Surge prevention control system for dynamic compressors

• US 5,798,941 A
• Filed: 02/18/1997
• Issued: 08/25/1998
• Est. Priority Date: 01/02/1996
• Status: Expired due to Term

• Current Assignee: Woodward Governor Company (Woodward Incorporated)
• Original Assignee: Woodward Governor Company (Woodward Incorporated)
• Inventors: McLeister, Larry D.
• Primary Examiner(s): Voeltz, Emanuel Todd
• Assistant Examiner(s): Wachsman, Hal D.
• Application Number:
  US08/802,781
• Time in Patent Office: 553 Days
• Field of Search: 364/510, 364/509, 364/431.02, 364/141, 364/142, 364/152-155, 364/162, 364/551.9, 415/28, 415/27, 415/1, 415/11, 415/17, 415/49, 415/50, 415/26, 415/15, 417/292, 417/300, 417/301, 417/307, 417/309, 417/20, 417/26, 417/28, 417/47, 417/53, 701/100
• US Class Current: 700/282
• CPC Class Codes: F04D 27/0215 Arrangements therefor, e.g. bleed or by-pass valves
• CPC Class Codes: F04D 27/0223 Control schemes therefor
• CPC Class Codes: G05B 11/42 for obtaining a characteristic which is both proportional and time-dependent, e.g. P. I., P. I. D.

Abstract

A surge prevention control system for use with a dynamic compressor provides a multiple module controller for operating an anti-surge valve to bypass flow around the dynamic compressor. The multiple module controller includes a PID control module and a rate control module. The PID control module controls the anti-surge valve to control the operating point of the dynamic compressor about the surge control line. The rate control module uses the rate of approach of the operating point to the surge control line as its process variable. In the event of high rate of approach, the rate control module takes control of the anti-surge valve. The setpoint of the rate control module is adjusted to open the anti-surge valve to control the rate of approach to the surge control line to minimize the overshoot of the PID control.

Claims

1. A control system for avoiding surge in a dynamic compressor, the compressor having a variable operating point definable on a compressor map which includes a stable region, a surge region, a surge line separating the two regions, and a surge control line in the stable region near but displaced from the surge line, the control system comprising in combination:

a selectively responsive anti-surge valve coupled to the compressor for controllably increasing compressor flow;

a multiple module controller for receiving a control variable indicative of the operating point of the compressor and producing a control signal for controlling the anti-surge valve;

the multiple module controller including;

a PID control module responsive to the control variable for producing a first output signal exerting control action on the operating point of the compressor between the surge control line and the surge line;

a closed loop rate control module responsive to a signal indicative of the rate of approach of the operating point to the surge control line for producing a second output signal having a magnitude which exerts control action on the operating point of the compressor to limit the rate of approach; and

,

an output signal selector for selectively coupling the first or second output signal as the control signal to the anti-surge valve.

2. A control system as defined in claim 1 in which the multiple module controller includes a derivative module responsive to the control variable for producing a rate signal indicative of the rate of approach of the operating point to the surge control line, and means coupling the rate signal to the rate control module.

3. A control system as defined in claim 2 wherein the PID control module is a closed loop controller having the control variable as a process input and having a set point corresponding to the surge control line.

4. A control system as defined in claim 3 wherein the rate control module includes a closed loop PID controller having the rate signal as a process input and a set point corresponding to a maximum acceptable rate of approach of the operating point to the surge control line.

5. A control system as defined in claim 4, wherein the rate control module has a supplemental integrator for controllably increasing output with zero rate error, thereby to assist in zeroing a rate error signal between the process input and setpoint.

6. A control system as defined in claim 5, wherein the integrator of the rate control module includes a derivative operator in a feedback path of the closed loop PID controller.

7. A control system as defined in claim 4 in which the output signal selector comprises a high signal selector coupled to the PID control module and the rate control module, and adapted to pass as the control signal to the anti-surge valve, the output signal demanding the largest anti-surge valve opening.

8. A control system as defined in claim 1, wherein the rate control module has a setpoint adjuster for adjusting the setpoint of the rate control module according to the proximity of the control variable to the setpoint of the PID control module.

10. A control system as defined in claim 8, wherein the setpoint adjuster produces a non-zero minimum when the difference between the control variable and the setpoint of the PID module is smaller than a selected value.

11. A control system as defined in claim 1, wherein each of the first and second output signals correspond to a degree of valve opening of the anti-surge valve, and wherein the output signal selector is a high signal selector for selecting the output signal corresponding to the largest valve opening.

12. A control system as defined in claim 1, wherein each of the PID control module and the rate control module have an output tracking line for receiving the control signal from the output signal selector, and a tracking control line indicating which of said modules is in control of the anti-surge valve, whereby the module not in control of the anti-surge valve tracks the control signal.

