Method and apparatus for continuous prediction, monitoring and control of compressor health via detection of precursors to rotating stall and surge
First Claim
1. A method for pro-actively monitoring and controlling a compressor, comprising:
- (a) monitoring at least one compressor parameter;
(b) analyzing the monitored parameter to obtain time-series data;
(c) processing the time-series data using a Kalman filter to determine stall precursors;
(d) comparing the stall precursors with predetermined baseline values to identify compressor degradation;
(e) performing corrective actions to mitigate compressor degradation to maintain a pre-selected level of compressor operability; and
(f) iterating said corrective action performing step until the monitored compressor parameter lies within predetermined threshold.
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Abstract
An apparatus for monitoring the health of a compressor having at least one sensor operatively coupled to the compressor for monitoring at least one compressor parameter, a processor system embodying a stall precursor detection algorithm, the processor system operatively coupled to the at least one sensor, the processor system computing stall precursors. A comparator is provided to compare the stall precursors with predetermined baseline data, and a controller operatively coupled to the comparator initiates corrective actions to prevent a compressor surge and stall if the stall precursors deviate from the baseline data, the baseline data representing predetermined level of compressor operability.
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Citations
24 Claims
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1. A method for pro-actively monitoring and controlling a compressor, comprising:
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(a) monitoring at least one compressor parameter;
(b) analyzing the monitored parameter to obtain time-series data;
(c) processing the time-series data using a Kalman filter to determine stall precursors;
(d) comparing the stall precursors with predetermined baseline values to identify compressor degradation;
(e) performing corrective actions to mitigate compressor degradation to maintain a pre-selected level of compressor operability; and
(f) iterating said corrective action performing step until the monitored compressor parameter lies within predetermined threshold. - View Dependent Claims (2, 3, 4, 5, 6)
i. processing the time-series data to compute dynamic model parameters; and
ii. combining, in the Kalman filter, the dynamic model parameters and a new measurement of the compressor parameter to produce a filtered estimate.
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3. The method of claim 2 further comprising:
iii. computing a standard deviation of difference between the filtered estimate and the new measurement to produce stall precursors.
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4. The method of claim 3 wherein said corrective actions are initiated by varying operating line parameters.
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5. The method of claim 4 wherein said operating line parameters are set to a near threshold value.
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6. The method of claim 3 wherein said corrective actions include reducing the loading on the compressor.
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7. An apparatus for monitoring the health of a compressor, comprising:
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at least one sensor operatively coupled to the compressor for monitoring at least one compressor parameter;
a processor system, embodying a Kalman filter, operatively coupled to said at least one sensor, said processor system computing stall precursors;
a comparator that compares the stall precursors with predetermined baseline data; and
a controller operatively coupled to the comparator, said controller initiating corrective actions to prevent a compressor surge and stall if the stall precursors deviate from the baseline data, said baseline data representing predetermined level of compressor operability. - View Dependent Claims (8, 9, 10)
an analog-to-digital (A/D) converter operatively coupled to said at least one sensor for sampling and digitizing input data from said at least one sensor;
a calibration system coupled to said A/D converter, said calibration system performing time-series analysis (t,x) on the monitored parameter to compute dynamic model parameters; and
a look-up-table (LUT) with memory for storing known sets of compressor data including corresponding stall measure data.
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9. The apparatus of claim 7 wherein the corrective actions are initiated by varying operating limit line parameters.
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10. The apparatus of claim 9 wherein said operating limit line parameters are set to a near threshold value.
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11. In a gas turbine of the type having a compressor, a combustor, a method for monitoring the health of a compressor comprising:
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(a) monitoring at least one compressor parameter;
(b) analyzing the monitored parameter to obtain time-series data;
(c) processing the time-series data using a Kalman filter to determine stall precursors;
(d) comparing the stall precursors with predetermined baseline values to identify compressor degradation;
(e) performing corrective actions to mitigate compressor degradation to maintain a pre-selected level of compressor operability; and
(f) iterating said corrective action performing step until the monitored compressor parameter lies within predetermined threshold. - View Dependent Claims (12, 13, 14, 15, 16)
i. processing the time-series data to compute dynamic model parameters; and
ii. combining, in the Kalman filter, the dynamic model parameters and a new measurement of the compressor parameter to produce a filtered estimate.
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13. The method of claim 12 further comprising:
iii. computing a standard deviation of difference between the filtered estimate and the new measurement to produce stall precursors.
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14. The method of claim 11 wherein the corrective actions are initiated by varying operating line parameters.
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15. The method of claim 14 wherein the corrective actions further include varying the loading on the compressor.
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16. The method of claim 14, wherein said operating line parameters are set to a near threshold value.
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17. An apparatus for monitoring and controlling the health of a compressor, comprising:
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means for measuring at least one compressor parameter;
means for computing stall measures;
means for comparing the stall measures with predetermined baseline values; and
means for initiating corrective actions if the stall measures deviate from said baseline values. - View Dependent Claims (18, 19, 20)
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21. A method for monitoring and controlling the health of a compressor, comprising:
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providing a means for monitoring at least one compressor parameter;
providing a means for computing stall measures;
providing a means for comparing the stall measures with predetermined baseline values; and
providing a means for initiating corrective actions if the stall measures deviate from said baseline values.
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22. A method of detecting precursors to rotating stall and surge in a compressor, the method comprising measuring the pressure and velocity of gases flowing through the compressor and using a Kalman filter in combination with offline calibration computations to predict future precursors to rotating stall and surge, wherein the Kalman filter utilizes:
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a definition of errors and their stochastic behavior in time;
the relationship between the errors and the measured pressure and velocity values; and
how the errors influence the prediction of precursors to rotating stall and surge.
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23. An apparatus for monitoring the health of a compressor, comprising:
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at least one sensor operatively coupled to the compressor for monitoring at least one compressor parameter;
a processor system, embodying a stall precursor detection algorithm, operatively coupled to said at least one sensor, said processor system computing stall precursors;
a comparator that compares the stall precursors with predetermined baseline data; and
a controller operatively coupled to the comparator, said controller initiating corrective actions to prevent a compressor surge and stall if the stall precursors deviate from the baseline data, said baseline data representing predetermined level of compressor operability. - View Dependent Claims (24)
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Specification