U.S. patent application number 10/371136 was filed with the patent office on 2003-08-28 for process for controlling a plurality of turbo engines in parallel or tandem operation.
Invention is credited to Blotenberg, Wilfried.
Application Number | 20030161731 10/371136 |
Document ID | / |
Family ID | 27675112 |
Filed Date | 2003-08-28 |
United States Patent
Application |
20030161731 |
Kind Code |
A1 |
Blotenberg, Wilfried |
August 28, 2003 |
Process for controlling a plurality of turbo engines in parallel or
tandem operation
Abstract
A plurality of turbo engines (1, 2, 3) cooperate in a station,
and each turbo engine with the drive machine (4, 5, 6) driving it
forms a machine unit, with which a machine controller (28, 29, 30)
is associated. To control these turbo engines (1, 2, 3) in parallel
or tandem operation to observe at least one process variable, which
is preset by the station and is common to all turbo engines (1, 2,
3), the preset, common process variable is set directly to each of
the machine controllers (28, 29, 30), and this preset, common
process variable is controlled exclusively via the machine
controllers (28, 29, 30) associated with the particular machine
unit.
Inventors: |
Blotenberg, Wilfried;
(Dinslaken, DE) |
Correspondence
Address: |
McGLEW AND TUTTLE, P.C.
SCARBOROUGH STATION
SCARBOROUGH
NY
10510-0827
US
|
Family ID: |
27675112 |
Appl. No.: |
10/371136 |
Filed: |
February 20, 2003 |
Current U.S.
Class: |
417/2 ;
417/53 |
Current CPC
Class: |
F04D 27/0269
20130101 |
Class at
Publication: |
417/2 ;
417/53 |
International
Class: |
F04B 041/06 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 28, 2002 |
DE |
102 08 676.1 |
Claims
What is claimed is:
1. A process for controlling a plurality of turbo engines
cooperating in a station in parallel or tandem operation to observe
at least one process variable, the process comprising: presetting
at least one process variable common to all turbo engines of the
station; forming a machine unit of each turbo engine with a drive
machine, with which a machine controller is associated; sending the
preset common process variable directly to each of the machine
controllers; and controlling the preset common process variable
based on a deviation of the preset common process variable and an
actual value associated with the variable sensed at the particular
machine unit exclusively via the machine controllers associated
with the particular machine unit.
2. A process in accordance with claim 1, wherein the final pressure
of the compressors is used as the process variable.
3. A process in accordance with claim 1, wherein the flow through
the compressors is used as the process variable.
4. A process in accordance with claim 1, wherein the suction
pressure of the compressors is used as the process variable.
5. A process in accordance with claim 1, wherein the pressure ratio
of the compressors is used as the process variable.
6. A process in accordance with claim 1, wherein the load
distribution in parallel operation is used as the process
variable.
7. A process in accordance with claim 1, wherein the load
distribution in tandem operation is used as the process
variable.
8. A process in accordance with claim 1, wherein the power of the
turbines used as drive machines is used as the process
variable.
9. A process in accordance with claim 1, wherein the inlet pressure
of the turbines used as drive machines is used as the process
variable.
10. A process in accordance with claim 1, wherein the outlet
pressure of the turbines used as drive machines is used as the
process variable.
11. A process in accordance with claim 1, wherein the tapping
pressure of the turbines used as drive machines is used as the
process variable.
12. A process in accordance with claim 1, wherein the flow through
a turbine used as a drive machine is used as the process
variable.
13. A process in accordance with claim 1, wherein the current of an
electric drive machine is used as the process variable.
14. A process in accordance with claim 1, wherein a plurality of
process variables are combined within a station.
15. A process in accordance with claim 1, wherein the output
variables of the capacity controllers are at the same ratio to one
another in order to reach a uniform load of all machines.
16. A process in accordance with claim 1, wherein the set points
for the load distribution controllers are at a fixed but not equal
ratio to each other in order to reach a predetermined, nonuniform
load of all machines.
