Patent Application
20190078574
Embodiments of the subject matter disclosed herein correspond to control systems for a rotary compressor driven by a rotary engine, synthesis plants and control methods.
Trains comprising a compressor driven by an engine are quite common, in particular in the field of “Oil & Gas”.
A typical control system for such trains, such as system 100 shown in annexed
Such typical control system works well if the effects of disturbances coming from units upstream or downstream the compressor or the effects of interactions between the compressor and said units, on compressor speed and/or on controlled performance variables are consistent; this applies, for example, if the composition of the gas mixture at the inlet of the compressor remains absolutely constant or, at least, quite constant.
The above-mentioned trains are used, for example, in synthesis plant for the production of ammonia. An example of a known process for producing ammonia is the one that may be licensed from KBR that will be called in the following “KBR process”.
In a synthesis plant, for example, there are units upstream the compressor arranged to prepare a gas mixture (often containing hydrogen and/or nitrogen and/or carbon monoxide) to be processed by the compressor. Although the plant is designed so to maintain the composition of the gas mixture constant, one or more of these units may adversely affect the composition in certain operating conditions. For example, in an ammonia plant implementing the “KBR process”, there is a so-called “purifier” (including a condensation reformer) upstream the compressor system (including two compressors) that may cause variations in the composition of the gas mixture.
In such synthesis plants, due to a (substantial) variation in the composition of the gas mixture and a consequential (substantial) variation in the rotation speed of the compressor, a typical control system implements a control action in the opposite direction to reject the disturbance. For this reason, the control system has to be switched from “automatic mode” or “automatic control” to “manual mode” or “manual control” in order to avoid amplifying the upset and reaching an unstable condition; after some time, the control system is switched back to “automatic mode” or “automatic control”. This means that the control system is semi-automatic.
It would be desirable to have a full-automatic control system that adjusts a rotational speed of a compressor to compensate for variations in the composition of a gas mixture at an inlet of the compressor.
Embodiments of the subject matter disclosed herein relate to a control system for a rotary compressor driven by a rotary engine.
According to embodiments, a control system for a rotary compressor driven by a rotary engine, comprises: a first control subsystem, a second control subsystem and a selector; the first control subsystem comprises: a performance input arranged to receive a first measure signal indicating performance of said rotary compressor, a speed input arranged to receive a second measure signal indicating rotation speed of said rotary compressor or said rotary engine, and a first control output arranged to provide a first control signal as a function of said first measure signal and said second measure signal; the second control subsystem comprises: a performance input arranged to receive a third measure signal indicating performance of said rotary compressor, and a second control output arranged to provide a second control signal as a function of said third measure signal; the selector comprises: a first input electrically connected to said first control output, a second input electrically connected to said second control output, and a third control output arranged to provide a third control signal to a power control input of said rotary engine; said selector is arranged to select said first control signal or said second control signal as said third control signal to be provided at said third control output.
Embodiments of the subject matter disclosed herein relate to a synthesis plant.
According to embodiments, the synthesis plant comprises: a rotary compressor comprising an inlet and an outlet, wherein said inlet is arranged to receive a gas mixture, a rotary engine driving said rotary compressor, and a control system as set out above.
Embodiments of the subject matter disclosed herein relate to a method of controlling a rotary compressor driven by a rotary engine.
According to embodiments, the method comprising: measuring a parameter of said rotary compressor, said parameter indicating performance of said rotary compressor, measuring a rotation speed of said rotary compressor or said rotary engine, generating a first control signal as a function of said parameter and said rotation speed, generating a second control signal as a function of said parameter, generating a third control signal by selecting between said first control signal and said second control signal, and providing said third control signal to control input terminals of said rotary engine.
The accompanying drawings, which are incorporated herein and constitute an integral part of the present specification, illustrate exemplary embodiments of the present invention and, together with the detailed description, explain these embodiments. In the drawings:
The following description of exemplary embodiments refers to the accompanying drawings.
The following description does not limit embodiments of the invention. Instead, the scope of embodiments of the invention is defined by the appended claims.
Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.
In the following, embodiments of the subject matter disclosed herein will be described through block diagrams made of blocks connected by lines entering into and exiting out of blocks as it is customary practice in the field of “control theory”.
It is to be noted that such block diagrams may be implemented in many different ways through various possible combinations of pieces of hardware and pieces of software.
