US20170058906A1 - Turbomachine Anti-Surge System - Google Patents

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Classifications

• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
  • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
  • F04D27/00—Control, e.g. regulation, of pumps, pumping installations or pumping systems specially adapted for elastic fluids
  • F04D27/02—Surge control
  • F04D27/0246—Surge control by varying geometry within the pumps, e.g. by adjusting vanes
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
  • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
  • F04D17/00—Radial-flow pumps, e.g. centrifugal pumps; Helico-centrifugal pumps
  • F04D17/08—Centrifugal pumps
  • F04D17/10—Centrifugal pumps for compressing or evacuating
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
  • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
  • F04D27/00—Control, e.g. regulation, of pumps, pumping installations or pumping systems specially adapted for elastic fluids
  • F04D27/02—Surge control
  • F04D27/0207—Surge control by bleeding, bypassing or recycling fluids
  • F04D27/0215—Arrangements therefor, e.g. bleed or by-pass valves
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
  • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
  • F04D27/00—Control, e.g. regulation, of pumps, pumping installations or pumping systems specially adapted for elastic fluids
  • F04D27/02—Surge control
  • F04D27/0207—Surge control by bleeding, bypassing or recycling fluids
  • F04D27/0223—Control schemes therefor
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
  • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
  • F04D29/00—Details, component parts, or accessories
  • F04D29/58—Cooling; Heating; Diminishing heat transfer
  • F04D29/582—Cooling; Heating; Diminishing heat transfer specially adapted for elastic fluid pumps
  • F04D29/5826—Cooling at least part of the working fluid in a heat exchanger
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
  • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
  • F04D29/00—Details, component parts, or accessories
  • F04D29/26—Rotors specially for elastic fluids
  • F04D29/28—Rotors specially for elastic fluids for centrifugal or helico-centrifugal pumps for radial-flow or helico-centrifugal pumps
  • F04D29/284—Rotors specially for elastic fluids for centrifugal or helico-centrifugal pumps for radial-flow or helico-centrifugal pumps for compressors
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
  • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
  • F04D29/00—Details, component parts, or accessories
  • F04D29/40—Casings; Connections of working fluid
  • F04D29/42—Casings; Connections of working fluid for radial or helico-centrifugal pumps
  • F04D29/44—Fluid-guiding means, e.g. diffusers
  • F04D29/441—Fluid-guiding means, e.g. diffusers especially adapted for elastic fluid pumps
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
  • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
  • F05D2270/00—Control
  • F05D2270/01—Purpose of the control system
  • F05D2270/10—Purpose of the control system to cope with, or avoid, compressor flow instabilities
  • F05D2270/101—Compressor surge or stall
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
  • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
  • F05D2270/00—Control
  • F05D2270/60—Control system actuates means
  • F05D2270/62—Electrical actuators