17. A process in accordance with claim 1, wherein the factor by
which the set points of the load distribution controllers deviate
from each other is a function of a process variable in order to
reach a desired load of all machines.
18. A process in accordance with claim 17, wherein the power of the
turbine used as the drive machine is used as the influencing
process variable.
19. A process in accordance with claim 17, wherein the distance of
a process variable from a limit or any other optimization algorithm
is determined.
20. A process in accordance with claim 1, wherein the factor by
which the set points of the load distribution controllers deviate
from each other can be influenced arbitrarily in order to reach a
desired load of all machines.
21. A process in accordance with claim 1, wherein set points and
actual values are preset and measured jointly for all machine
units.
22. A process in accordance with claim 1, wherein set points and
actual values are preset and measured individually for each machine
unit.
23. A process in accordance with claim 1, wherein one deviation is
selected among the deviations of a plurality of process variables
and the other, not needed deviations are switched to zero.
24. A process in accordance with claim 1, wherein one deviation is
selected among the deviations of a plurality of process variables,
and the set point of one of the non-selected process variables is
switched to zero.
25. A process in accordance with claim 1, wherein the deviations of
all process variables are switched to zero and that the control is
performed manually.
26. A process in accordance with claim 23, wherein a machine
controller with a proportional part and an integral part is used
and the control is performed manually such that the manual
intervention acts only on the integral part.
27. A process in accordance with claim 1, wherein the deviation of
the machine controllers of the machine units, which are operated at
the upper power limit, is reduced to zero, and that the actually
effective deviation is added to the deviation of the other machine
units.
28. A process in accordance with claims 1, wherein the deviation is
switched via an extreme selection.
29. A process in accordance with claim 1, wherein the deviations
for limitations are switched to a maxima of a minimum selection and
that the deviations for a minimum limit act on a maximum
selection.
30. A process in accordance with claim 1, wherein the deviations
for different process variables are multiplied by different gain
factors.
31. A process in accordance with claim 1, wherein the adjustment
time of the controllers is adapted individually such that the
process variable that is the leading process variable is determined
from a comparison of the individual inputs of the maximum and
minimum selection with the output and the controller that is in
operation is determined from the position of changeover switches of
the controllers for the process variables, and it is determined via
a selection matrix of control functions which adjustment time shall
be effective at which controller combination.
32. A control system for a plurality of turbo engines, comprising:
a plurality of turbo engines cooperating in parallel or in tandem
and forming a turbo engine station; a machine unit formed by each
turbo engine, each machine unit including a drive machine driving
the operation of the turbo engine; a machine controller at each a
machine unit; a station input for at least one process variable to
control the turbo engines in parallel or tandem operation, the at
least one process variable being preset by the station and being in
common to all turbo engines; connections for setting the preset
common process variable directly to each of the machine controllers
with the preset common process variable being controlled
exclusively via the machine controllers associated with the
particular machine unit.
Description
FIELD OF THE INVENTION
[0001] The present invention pertains to a process for controlling
a plurality of turbo engines cooperating in a station in parallel
or tandem operation for observing at least one process variable
that is preset by the station and is common to all turbo engines,
wherein each turbo engine with the drive machine forming it forms a
machine unit, with which a machine controller is associated.
BACKGROUND OF THE INVENTION
[0002] A process for operating a plurality of turbocompressors
connected in parallel, which are provided each with a surge limit
control to prevent surge, is described in EP-B 0 132 487. The
turbocompressors are controlled jointly by load distribution
controllers and individually by a pressure controller each. The
load distribution controllers control the setting of the
compressors among each other such that there are equal distances
between the working point and the blow-off line for all
compressors. Only one of the compressors is controlled by its
pressure controller, whereas the others are adjusted by the load
distribution control.
