The invention relates to a method for operating a compressor, having the following steps:
feeding an intake flow into an inlet of the compressor, —compressing the intake flow by means of the compressor to give an outlet flow, —introducing at least one first part flow of the outlet flow into a bypass station as first bypass flow, —controlling the feeding-in of the first bypass flow from the bypass station into the inlet of the compressor, depending on operating parameters of the compressor, characterized by the following steps: —cooling at least one second part flow of the intake flow, —controlling the feeding-in of the cooled second part flow as second bypass flow into the inlet of the compressor, depending on operating parameters of the compressor. In addition, the invention also relates to an arrangement by means of which the method can be carried out.
Compressors, in particular turbocompressors, generally require a bypass line such that, during startup or in low-flow operating states, sufficient flow or mass flow or flow rate or volume flow can always be passed through the compressor, in order not to drop below the surge limit. In the surge state, particularly large vibrations arise in the compressor, which can result in destruction of the machine. For that reason, the surge limit—a limit line in the characteristic diagram of the compressor —should be approached no closer than a determined safety margin during operation of the compressor. In this context, a surge limiter establishes, where relevant, a critical proximity to the surge limit in the characteristic diagram of the compressor and, in the event of corresponding approximation, prompts the opening of a bypass valve in order to expand, in an outlet line of the compressor, the gas at increased pressure, such that it can be fed back in on the suction side of the compressor. In this context, the compressor generally refers to a compressor unit which delivers a process gas flow at an increased pressure. The compressor is also often termed a process stage.
A fundamental difference is drawn between cooled bypass lines and un-cooled bypass lines. The gas is drawn either directly downstream of the last stage of the compressor—that is to say upstream of an after cooler which may be present—or downstream of a cooler located downstream of the last stage—such that the bypass is either un-cooled or cooled. In addition, there is also the possibility of providing a cooler only for the bypass line, such that the outlet of the compressor is un-cooled during closed-loop control with a closed bypass line.
The un-cooled bypass is principally used for media with a pronounced Joule-Thomson effect. The throttling in the bypass valve causes the temperature of the medium to drop, such that, in the case of these gases, additional cooling of the diverted quantity is often not necessary. The magnitude is dependent on the end pressure. The suction temperature of the compressor changes in regular fashion with the opening of a bypass valve. This change has an influence on the characteristic diagram of the compressor, in particular on the first stage of the compressor. A colder and “heavier” intake flow increases the pressure ratio which can be achieved. Increasing the temperature and reducing the molecular weight have an opposite effect. As a consequence of the changed characteristic of the first stage, the calibration of the stages with respect to one another also changes. This gives rise to closed-loop control problems, such that partially guaranteed operating points are no longer possible under certain circumstances. A particularly critical problem arises from the fact that opening the bypass valve can cause the temperature of the intake flow to rise, as a consequence of which the operating point of the compressor moves closer to the surge limit, which can cause the surge limiter to further open the bypass valve. This self-reinforcing procedure leads to the entire flow of the compressor being guided into the bypass. Such positive feedback is undesirable.
Turbocompressors with bypasses which, in the event of surge, can be used to leave the critical operating state are already known from JP 2003 287 299 A and US 2011/0048046 A1.
Arrangements containing features of the preamble of the independent claims are already known from documents WO 2009/050175 A1, U.S. Pat. No. 4,921,399 A, WO 2012/007553 A1.
The invention has the object of resolving the above-described problems with the surge limiter and the opening of the bypass valve, and thus of increasing the availability of the compressor.
The inventive solution provides a method of the type mentioned in the introduction, with the additional characterizing features of the independent method claim. Also proposed is an arrangement as claimed in the independent device claim.
The subclaims which respectively refer back, contain advantageous refinements of the invention. A compressor according to the invention is also often termed a process stage, which process stage generally has multiple stages or impellers. While the invention is adapted for use in turbocompressors, use in piston engines is also possible in principle. The invention permits rapid closed-loop control of the thermodynamic parameters of the bypass flow—in particular of the temperature—so as to prevent a disadvantageous change in the corresponding thermodynamic parameters of the intake flow due to the feeding-in of the bypass flow, as is the case in the prior art. According to the invention, the first bypass flow, the second bypass flow and a mixture of the two bypass flows can be regulated such that it is possible to set a temperature which is advantageous for the intake condition of the compressor. It is thus also possible, in addition to avoiding surge, to optimize the efficiency of the overall installation with the aid of the surge limiter. Since an inventive bypass station generally sets, by means of valves, the magnitude of the first bypass flow, of the second bypass flow and of a mixture of the two bypass flows, a rapid reaction to thermal demands of the compression process is possible.