Definitions

• This specification relates to turbomachine control and protection systems.
• Compressors increase the pressure on a fluid. As gases are compressible, the compressor also reduces the volume of a gas.
• a compressor stall is a local disruption of the airflow in a gas turbine or turbocharger compressor.
• Axi-symmetric stall also known as compressor surge, is a breakdown in compression resulting in a reversal of flow and the violent expulsion of previously compressed gas out in the direction of the compressor intake. This condition is a result of the compressor's inability to continue working against the already-compressed gas behind it. As a result, the compressor may experience conditions that exceed its pressure rise capabilities, or the compressor may become loaded such that a flow reversal occurs, which can propagate in less than a second to include the entire compressor.
• a compressor anti-surge system includes a first actuator configured to actuate a first valve of a first turbomachine, and a first controller at least partially integrated with the first actuator or the first valve, and comprising circuitry configured to perform at least one of a control operation or a protection operation for the first turbomachine.
• the first actuator can be configured to actuate the first valve through a mechanical coupler or a fluid circuit.
• the compressor anti-surge system can include a first field sensor configured to sense a first turbomachine parameter of the first turbomachine, wherein the first controller is further configured to receive the first turbomachine parameter from the first field sensor and perform at least one of a control operation or a protection operation for the first turbomachine, based at least in part on the received first turbomachine parameter.
• the valve can be a sliding stem turbomachinery control valve, rotary turbomachinery control valve, or a guide vane.
• the compressor anti-surge system can include an integral or adjacent heat exchanger in fluid communication with the valve and configured to cool fluids that are passed through the valve.
• the first controller can include a first communication port and can be configured to provide controller operations information through the first communications port, a second actuator configured to actuate a second valve of a second turbomachine, and a second controller at least partially integrated with the second actuator or the second valve, a second communication port configured to communicate with the first communication port and receive controller operations information, and comprising circuitry configured to perform at least one of a control operation or a protection operation for the second turbomachine based at least in part on the received controller operations information.
• the first controller can include a first communication port and is configured to provide controller operations information through the first communications port, a second actuator configured to actuate a second valve of the first turbomachine, and a second controller at least partially integrated with the second actuator or the second valve, a second communication port configured to communicate with the first communication port and receive controller operations information, and comprising circuitry configured to perform at least one of a control operation or a protection operation for the first turbomachine based at least in part on the received controller operations information.
• a method of responding to compressor surge includes receiving at a first controller at least partially integrated with a first valve and from a first field sensor a first turbomachine parameter of a first turbomachine, determining by the first controller at least one of a control operation or a protection operation for the first turbomachine, based at least in part on the received first turbomachine parameter, and actuating by a first actuator at least partially integrated with the first valve or the first controller the first valve to perform the determined control operation or protection operation for the first turbomachine.
• the first actuator can be configured to actuate the first valve through a mechanical coupler or a fluid circuit.
• the valve can be a sliding stem turbomachinery control valve, rotary turbomachinery control valve, or a guide vane.
• At least one of the control operation or the protection operation for the first turbomachine can include actuating the first valve to control flow of fluids to an integral or adjacent heat exchanger in fluid communication with the valve and configured to cool fluids that are passed through the valve.
• the method can include providing by the first controller operations information through a first communications port, receiving at a second communications port of a second controller at least partially integrated with a second valve of a second turbomachine or a second actuator configured to actuate the second valve the controller operations information, and actuating by the second actuator the second valve perform at least one of a control operation or a protection operation for the second turbomachine based at least in part on the received controller operations information.
• the method can include providing by the first controller operations information through a first communications port, receiving at a second communications port of a second controller at least partially integrated with a second valve of the first turbomachine or a second actuator configured to actuate the second valve the controller operations information, and actuating by the second actuator the second valve perform at least one of a control operation or a protection operation for the first turbomachine based at least in part on the received controller operations information.
• a system can widen the turbomachine operating envelope.
• the system can increase turbomachine safety.
• the system can reduce of the effective valve size.
• the system can reduce process time lags in the anti-surge system.
• the system can improve the reliability and predictability of turbomachine system dynamic performance.
• FIG. 1 is a schematic diagram that shows an example of a prior art turbomachine system
• FIG. 2 is a schematic diagram that shows an example of a compressor system.
• FIG. 3 is flow chart that shows an example of a process for protecting a turbomachine system.
• turbomachine anti-surge systems described in the descriptions of FIGS. 2-3 combine all or some of one or more fast, high dynamic performance electrically actuated anti-surge valves, electronic controls fully or partially integrated into the valve assembly and executing surge prevention and surge protection control algorithms, compact heat exchangers adjacent to the anti-surge valves to cool the medium flowing through the anti-surge valves, and reducing process time lag in the anti-surge control loop.