[0003] A process for the optimized operation of a plurality of
compressors in parallel or tandem operation has been known from
EP-B 0 431 287. Using algorithms, a combination of machine
parameters in which the total shaft power of all drive machines
becomes minimal is determined here for any working point. A
higher-level master controller is used in this process.
[0004] A higher-level master controller, also called master
controller, is bound to be always necessary according to the
hitherto common state of the art in case of the tandem or parallel
connection of turbo engines with individual control devices and
individual controllers. The master controller has a higher-level
task. It determines the necessary adjusting commands for the
individual machine units from the required total capacity (desired
pressure or desired flow of all compressors). Especially in the
case of plants of an asymmetric design, the master controller
calculates different manipulated variables for the individual
machine controllers. According to the pertinent state of the art,
it is emphasized time and time again that there must be only one
controller for distributing the load among different compressors,
which controller processes only one set point and only one actual
value, because conflicts may otherwise arise in the downstream
machine controllers. Each machine unit needs an unambiguous
manipulated variable, which is coordinated with the other
manipulated variables such that no conflicts can arise. In case of
flow control, the flow may be measured at a single point only. In
case of pressure control, the pressure may likewise be measured at
a single point only. There may also be only a single set point for
the common pressure or flow controller. Observing this rule is
particularly important especially in case of use as a pressure
controller for the final pressure or the suction pressure. If each
machine unit were equipped with a pressure controller of its own,
and if the set point of the pressure and the actual value of the
pressure deviated even only slightly between the different
controllers, which may be caused even by the analog/digital
conversion of the input signals alone, the controllers of the
parallel-connected compressors would work against each other such
that one controller would slow down the machine and the other would
speed it up. The machine controllers with their downstream machines
work against each other until one of the two machines reaches the
upper or lower limit of capacity. Moreover, the master controller
is a complicated component, whose failure leads to the stoppage of
the entire plant.
SUMMARY OF THE INVENTION
[0005] The basic object of the present invention is to simplify the
control of this type, to increase the availability of the
individual controllers and to avoid colliding interactions between
the controllers.
[0006] According to the invention a process is provided for
controlling a plurality of turbo engines cooperating in a station
in parallel or tandem operation to observe at least one process
variable, which is preset by the station and is common to all turbo
engines. Each turbo engine with the drive machine forming it forms
a machine unit, with which a machine controller is associated.
[0007] A master controller affecting all turbo engines for
controlling the process variable is done away with in the process
according to the present invention by the functionality of this
process variable controller being divided among the individual
machine controllers. The algorithm for the distribution of the load
among the individual compressors, which takes place exclusively in
the master controller according to the known state of the art, is
embodied according to the present invention in every individual
machine controller. The flow, the final pressure, the suction
pressure, the pressure ratio, the temperature, the level in a tank,
the power of the drive machine or the load distribution of the
compressors can be used as the process variable individually or in
a combination. Since storage space and computing power are
available to a sufficient extent with modern hardware, there are no
restrictions in this respect. Due to the elimination of the
higher-level master controller, an existing station can be expanded
by additional machine units without problems. Only a machine unit
with a machine controller is to be added, which machine controller
contains the same control and regulation as each of the existing
machine units. No investment, operating or maintenance costs arise
due to the use of the process according to the present invention.
The elimination of the master controller is likewise unlikely to
lead to disturbances in operation in a station. Since there are no
higher-level and lower-level controllers, colliding interactions
between different controllers are eliminated. The process according
to the present invention is applicable to the parallel operation,
the tandem operation and the combined parallel and tandem operation
of the turbo engines in a station.