13. A control system as defined in claim 1, wherein the rate control module has a gain adjuster for adjusting a gain of the rate control module in dependance on process conditions of the dynamic compressor.

9. A control system as defined in 8, wherein the setpoint adjuster reduces the setpoint of the rate control module when a difference between the control variable and the setpoint of the PID control module decreases.

14. A control system for avoiding surge in a dynamic compressor, the compressor having a variable operating point definable on a compressor map which includes a stable region, a surge region, a surge line separating said regions, and a surge control line in the stable region near but displaced from the surge line, the control system comprising, in combination:

an anti-surge valve coupled to the compressor and responsive to an electrical control signal for controllably increasing compressor flow;

a multiple module controller responsive to a control variable indicative of operating point of the compressor for producing said control signal, the multiple module controller including;

a closed loop PID control module responsive to the control variable for exerting control action on the operating point of the compressor when said operating point is between the surge control line and the surge line;

a closed loop rate control module responsive to a signal indicative of the rate of approach of the operating point to the surge control line for exerting control action on the operating point of the compressor anywhere in the compressor map when the rate of approach exceeds a given level, and

selector means for passing control of the anti-surge valve between the PID control module and the rate control module.

15. A control system according to claim 14 wherein the selector means comprises a high signal selector coupled to the PID and rate control modules for outputting, as the control signal, the output of the module which demands the largest anti-surge valve opening.

16. A control system according to claim 14 in which the rate control module is a PID controller having a process input responsive to rate of approach of the operating point to the surge control line, and a setpoint corresponding to a maximum acceptable rate of approach.

17. A control system according to claim 16 including a setpoint adjuster for establishing the setpoint for the rate control module, and altering the maximum acceptable rate of approach in accordance with the distance between the compressor operating point and the surge control line.

18. A control system according to claim 16 in which the PID controller of the rate control module is modified to include an integrator term integrating the rate of approach process input to allow the rate controller to zero a rate error signal determined between the process input and the set point.

19. A method for preventing surge in a dynamic compressor, the dynamic compressor having a variable operating point definable on a compressor map which includes a surge region and a stable region separated by a surge line, and a surge control line in the stable region displaced from the surge line, the method comprising the steps of:

providing an anti-surge valve having an adjustable opening for increasing flow through the dynamic compressor;

sensing process conditions in the dynamic compressor to produce a control variable indicative of the operating point of the dynamic compressor;

operating a first closed loop PID to generate a first output signal for controlling the anti-surge valve to control the operating point about the surge control line;

monitoring a rate of approach of the operating point to the surge control line;

operating a second closed loop PID to generate a second output signal for controlling the anti-surge valve to control the rate of approach;

selecting among the first and second output signals as a control signal; and

adjusting the opening of the anti-surge valve according to the control signal.

20. A method as defined in claim 19, including the step of adjusting a setpoint of the second closed loop PID according to the difference between the control variable and the surge control line.

21. A method as defined in claim 20, wherein the step of adjusting the setpoint reduces the setpoint of the second closed loop PID when the difference between the control variable and the surge control line decreases.

22. A method as defined in claim 19, including the step of adjusting the gain of the second closed loop PID according to process conditions of the dynamic compressor.

23. A method as defined in claim 19, wherein the step of selecting output signal selects the larger of the first and second output signals.

24. A method as defined in claim 19, wherein the step of operating the second closed loop PID includes determining an integral in conjunction with a PID process to achieve zero error.

25. A method as defined in claim 19, in which the step of selecting defines an active PID whose output signal is the control signal and an inactive PID whose output signal is not selected, and further including the step of tracking the non-selected PID to match its output signal to the control signal for transfer between PIDs.

26. A method for preventing surge in a dynamic compressor, the dynamic compressor having a variable operating point definable on a compressor map which includes a surge region and a stable operation region separated by a surge line, and a surge control line in the stable region displaced from the surge line, the method comprising the steps of:

providing an anti-surge valve having an adjustable opening for increasing flow through the dynamic compressor;

sensing process conditions of the dynamic compressor to produce a control variable indicative of the operating point of the dynamic compressor;

performing a closed loop PID control on the anti-surge valve using the control variable as a process variable and the surge control line as a setpoint;

monitoring a rate of approach of the operating point toward the surge control line; and

in the event of high rate of approach, taking control of the anti-surge valve by performing a closed loop PID control using the rate of approach as a process variable.

27. A method as defined in claim 26, wherein the step of performing the closed loop PID on the rate of approach includes performing an integral operation in conjunction with a PID operation to achieve zero error.