• Compressor systems as commonly used in gas transmission compressor stations, petro-chemical refining and processing installations, for example, can undergo a potentially destructive phenomenon called “surge”.
• the operational status of compressor systems can be represented by an operating map with axes representing changes in pressure (deltaP) and changes in flow (deltaQ).
• the operating point of the compressor Upon further reduction of the flow-rate, the operating point of the compressor will oscillate between a point left and right of this surge line. The oscillation can cause undesired motion of the compressor blades and the drive shaft such that the blades contact the stators within the compressor which can cause catastrophic damage in a very short time period.
• FIG. 1 is a schematic diagram that shows an example of a prior art turbomachine system 100 .
• the turbomachine system 100 is illustrated as a centrifugal compressor that includes a compressor 102 a and a compressor 102 b that are driven by a prime mover 104 (e.g., a motor).
• the compressors 102 a , 102 b pressurize a gas received at an inlet 106 (e.g., a suction port) and discharge the pressurized gas at a discharge 108 (e.g., an outlet port).
• a process gas cooler 107 e.g., a heat exchanger
• the system 100 commonly includes a controller 110 , a hot recycle valve 112 controlling forward flow along a hot recycle conduit 114 , a cold recycle valve 116 controlling return flow along a cold recycle conduit 118 , and an actuator bypass loop with a gas inter-cooler 107 (heat exchanger).
• a fluid actuator 113 e.g., hydraulic, pneumatic
• a fluid actuator 117 is configured to actuate the cold recycle valve 116 .
• the controller 110 is configured to monitor either one or a plurality of a collection of surge parameter values.
• the surge parameter values are based on measurement signals received from a collection of system sensors and feedback devices.
• the controller 110 receives measurement signals from a flow sensor 130 a , a suction pressure sensor 130 b , and a discharge pressure sensor 130 c.
• the controller 110 may directly or indirectly control a safeguard operation. For example, the controller 110 may trigger compressed gas at the discharge 108 to flow back to the inlet 106 through the cold recycle valve 116 to relieve the surge condition. In another example, the controller 110 may trigger uncompressed gas at the inlet 106 to flow forward to the discharge 108 through the hot recycle valve 112 to relieve the surge condition.
• FIG. 2 is a schematic diagram that shows an example of a compressor system 200 .
• the turbomachine system 200 is illustrated as a centrifugal compressor that includes a compressor 202 a and a compressor 202 b that are driven by a prime mover 204 (e.g., a motor).
• the compressors 202 a , 202 b pressurize a gas received at an inlet 206 (e.g., a suction port) and discharges the pressurized gas at a discharge 208 (e.g., an outlet port).
• a process gas cooler 207 e.g., a heat exchanger
• a flow sensor 230 a is configured to measure inlet gas flow.
• a suction pressure sensor 230 b is configured to measure gas pressure at the inlet 206 .
• a discharge pressure sensor 230 c is configured to measure gas pressure at the discharge 208 .
• the inlet 206 is in fluid communication with the discharge 208 through a recycle valve 212 and a gas cooler 250 (e.g., heat exchanger).
• the recycle valve can be a sliding stem turbomachinery control valve, a rotary turbomachinery control valve, a guide vane, or any other appropriate turbomachine valve.
• an electric actuator 213 is configured to actuate the recycle valve 212 .
• the electric actuator 213 is an all-electric, high performance actuator.
• the electric actuator 213 can start moving the recycle valve 212 more quickly (e.g., about 25 mS typical) than is possible with the fluid actuators 113 and 117 of FIG. 1 .
• the electric actuator 213 can move the recycle valve 212 from closed to fully open in about 0.3 to 0.6 seconds, although in some embodiments longer times may occur when actuating larger valves.
• the electric actuator 213 may actuate the recycle valve 212 through a mechanical coupler or a fluid circuit.
• use of the electric actuator 213 rather than the relatively slower fluid actuators 113 and 117 of FIG. 1 allows the compressor system 200 to be operated more efficiently than the compressor system 100 .
• safety margins away from the surge line are generally used. The magnitudes of these safety margins are at least partly proportional to the amount of time needed for their corresponding compressor systems to take corrective, anti-surge actions before deltaP/deltaQ reaches zero.
• the recycle valve 212 can be a high turn down valve that can be modulated near the fully closed position without causing damage to the internal metering elements of the recycle valve 212 due to high throttling conditions.
• the recycle valve 212 can includes noise reduction trim, either within the recycle valve 212 or externally, depending upon operational requirements.
• the electric actuator 213 of the example compressor system 200 includes an at least partly integrated anti-surge controller configured to receive surge parameter values, calculate proximity to surge control line, and take corrective control actions.
• the surge parameter values are based on measurement signals received from a collection of system sensors and feedback devices.
• the electric actuator 213 receives measurement signals from the sensors 230 a - 230 c.
• the electric actuator 213 of the example compressor system 200 includes an at least partly integrated surge detection system configured to receive surge parameter values, detect surge conditions, and/or take corrective safety actions.
• the surge parameter values are based on measurement signals received from a collection of system sensors and feedback devices.
• the electric actuator 213 receives measurement signals from the sensors 230 a - 230 c .
• different and/or additional sensors may be used (e.g., temperature, torque, speed, vibration).
• the fully integrated surge controller of the electric actuator 213 of the example compressor system 200 is programmed and dynamically matched to the characteristics of the recycle valve 212 and the flow measurement system of the example compressor system 200 (e.g., the sensors 230 a - 230 c ) such that the total system dynamics of the compressor system 200 are well controlled and predictable.