[0008] Further advantages of the present invention will be
mentioned in connection with the following description of exemplary
embodiments of the present invention and the state of the art,
which are shown in the drawings. The various features of novelty
which characterize the invention are pointed out with particularity
in the claims annexed to and forming a part of this disclosure. For
a better understanding of the invention, its operating advantages
and specific objects attained by its uses, reference is made to the
accompanying drawings and descriptive matter in which preferred
embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] In the drawings:
[0010] FIG. 1 is a system diagram of a control system for
compressors in parallel operation according to the state of the
art;
[0011] FIG. 2 is a system diagram of a control system in tandem
operation according to the state of the art;
[0012] FIG. 3 is a signal flow diagram for the control system
according to FIG. 1 or 2;
[0013] FIG. 4 is a system diagram of a control system for
compressors in parallel operation according to the present
invention;
[0014] FIG. 5 is a system diagram of a control system for
compressors in tandem operation according to the present
invention;
[0015] FIG. 6 is a system diagram of a system for surge limit
control according to the state of the art;
[0016] FIG. 7 is a signal flow diagram for the control system
according to FIG. 4 or 5;
[0017] FIG. 8 is a system diagram of a control system for
compressors in parallel operation according to another embodiment
of the present invention;
[0018] FIG. 9 is a system diagram of a control system for
compressors in parallel and tandem operation;
[0019] FIG. 10 is a system diagram of a control system for
compressors in parallel and tandem operation, where the control of
one of the compressors is faded in; and
[0020] FIG. 11 is a control system for compressors in parallel and
tandem operation, where the control of one of the compressors is
faded in, according to another embodiment of the present
invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] Referring to the drawings in particular, FIG. 1 shows three
compressors 1, 2, 3 in parallel operation, which are driven by a
turbine 4, 5, 6 each acting as a drive machine. One compressor each
forms a machine unit with a drive machine. The three machine units
are integrated within one station, which may in turn be part of a
pipeline system or is bound in a process. The delivery capacity of
the compressor 1, 2, 3 can be varied by varying the speed of the
turbines. As an alternative, the turbines may also be replaced with
motors with a fixed speed, and adjustable guide vanes are used with
the adjusting drives 7, 8, 9 in the compressors 1, 2, 3 or
butterfly valves are used in front of the compressors (not shown)
in this application.
[0022] The compressors 1, 2, 3 are connected by inlet lines 10, 11,
12 to a suction-side bus bar 13, which in turn has a connection to
a suction-side process 14 or to a pipeline or to a gas storage
unit. On the pressure side, the compressors 1, 2, 3 are connected
via outlet lines 15, 16, 17 to a pressure-side bus bar 18, which in
turn has a connection to a pressure-side process 19 or to a
pipeline or to a gas storage unit.
[0023] A station governor level, which presets as the set point
presetter 20 the set points for the operation of the station, is
superordinate to the entire station. The actual capacity of the
mechanical equipment, usually the final pressure or the suction
pressure of the compressor plant or the flow, is measured with a
sensor 22 and transmitted as an actual value via a signal line 23
to a master controller 24. The set point of the process variable
for the entire station is sent by the set point presetter 20 via a
signal line 21 to the machine controller 24, which calculates the
necessary load of the individual machine units according to a
preset algorithm and presets the set point for the speed or the
position of the guide vanes or the throttling fitting for the
respective machine controllers 28, 29, 30 via the signal lines 25,
26 and 27. The machine controllers 28, 29, 30 in turn set the speed
of the turbines 4, 5, 6 and the position of the butterfly valves or
suction throttles to this set point.
[0024] The master controller 24 has a higher-level task. It
determines the necessary adjusting commands for the individual
machine units from the required total capacity (desired pressure or
desired flow) of all three compressors 1, 2, 3. Especially in the
case of plants of an asymmetric design, the master controller 24
calculates different manipulated variables for the individual
machine controllers 28, 29, 30.
[0025] FIG. 2 shows the case of application for three compressors
1, 2, 3 in tandem operation. The design of this station extensively
corresponds to that of the station shown in FIG. 1 for the parallel
operation. The difference is only that the first compressor 1 is
connected to the inlet line 11 and, via the outlet line 15, to the
second compressor 2, and this is connected via the outlet line 16
and the inlet line 12 to the third compressor 3. The suction-side
bus bar 13 is not present, and the process 14 is connected directly
to the inlet line 10 acting as a suction line. The pressure-side
bus bar is likewise absent, and the outlet of the third compressor
3 is connected directly to the process 19 via the outlet line
17.
