Method for detecting the occurrence of surge in a centrifugal compressor

• US 5,971,712 A
• Filed: 05/22/1997
• Issued: 10/26/1999
• Est. Priority Date: 05/22/1996
• Status: Expired due to Fees

• Current Assignee: Ingersoll-Rand Company (Trane Technologies plc)
• Original Assignee: Ingersoll-Rand Company (Trane Technologies plc)
• Inventors: Kann, Meng Jeng
• Primary Examiner(s): Freay, Charles G.
• Assistant Examiner(s): Evora, Robert Z.
• Application Number:
  US08/861,974
• Time in Patent Office: 887 Days
• Field of Search: 417/282, 417/18, 417/31, 417/32, 417/38, 417/43, 417/44.1, 417/45, 417/44.2, 417/44.11, 415/27, 60/223
• US Class Current: 417/18
• CPC Class Codes: F04D 27/001 Testing thereof; Determination or simulation of flow characteristics; Stall or surge detection, e.g. condition monitoring
• CPC Class Codes: F04D 27/0207 by bleeding, bypassing or recycling fluids influencing the boundary layer by an uncontrolled bleeding of the working fluid F04D29/681

Abstract

A method for detecting the occurrence of surge in a centrifugal compressor includes the step of calculating a time rate of change of a discharge pressure of the fluid discharged from the compressor. In one preferred embodiment, the time rate of change of the discharge pressure is calculated by initially setting PREV PRESS and RATE PRESS variables equal to zero (0), and commencing a RATE PRESS subroutine having a time limit for cycling therethrough. The RATE PRESS subroutine includes the steps of obtaining a discharge pressure reading for the fluid discharged from the compressor, subtracting the discharge pressure reading from the PREV PRESS variable to establish the RATE PRESS variable, and resetting the PREV PRESS variable equal to the value of the discharge pressure reading. After the RATE PRESS variable has been determined, the RATE PRESS is compared with an acceptable set time point rate of change for the discharge pressure. If the calculated value of the time rate of change of the discharge pressure is greater than or equal to the acceptable set point time rate of change for the discharge pressure, then a surge detection subroutine having a time limit for cycling therethrough is commenced. The surge detection subroutine may include the steps of calculating a time rate of change of a temperature of the fluid discharged from the compressor, and comparing the calculated time rate of change of the temperature of the fluid discharge from the compressor with an acceptable set point time rate of change for the temperature of the fluid discharged from the compressor. If both calculated time rates of change for the discharge pressure and the discharge temperature are greater than or equal to the respective set point time rates of change for the discharge pressure and the discharge temperature, then the system generates a signal indicating the occurrence of surge.

Claims

1. A method for detecting the occurrence of surge in a centrifugal compressor, said compressor having an inlet valve for introducing a fluid therein and an outlet for discharging compressed fluid therefrom, said method including the steps of:

A. calculating a time rate of change of a discharge pressure of the fluid discharged from said compressor including the steps of;

i) initially setting PREV PRESS and RATE PRESS variables equal to zero (0), and

ii) commencing a RATE PRESS subroutine having a time limit for cycling therethrough, the subroutine including the steps of;

a) obtaining a discharge pressure reading for the fluid discharged from the outlet of said compressor,

b) subtracting the discharge pressure reading from the PREV PRESS variable to establish the RATE PRESS variable, and

c) resetting the PREV PRESS variable equal to the discharge pressure reading obtained during step ii) a); and

B. comparing the RATE PRESS variable with an acceptable set point time rate of change for the discharge pressure, wherein if the RATE PRESS variable calculated in step A. ii) b) is greater than or equal to the acceptable set point time rate of change for the discharge pressure, then commencing a surge detection subroutine having a time limit for cycling therethrough, the surge detection subroutine including the steps of;

i) calculating a time rate of change of a temperature of the fluid discharged from said compressor, and

ii) comparing the calculated time rate of change of the temperature of the fluid discharge from said compressor with an acceptable set point rate of change for the temperature of the fluid discharged from said compressor, wherein if both calculated rates of change for the discharge pressure and the discharge temperature are greater than or equal to the respective set point rates of change for the discharge pressure and the discharge temperature, then generating a signal indicating the occurrence of surge.