• the electric actuator 213 may directly or indirectly control a safeguard operation.
• the electric actuator can actuate the recycle valve 212 to allow compressed gas at the discharge 208 to flow back to the inlet 206 through the recycle valve 212 and the gas cooler 250 to relieve the surge condition.
• the electric actuator 213 may provide signals that can be used to trigger other remedial actions, for example, such as a controlled reduction or shutdown of the prime mover 204 .
• the electric actuator 213 may also include functions such as surge control, choke control, steam turbine extraction control, gas turbine speed control, steam turbine speed control, compressor guide vane capacity control, compressor inlet throttle valve capacity control, or combinations of these and/or any other appropriate functions for compressor system control.
• the surge controller of the electric actuator 213 can include a communication port that is configured to provide controller operations information through the communications port.
• a second actuator can be configured to actuate a second valve of a second turbomachine, and a second controller can be at least partially integrated with the second actuator or the second valve.
• the second controller can include a second communication port configured to communicate with the first communication port and receive controller operations information, and include circuitry configured to perform at least one of a control operation or a protection operation for the second turbomachine based at least in part on the received controller operations information.
• the electric actuator 213 may provide information to an electric actuator of another compressor system.
• the surge controller of the electric actuator 213 can include a communication port that is configured to provide controller operations information through the communications port.
• a second actuator can be configured to actuate a second valve of the compressor system 200 , and a second controller can be at least partially integrated with the second actuator or the second valve.
• the second controller can include a second communication port configured to communicate with the first communication port and receive controller operations information, and include circuitry configured to perform at least one of a control operation or a protection operation for the compressor system 200 based at least in part on the received controller operations information.
• FIG. 3 is flow chart that shows an example of a process 300 for protecting a turbomachine system.
• the process 300 can be used to protect the example compressor system 200 of FIG. 2 .
• a first controller at least partially integrated with a first valve receives a first turbomachine parameter of a first turbomachine from a first field sensor.
• the compressor system 200 includes the electric actuator 213 which is configured to receive feedback from the sensors 230 a - 230 c.
• the first controller determines at least one of a control operation or a protection operation for the first turbomachine, based at least in part on the received first turbomachine parameter.
• the electric actuator 213 can receive feedback from the sensors 230 a - 230 c and determine that a surge event is underway (e.g., deltaP/deltaQ is within the predetermined safety margin around the surge line).
• the first actuator at least partially integrated with the first valve or the first controller actuates the first valve to perform the determined control operation or protection operation for the first turbomachine.
• the electric actuator 213 can actuate the recycle valve 212 in an attempt to remedy the surge condition.
• at least one of the control operation or the protection operation for the first turbomachine can include actuating the first valve to control flow of fluids to an integral or adjacent heat exchanger in fluid communication with the valve and configured to cool fluids that are passed through the valve.
• the recycle valve 212 can be actuated to allow compressed gasses to pass through the gas cooler 250 and on to the inlet 206 .
• the process 300 can include providing, by the first controller, controller operations information through a first communications port, receiving, at a second communications port of a second controller at least partially integrated with a second valve of a second turbomachine or a second actuator configured to actuate the second valve, the controller operations information, and actuating, by the second actuator, the second valve perform at least one of a control operation or a protection operation for the second turbomachine, based at least in part on the received controller operations information.
• the electric actuator 213 can provide control signals to another electric actuator of another compressor system 200 to cause another recycle valve to be actuated.
• the process 300 can include providing, by the first controller, controller operations information through a first communications port, receiving, at a second communications port of a second controller at least partially integrated with a second valve of the first turbomachine or a second actuator configured to actuate the second valve, the controller operations information, and actuating, by the second actuator, the second valve perform at least one of a control operation or a protection operation for the first turbomachine, based at least in part on the received controller operations information.
• the electric actuator 213 can provide control signals to another electric actuator of the compressor system 200 to cause another recycle valve of the compressor system 200 to be actuated.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• General Engineering & Computer Science (AREA)
• Life Sciences & Earth Sciences (AREA)
• Sustainable Development (AREA)
• Physics & Mathematics (AREA)
• Thermal Sciences (AREA)
• Geometry (AREA)
• Control Of Positive-Displacement Air Blowers (AREA)
• Structures Of Non-Positive Displacement Pumps (AREA)

Abstract

Description

Claims (13)

Priority Applications (4)

Applications Claiming Priority (1)

Publications (1)

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ID=56896844

Family Applications (1)

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Cited By (1)

Citations (2)

Family Cites Families (5)

• 2015
  • 2015-09-02 US US14/843,486 patent/US20170058906A1/en not_active Abandoned
• 2016
  • 2016-09-01 EP EP16763700.8A patent/EP3344877A1/en not_active Withdrawn
  • 2016-09-01 CN CN201680064094.6A patent/CN108291553A/en active Pending
  • 2016-09-01 WO PCT/US2016/049939 patent/WO2017040807A1/en active Application Filing

Patent Citations (2)

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