An advantageous refinement of the invention provides that the operating parameters of the compressor for controlling the feeding-in of the first bypass flow and/or of the second bypass flow can be the temperature of the intake flow upstream or downstream of the feeding-in of the first bypass flow and of the second bypass flow, or the temperature of the first bypass flow, or the temperature of the second bypass flow, or the temperature of a mixture of the first bypass flow and the second bypass flow, or the mass flow of the first bypass flow, or the mass flow of the second bypass flow, or the chemical composition of the intake flow, or the chemical composition of the first bypass flow, or the chemical composition of the second bypass flow, or a speed of rotation of the compressor, or a pressure characteristic number or a pressure ratio of the compressor.
Advantageous refinements of the invention provide that the operating parameters of the compressor for controlling the feeding-in of the first bypass flow and/or of the second bypass flow are: the temperature of the intake flow upstream of the feeding-in of the first bypass flow and of the second bypass flow and/or the temperature of the intake flow downstream of the feeding-in of the first bypass flow and of the second bypass flow and/or the temperature of the first bypass flow and/or the temperature of the second bypass flow and/or the temperature of a mixture of the first bypass flow and the second bypass flow and/or the mass flow of the first bypass flow and/or the mass flow of the second bypass flow and/or the composition of the intake flow and/or the composition of the first bypass flow and/or the composition of the second bypass flow and/or a speed of rotation (N) of the compressor and/or a pressure characteristic number or a pressure ratio of the compressor.
It is in addition also possible that the feeding-in of the first bypass flow or of the second bypass flow is controlled on the basis of a combination of the above-mentioned parameters. The chemical composition of the bypass flows are in this case particularly expedient as the basis for a closed-loop control, because the outlet flow from the compressor, after cooling, is often thermodynamically in the two-phase range and, in the event of corresponding cooling, liquid components can precipitate out such that the outlet flow can have a different chemical composition to that of the intake flow of the compressor. This difference can have a significant influence on the characteristic diagram of the compressor when feeding the bypass flow into the intake flow. If the process medium or intake flow is for example moist air or moist carbon dioxide, the bypass flow can be significantly drier than the intake flow.
Expediently, the control of the feeding-in of the first bypass flow and/or of the second bypass flow is configured such that the intake flow into the inlet of the compressor approaches a first setpoint temperature after feeding-in of the first bypass flow and/or the second bypass flow.
Corresponding direct temperature measurements of the intake flow of the compressor in the inlet can be used as a basis for this. Other possibilities emerge through the temperature measurement of the intake flow upstream of the feeding-in of the bypass flow and the measurement of the first bypass flow or of the second bypass flow or of a mixture thereof, and a thermodynamic calculation, which takes place in the control unit, of the resulting temperature in the inlet of the compressor. It is further conceivable that the first bypass flow and the second bypass flow, or a mixture of the two bypass flows, is expanded by means of a valve or other throttle prior to entry into the intake flow, and the resulting Joule-Thomson effect is taken into account by the closed-loop control algorithm of the control unit as a temperature change, such that temperature measurements upstream of this expansion valve or of this expansion throttle are sufficient to determine the temperature of the feeding-in of the bypass flow into the intake flow with sufficient precision. To that end, a state equation of the process fluid is stored in the closed-loop control.
In addition, it may be expedient to determine the mass flow of the first bypass flow and/or of the second bypass flow and/or of a mixture of the two bypass flows—for example by means of a differential pressure measurement across a throttle—and to feed this measurement value to the control unit of the bypass station, such that the sum of bypass flows fed into the intake flow leads, in dependence on their temperature and composition, to the desired thermodynamics, in particular to the desired temperature of the intake flow entering the compressor.
In essence, the purpose of the control unit is to control bypass valves for setting the first bypass flow, the second bypass flow and/or a mixture of the two bypass flows on the basis of the measured thermodynamic parameters of the various bypass flows and/or of the intake flow.
Particularly expediently, the feeding-in of the first bypass flow and/or of the second bypass flow is controlled in such a manner that the intake flow approaches a setpoint value of the product of the specific gas constant of the intake flow, the real gas factor of the intake flow and the temperature of the intake flow after feeding-in of the bypass flows. The specific gas constant of the intake flow is in this case dependent on the composition of the intake flow, while the real gas factor is dependent on the composition of the intake flow, the pressure of the intake flow and the temperature of the intake flow. The corresponding state equations for determining these thermodynamic parameters can be implemented in the control unit according to the invention.
The invention is explained in more detail below with reference to special exemplary embodiments.
In the drawings:
The arrangements shown in
A further alternative is indicated in
A further modification to the system is shown in
Number | Date | Country | Kind |
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10 2013 210 067.1 | May 2013 | DE | national |
This application is the US National Stage of International Application No. PCT/EP2014/060660 filed May 23, 2014, and claims the benefit thereof. The International Application claims the benefit of German Application No. DE 102013210067.1 filed May 29, 2013. All of the applications are incorporated by reference herein in their entirety.
Filing Document | Filing Date | Country | Kind |
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PCT/EP2014/060660 | 5/23/2014 | WO | 00 |