[0026] According to the known state of the art, exactly the same
statements apply to the control of compressors in tandem operation
as to the parallel operation. If the compressors 1, 2, 3 are to be
run at constant flow in tandem operation, the master controller 24
determines the speeds to which the individual machine units are to
be run to reach the desired flow. If the compressors 1, 2, 3 are
run at constant final pressure or constant pressure ratio, the
master controller 24 determines the pressure ratio that every
individual compressor 1, 2, 3 has to reach in order to reach the
required total pressure ratio. It also applies to the tandem
operation according to the general state of the art that there may
be only one master controller, which receives only one set point
and one actual value.
[0027] FIG. 3 shows a signal flow diagram for a control system for
a station with three compressors 1, 2, 3. The station set point
(flow set point or pressure set point) is sent via the signal line
21 and a converter 31 to a variance comparison unit 32. The actual
value (measured flow or pressure) reaches the same comparison unit
32 via the signal line 23 and a converter 33. The difference
between the set point and the actual value is formed in this
comparison unit and is sent to a station controller 34. The station
controller 34 adjusts its output variable until the actual value
corresponds to the set point. The output of the station controller
34 is sent to the signal lines 25, 26, 27 via percentage setters
35, 36, 37 and converters 38, 39, 40. These signal lines 25, 26, 27
connect the station controller 34 to the three unit controllers 41,
42, 43. Each unit controller 41, 42, 43 has a converter 44, 45 and
46 for the input variable and another input converter (not shown)
for the actual value of the machine, typically the speed of the
drive turbine 4, 5, 6, or the position of the inlet guide vanes in
guide vane-controlled compressors. The difference between the
actual value of the machine and the set point of the machine is
formed in the comparison units 47, 48 and 49 and is sent to the
respective unit controllers 41, 42 and 43. These in turn now adjust
the speed of the turbine 4, 5, 6 (or the position of the guide
vanes) via converters 50, 51 and 52 such that the actual value of
the machine will exactly correspond to the set point of the
machine.
[0028] The manipulated variable of the station controller 34 is
divided among the individual machine units in the percentage
setters 38, 39 and 40. The adjustment law may be linear or
nonlinear depending on the needs of the plant. If necessary, it may
be dependent on various parameters. A linear adjustment law,
according to which the turbines 4 and 6 are each to contribute 30%
of the total power and the turbine 5 shall contribute 40%, shall be
assumed for simplicity's sake. Consequently, a factor of 0.3 is set
in the percentage setters 35 and 37, and a factor of 0.4 is set in
the percentage setter 36. Should the station controller 34 call for
10% more power, the machine set point, which is sent to the turbine
4 via the signal line 25, increases by 3%, the machine set point of
turbine 5 increases by 4%, and the machine set point of turbine 6
increases by 3%.
[0029] According to FIG. 3, the elements 31 through 40 belong to
the common master controller 24, the components 44, 47, 41 and 50
belong to the machine controller 28 of turbine 4 with the
compressor 1, the components 45, 48, 42 and 51 belong to the
machine controller 29 of turbine 5 with the compressor 2, and the
components 46, 49, 43 and 52 belong to the machine controller 30 of
turbine 6 with the compressor 3.
[0030] In many applications, the machine controller usually
contains an additional control function. For example, a pressure
control circuit may be designed such that flow controllers, which
control the particular flow through the individual machines, are
subordinated to the master pressure controller. Speed controllers,
which will then control the speed, are in turn subordinated to
these flow controllers. The flow controller associated with the
machines is part of the respective unit controller 41, 42, 43 in
these applications.
[0031] Each turbocompressor needs a surge limit control, which is
part of each machine control and whose task it is to protect the
compressor from operating in the unstable working range. The
operation in the unstable working range is called compressor surge.