Therefore, throughout the specification (i.e. description, claims and abstract) and drawings, a “block” may refer to a piece of hardware or piece of software (running on a piece of hardware), an “input” or an “output” may refer to electrical terminals or a piece of data stored in a computer memory (that may be for example internal to a PLC), the expression “receiving a signal” may mean “letting an electrical signal flow into electrical terminals” or “reading a piece of data from a memory”, the expression “providing an output” may mean “letting an electrical signal flow out of electrical terminals” or “writing a piece of data to a memory”, the expression “electrically connected” (when referred for example to blocks) may correspond to having electrical wires between electrical terminals of a block and electrical terminals of another block or to having a block writing a piece of data to a memory and another block reading the same piece of data from the same memory.
According to a typical implementation, a new and inventive fully-automatic control system may be implemented for example through a single PLC (=Programmable Logic Controller) and one or more pieces of software; in this case, in particular, a block may correspond to a piece of software, i.e. a software program or a software subroutine.
The new full-automatic control system differs from prior control systems in that it includes not one, but at least two control subsystems. The first control subsystem performs control based, in an embodiment, only on a performance parameter of the compressor, in particular its suction pressure, and the rotation speed of the engine or the compressor. The second control subsystem performs control based, in an embodiment, only on a performance parameter of the compressor, in particular its suction pressure. The second control subsystem is used for example when the suction pressure of the compressor is very high (i.e. much higher than expected from design) and/or when the suction pressure of the compressor is varying very quickly (i.e. much quicker than expected from design); this means for example that the composition of the gas mixture at the inlet of the compressor is far from expected; otherwise the first control subsystem is used. Therefore, no human intervention is necessary.
Referring to
Control system 200 may include: a first control subsystem 210, a second control subsystem 220 and a selector 230.
It is to be noted that a control subsystem may be implemented in many different ways through various possible combinations of pieces of hardware and pieces of software. If the control system is implemented for example through a single PLC, each or any of the control subsystems may be implemented through a so-called “software module”, i.e. a set of software programs or software subroutines cooperating for a specific purpose, running on the PLC.
Control system 200 has a first input 201, a second input 202, a third input 203 and an output 204.
First control subsystem 210 comprises: a performance input 211 arranged to receive a first measure signal 21 indicating performance of the rotary compressor, a speed input 213 arranged to receive a second measure signal 23 indicating rotation speed of the rotary compressor or the rotary engine (usually the two rotation speeds are equal or at a fixed ratio), and a first control output 212 arranged to provide a first control signal 26 as a function of signal 21 and signal 23. Typically, first measure signal 21 indicates suction pressure of the rotary compressor; alternatively, it indicates another performance variable of the compressor such as, for example, discharge pressure of the compressor or net gas (mass or volumetric) flow rate processed by the compressor. Typically, control signal 26 is a power control signal, in particular a speed control signal (in case there is a direct relation between speed and power generated by the engine). Typically, the first control signal 26 is a function of only signals 21 and 23 (but also of other parameters and constants).
Second control subsystem 220 comprises: a performance input 221 arranged to receive a third measure signal 22 indicating performance of the rotary compressor, and a second control output 222 arranged to provide a second control signal 27 as a function of signal 22. Typically, first measure signal 22 indicates suction pressure of the rotary compressor; alternatively, it indicates another performance variable of the compressor such as, for example, discharge pressure of the compressor or net gas (mass or volumetric) flow rate processed by the compressor. Typically, control signal 27 is a power control signal, in particular a speed control signal (in case there is a direct relation between speed and power generated by the engine). Typically, the second control signal 27 is a function of only signal 22 (but also of other parameters and constants).
In the following, the suction pressure of the compressor will be considered the performance variable of the compressor without limiting the generality of the foregoing.
In the embodiment of
Selector 230 comprises: a first input 231 electrically connected to the first control output 212, a second input 232 electrically connected to the second control output 222, and a third control output 234 arranged to provide a third control signal 24 to a control input of the rotary engine.
Typically, control signal 24 is a power control signal, in particular a speed control signal (in case there is a direct relation between speed and power generated by the engine). For example, if the engine is a steam turbine, control signal 24 may be a signal indicating the opening degree of its steam valve; more in particular, it is the opening percentage of this valve.
Selector 230 is arranged to select control signal 26 or control signal 27 as control signal 24 to be provided at control output 234.
Input 211 is electrically connected to input 201 of control system 200; input 221 is electrically connected to input 202 of control system 200; input 213 is electrically connected to input 203 of control system 200; output 234 is electrically connected to out 204 of control system 200.
Selector 230 may carry out selection of input signal coming from the second control subsystem (instead of the input signal coming the first control subsystem) according to one or more predetermined selection criteria, for example one or more of at least the following criteria:
A) an absolute value of a difference between suction pressure measure signal 21 and a suction pressure setpoint exceeds a first threshold value,
B) an absolute value of a derivative of a difference between suction pressure measure signal 21 and a suction pressure setpoint exceeds a second threshold value.
