristic frequency, and each said first characteristic peak further having at least one first peak parameter respective to those portions of the respective resultant frequency signal which are not a part of said first characteristic peak, retaining the value of said first peak parameter, further prompting said compressor control unit to incrementally increase the load on said axial compressor at said known rotational speed, deriving the respective resultant frequency components from each resultant sensor signal, and smoothing said respective resultant frequency components into a respective resultant frequency signal respective to the above operations to define at least one second characteristic peak, said second characteristic peak having a frequency range proximate to said frequency interval and a mean frequency essentially equal to said characteristic frequency, and each said second characteristic peak further having at least one second peak parameter respective to that portion of the frequency signal which is not a part of any said second characteristic peak, comparing the value of said second peak parameter with the value of said first peak parameter, further prompting said compressor control unit to incrementally modify the load on said axial compressor at said known rotational speed to a higher level if the value of said second peak parameter is greater than or equal to the value of said first peak parameter, and to a lower level if the value of said second peak parameter is less than the value of said first peak parameter, and respective to the above operations, perpetually repetitively deriving respective subsequent frequency components from each subsequent sensor signal, smoothing said respective subsequent frequency components into a subsequent frequency signal, retaining a peak parameter value so that a prior peak parameter value is available for the subsequent comparison step, comparing a subsequent peak parameter value with its respective prior peak parameter value, and prompting said compressor control unit to incrementally modify the load on said axial compressor on a periodic basis to, in each case, increase the load on said axial compressor at said known rotational speed to a higher level if the value of a peak parameter is greater than or equal to the value of its respective prior peak parameter, and decrease the load on said axial compressor to a lower level if the value of a peak parameter is less than the value of its respective prior peak parameter. - View Dependent Claims (26, 27, 28, 29, 30)
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31. Computer implemented system for controlling an axial compressor, said axial compressor comprising:
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a rotor, a housing, an inlet where, in operation, gas enters at a first pressure, and an outlet where, in operation, gas exits at a second pressure higher than said first pressure, said rotor being rotatably mounted within said housing for rotation about a rotational axis, said axial compressor further comprising at least one axial compressor stage, each said axial compressor stage comprising; a row of rotor blades mounted on said rotor and being arranged one following the other in a circumferential direction with respect to said rotational axial, and a row of stator blades mounted on said housing and being arranged one following the other in a circumferential direction with respect to said rotational axis, each said axial compressor stage having, in operation, a turbulent fluid layer surrounding each said rotor in the region of said housing, each said axial compressor stage further having, in operation, a characteristic frequency defined as the product of the number of rotor blades mounted in said row of rotor blades and the rotational speed of said rotor, each said characteristic frequency having an associated frequency interval contiguous above and below said characteristic frequency, said axial compressor further having a stability control target value, said computer implemented system comprising; a compressor control unit for controlling said axial compressor to a first load level and known rotational speed such that the first load level is sufficiently low in value to avoid the risk of surge and stall conditions in said axial compressor and for subsequently increasing, decreasing, and modifying the load on said axial compressor; pressure sensing means responsive at said characteristic frequency for measuring the pressure fluctuations of each said turbulent fluid layer respective to a preselected control set of a plurality of axial compressor stages and generating thereby a sensor signal respective to each turbulent fluid layer; and an evaluation unit for; deriving a plurality of frequency components within the frequency interval from each sensor signal in the control set, wherein one of the frequency components is derived at a frequency essentially equivalent to the characteristic frequency, smoothing each said plurality of frequency components into a respective frequency signal, prompting said compressor control unit to incrementally increase the load on said axial compressor at said known rotational speed, deriving respective resultant frequency components from each resultant sensor signal, and smoothing said respective resultant frequency components into a respective resultant fequency signal at each resulting load increment respective to the above operations until a first characteristic peak is defined in at least one frequency signal, said first characteristic peak having a frequency range proximate to said frequency interval and a mean frequency essentially equal to said characteristic frequency, and said first characteristic peak further having at least one first peak parameter respective to those portions of the respective resultant frequency signal which are not a part of said first characteristic peak, combining each first peak parameter value from each defined characteristic peak into a characteristic peak stability measurement respective to a preidentified sensor signal control parameter respective to both said control set and said stability control target value, using the value of said characteristic peak stability measurement to define an increment of load change at said known rotational speed such that the difference between said characteristic peak stability measurement and said stability control target value will diminish, prompting said compressor control unit to use the increment of load change value to diminish the difference between said characteristic peak stability measurement and said stability control target value, and respective to the above operations, perpetually repetitively deriving respective subsequent frequency components from each of the plurality of subsequent sensor signals, smoothing said respective subsequent frequency components into a subsequent frequency signals, combining each respective subsequently derived peak parameter value from each respective subsequent characteristic peak into a subsequent characteristic peak stability measurements, and prompting said compressor control unit to use the value of said subsequent characteristic peak stability measurement to control said axial compressor at said known rotational speed to achieve said stability control target value. - View Dependent Claims (32, 33, 34, 35, 36)
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Specification
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Current AssigneeDow Deutschland Inc (Dow, Inc.)
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Original AssigneeDow Deutschland Inc (Dow, Inc.)
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InventorsGallus, Heinz E., Honen, Herwart, Walter, Hilger A.
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Primary Examiner(s)Voeltz, Emanuel T.
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Assistant Examiner(s)Stamber, Eric W.
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Application NumberUS08/246,906Time in Patent Office970 DaysField of Search364/558, 364/431.02, 364/505, 364/508, 364/494, 73/116, 73/660, 417/20, 417/43, 415/26, 60/39.29US Class Current700/301CPC Class CodesF04D 27/001 Testing thereof; Determinat...