2. The method as claimed in claim 1, wherein the generating a signal indicating the occurrence of surge step includes the step of increasing the flow of fluid introduced into said centrifugal compressor.

3. The method as claimed in claim 2, wherein said compressor includes a bypass valve and a bypass valve controller, the generating a signal indicating the occurrence of surge step further comprising the steps of transmitting signals to the bypass controller and the inlet valve to respectively open the bypass valve and reposition the inlet valve to a compressor unloaded position the generating a signal indicating the occurrence of surge step further comprises the step of transmitting signals to the bypass controller and inlet valve controller to open the bypass valve and to reposition the inlet valve to a compressor unloaded position.

4. The method as claimed in claim 1, further comprising the step of establishing the set point value for the rate of change of the discharge pressure and the set point value for the rate of change of the temperature level.

5. The method as claimed in claim 1, wherein the surge detection subroutine includes the steps of:

i) initially setting PREV TEMP, RATE TEMP and SUM TEMP variables equal to zero (0);

ii) obtaining a temperature reading of the fluid discharged from the compressor;

iii) subtracting the PREV TEMP variable from the temperature reading obtained during step ii) to establish the RATE TEMP variable;

iv) adding the RATE TEMP variable of step iii) and the SUM TEMP variable of step i) to establish an updated SUM TEMP variable; and

v) if the SUM TEMP variable is greater than or equal to the RATE TEMP set point, then generating a signal indicating the occurrence of surge.

6. A method for detecting the occurrence of surge in a centrifugal compressor, said compressor having an inlet valve for introducing a fluid therein and an outlet for discharging compressed fluid therefrom, said method including the steps of:

A. calculating a time rate of change of compressor discharge pressure;

B. comparing the calculated time rate of change of the compressor discharge pressure with a set point time rate of change of compressor discharge pressure;

C. calculating a time rate of change of the current drawn by the motor; and

D. comparing the calculated time rate of change of the current drawn by the motor with a set point time rate of change for the motor current, wherein steps B and D occur substantially simultaneously so that if both the time rate of change of the motor current and the time rate of change of the compressor discharge pressure are greater than the respective set point time rates of change of the discharge pressure and motor current, then generating a signal indicating the occurrence of surge.

7. The method of detecting the occurrence of surge as claimed in claim 6, wherein the generating a signal indicating the occurrence of surge step includes the step of changing the volume of the fluid passing through the inlet valve.

8. The method as claimed in claim 6, further comprising the step of establishing the acceptable set point value for the rate of change of the discharge pressure and the acceptable set point value for the rate of change of the current drawn by the motor.

9. The method as claimed in claim 6, wherein step B includes the steps of:

i) initially setting PREV PRESS and RATE PRESS variables equal to zero (0); and

ii) commencing a RATE PRESS subroutine having a time limit for cycling therethrough including;

a) obtaining a discharge pressure reading at the outlet of the compressor,

b) subtracting the discharge pressure reading from PREV PRESS variable to establish the RATE PRESS variable,

c) resetting the PREV PRESS variable equal to the discharge pressure reading obtained during step ii) a), and

d) returning to step ii) for recommencing the RATE PRESS subroutine after the time limit for cycling through the RATE PRESS subroutine has expired.

10. The method as claimed in claim 9, further comprising the step of continuously repeating steps a)-d) of the RATE PRESS subroutine during operation of said compressor.

11. The method as claimed in claim 6, wherein step C includes the steps of:

i) initially setting PREV CURRENT and RATE CURRENT variables equal to zero (0); and

ii) commencing a RATE CURRENT subroutine having a time limit for cycling therethrough including;

a) obtaining a reading for a level of current drawn by the motor,

b) subtracting the current reading from the PREV CURRENT variable to establish the RATE CURRENT variable,

c) resetting the PREV CURRENT variable equal to the current reading obtained during step ii) a), and

d) returning to step ii) for recommencing the RATE CURRENT subroutine after the time limit for cycling through the RATE CURRENT subroutine has expired.

12. The method as claimed in claim 11, further comprising the step of continuously repeating steps a)-d) of the RATE CURRENT subroutine during operation of said compressor.