Criterion A means that the suction pressure of the compressor is very high.
Criterion B means that the suction pressure of the compressor is varying very quickly.
Additional selection criteria that lead selector 230 selecting the input signal coming from the first control subsystem (instead of the input signal coming the second control subsystem) may be for example one or more of at least the following criteria:
C) rotation speed of the engine and/or the compressor is lower than a low limit,
D) rotation speed of the engine and/or the compressor is higher than a high limit,
E) the first control subsystem is contributing to anti-surge control.
It is to be noted that the low limit and/or the high limit is not a predetermined value. For example, given a current rotation speed, the low limit may be the current speed with a subtracted percentage of e.g. 1 or 3 or 10% and the high limit may be the current speed with an added percentage of e.g. 1 or 3 or 10%; the subtracted percentage and the added percentage may be different between each other; the subtracted percentage and/or the added percentage may depend on e.g. the current speed.
Second control subsystem 220 may comprise or correspond to a PID controller arranged to determine control signal 27 based only on suction pressure signal 22 (but also of other parameters and constants); in an embodiment, only the P term and the I term are used, and, in this case, the controller may be defined a PI controller.
The embodiment of
Control system 400 comprises a first control subsystem, a second control subsystem and a selector. The first control subsystem corresponds to blocks 405, 412, 414, 416 and 418. The second control subsystem corresponds to blocks 405 and 422. The selector corresponds to selector 430. Block 405 is shared between the first and the second control subsystems.
The second control subsystem of the embodiment of
The second control subsystem of the embodiment of
The first control subsystem of the embodiment of
The first control subsystem of the embodiment of
The first control subsystem of the embodiment of
Converter 414 is, in particular, a split converter and is arranged to provide alternatively a rotation speed setpoint 45 and an anti-surge control signal 93. Converter 414 may choose to provide one or the other signal depending on the compressor operative status, more in particular on the compressor operative point on the compressor envelop map (for example pressure ratio vs. suction volumetric flow rate).
The first control subsystem of the embodiment of
Selector 430 is arranged to receive first control input 48-1 and second control input 48-2, to provide a third control signal 49 to a power control input of the rotary engine. Selector 430 may carry out selection of input signals according to one or more predetermined selection criteria, for example one or more of the criteria A, B, C, D and E previously mentioned in connection to selector 230.
Both the embodiment 400 of
The anti-surge control subsystem comprises a controller 902 and selector 904.
Controller 902 determines an anti-surge control signal 92 based on a set 91 of parameters; this set comprises in particular the pressure and the temperature at the inlet of the compressor, the pressure and the temperature at the outlet of the compressor, and the volumetric flow rate processed by the compressor. Such controller may determine an anti-surge control signal in a known way.
Selector 904 is arranged to receive the anti-surge control signal 92 and another anti-surge control signal 93, and to select one of them as anti-surge control signal 94 to be provide to an anti-surge valve of the compressor; control signal 94 may be a signal indicating the opening degree of the anti-surge valve, more in particular its opening percentage. Selector 904 may select, for example, the anti-surge control signal having higher value.
In the embodiment of
In the embodiment of
The embodiment 500 of
The corrected signal 56C derives from correcting a speed measure signal 56 that indicates the rotation speed of the rotary compressor or the rotary engine being controlled by control system 500.
Determination of signal 56C is carried out by a corrector 517.
As known, the “corrected speed” of a compressor is the speed at which the pressure ratio calculated from the compressor performance map at the actual gas flow processed by the compressor is equal to the actual pressure ratio delivered by the compressor.
The “corrected speed” is equal to the actual speed (i.e. the measured speed) if the actual condition of the gas mixture at the inlet of the compressor is equal to the design condition of the gas mixture at the inlet of the compressor.
Corrector 517 determines the corrected speed 56C based on the measured speed 56 and a set 91 of parameters; this set comprises in particular the pressure and the temperature at the inlet of the compressor, the pressure and the temperature at the outlet of the compressor, and the volumetric flow rate processed by the compressor.
It is to be noted that, in the embodiment if
Corrected speed 56C for a compressor is calculated as follows.
The corrected rotation speed derives from the following formula
wherein μ2,corr is a corrected peripheral speed of the impeller of the compressor at its outlet section and D2 is a geometrical parameter of the impeller (external diameter).
The corrected peripheral speed derives from the following formula
wherein HP is the polytropic head and ψ is the dimensionless polytropic head.
The polytropic head derives from the following formula:
wherein η is the polytropic efficiency of the compressor, given by the compressor map as a function of the dimensionless volumetric flow φ and the mach number Mu, r is the actual pressure ratio of the compressor i.e. the ratio between the gas pressure at the outlet of the compressor and the gas pressure at the inlet of the compressor
k is the ratio between the specific heat capacity at constant pressure of the gas at the inlet of the compressor and the specific heat capacity at constant volume of the gas at the inlet of the compressor
z1 is the compressibility factor of the gas at the inlet of the compressor,
z1 is the specific constant of the gas processed by the compressor, and T1 is the temperature of the gas at the inlet of the compressor.
The dimensionless volumetric flow derives from the following formula
wherein m is the mass flow of the gas processed by the compressor, ρ1 is the density of the gas at compressor's inlet conditions, AC is the gas flow area, μ2 is the peripheral speed of the impeller of the compressor at its outlet section
(i.e. wherein ω is the actual rotational speed of the compressor) and DM is a geometrical parameter of the compressor's impeller (impeller family diameter). It is to be noted that the above formula of the dimensionless volumetric flow contains the components of the volumetric flow Q of the gas processed by the compressor.
The mach number derives from the following formula
wherein c is the speed of sound calculated as √{square root over (z1·k·R·T1)}.
The dimensionless polytropic head derives from the following formula
The specific gas constant derives from the following formula
wherein
The molecular weight of the gas processed by the compressor may be estimated from compressor performance maps through the following formula:
Plant 1000 comprises: a rotary compressor 350, a rotary engine 360 driving the rotary compressor 350, and a control system 300.
Control system 300 is of the type comprising a first control subsystem and second control subsystem as, for example, the one shown in
In the embodiment of
Compressor 350 has an inlet 352 for receiving an uncompressed gas mixture flow 38 and an outlet 353 for providing a compressed gas mixture flow 39.
Control system 300 has a first input 301 for receiving a suction pressure measure signal 31, a second input 302 for receiving a rotation speed measure signal 32, and an output 304 for providing a power control signal 34.
Output 304 is electrically connected to an input 362 being a power control input of engine 360; typically, by varying power, also rotation speed varies; therefore, engine 360 is a variable-speed rotary engine.
There is a pressure sensor 381 that is positioned and configured to monitor to uncompressed gas mixture flow 38 and electrically connected to input 301.
There is a rotation speed sensor 382 that is positioned and configured to monitor to shaft 351 and electrically connected to input 302.
Engine 360 is a steam turbine; alternatively, it may be, for example, a gas turbine or a (variable-speed) motor such as an electric motor. The use of a steam turbine in a synthesis plant heat is generated and a steam turbine allows to recycle some of this generated heat for a useful purpose, i.e. rotating the compressor.
Synthesis plant 1000 may comprise one or more further compressors. For example, two compressors may be fluidly connected in series and may be controlled by the same control system 300 through the same control signal or through the same measure signals.
Upstream compressor 350 there is a unit 370, for example a reformer (in particular a condensation reformer). In the embodiment of
It is to be noted that, due to the presence of unit 370, gas mixture 38 may sometimes vary its composition. This is particular the case if unit 370 is a condensation reformer.
Synthesis plant 1000 is a plant for producing ammonia. If the synthesis plant 1000 were licensed to perform the KBR ammonia process, then a purifier arrangement including a condensation reformer is typically placed upstream the synthesis gas compressor arrangement. Although the purifier arrangement would be configured to maintain the composition of the output gas mixture constant, it could do so only to a certain extent and not at all times for any operating condition of the plant, unless the synthesis plant 1000 was built or upgraded to include an embodiment of the new two-subsystem control system described, shown and claimed herein.
It is to be noted that compression of so-called “syngas” may be used in several synthesis processes, for example in order to synthetize ammonia, methanol, etc.
Block 601 corresponds to the start of a control process.
Block 608 corresponds to the end of the control process.
The activities corresponding to blocks from 602 to 607 are cyclically repeated.
Block 602 corresponds to measuring a parameter of the rotary compressor indicating performance of the rotary compressor; in embodiment of
Block 603 corresponds to measuring a rotation speed of the rotary compressor or the rotary engine; in embodiment of
Block 604 corresponds to generating a first control signal as a function of the performance parameter and the rotation speed; in embodiment of
Block 605 corresponds to generating a second control signal as a function of the performance parameter; in embodiment of
Block 606 corresponds to generating a third control signal by selecting between the first control signal and the second control signal; in embodiment of
Block 607 corresponds to providing the third control signal to control input terminals of the rotary engine; in embodiment of
As explained previously, the second control signal may be selected based on one or more of at least the following criteria:
Other functionalities of the novel and inventive control method correspond to components of the novel and inventive control system.
This written description uses examples to disclose the invention, including the preferred embodiments, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 102017000100704 | Sep 2017 | IT | national |