FIG. 6 shows a block diagram of a typical surge limit control for a
compressor with variable suction pressure. A compressor 53 is
equipped with a suction line 54 and a delivery line 55. A blow-by
valve 56 in a blow-by line 57 may be opened in a controlled manner
when needed, thus increasing the flow through the compressor when
the gas consumption by the process is smaller than the minimum
allowable compressor flow. A blow-by valve 56, also called surge
limit control valve, is actuated via a control line 58 by the surge
limiter 59, whose input variables are the inlet pressure measured
with the sensor 60, the inlet flow measured with the sensor 61, the
final pressure measured with the sensor 62, and the inlet
temperature measured with the sensor 63. Since the surge limiter 59
is usually embodied within the same controller hardware as the
machine controller (it is an essential part of the machine
controller), signals such as compressor flow as well as pressure
before and after the compressor are available within the machine
controller and can thus be also used for the load distribution
controller and the capacity controller.
[0032] FIGS. 4 and 5 show the control process according to the
present invention for three compressors 1, 2, 3 integrated to form
a station in parallel operation and in tandem operation. As was
already described in connection with FIGS. 1 and 2, the compressors
1, 2 and 3 are coupled with turbines 4, 5 and 6 as drive machines
and are driven by these. The delivery capacity of the compressor 1,
2, 3 can be varied by varying the speed of the turbine. As an
alternative, the drive turbines may also be replaced with motors
with a fixed speed, and adjustable guide vanes with the adjusting
drives 7, 8, 9 are used in the compressors 1, 2, 3 or butterfly
valves are used in front of the compressors (not shown) in this
case of application.
[0033] The compressors 1, 2, 3 shown in FIG. 4 are connected by the
inlet lines 10, 11, 12 to the suction-side bus bar 13, which in
turn has a connection to the suction-side process 14 or to a
pipeline or to a gas storage unit. On the pressure side, the
compressors 1, 2, 3 are connected via the outlet lines 15, 16, 17
to the pressure-side bus bar 18, which in turn has a connection to
a pressure-side process 19 or to a pipeline or to a gas storage
unit. According to FIG. 5, the first compressor 1 of the
compressors 1, 2, 3 connected in tandem is connected to the inlet
line 11 and, via the outlet line 15, to the second compressor 2.
This is connected to the third compressor 3 via the outlet line 16
and the inlet line 12. The process 14 is directly connected to the
suction line 10, and the outlet of the third compressor 3 is
directly connected to the process 19 via the outlet line 17.
[0034] The master controller is eliminated in the control process
according to the present invention. The total set point is sent,
instead, to each of the machine controllers 28, 29, 30 from the set
point presetter 20 of the station directly via the signal line 21.
The actual value is likewise sent directly to each machine
controller 28, 29, 30 via the signal line 23, so that each machine
controller 28, 29, 30 can perform the necessary calculations on its
own and can adjust the downstream control units just as if a
common, higher-level master controller were used.
[0035] FIG. 7 shows the signal flow diagram for a parallel or
tandem connection of three compressors 1, 2, 3 according to the
present invention. The station set point of the set point presetter
20 is divided, sent in parallel to three converters 64, 65, 66, and
passed on to the comparison units 70, 71, 72. The actual value from
the signal line 23 is sent to three converters 67, 68, 69 and
passed on to the comparison units 70, 71, 72. In the percentage
setters 35, 36 and 37, which are arranged between the converters
64, 65, 66, the set point is divided among the individual machine
units, comprising the compressors 1, 2, 3 and the turbines 4, 5, 6.
The difference between the set point and the actual value is formed
in the comparison units 70, 71, 72 and is sent to an amplifier 73,
74, 75 each to the controllers 76, 77, 78 of the units. The unit
controllers 76, 77, 78 adjust in turn the turbine speed or the
guide vanes of the respective compressor 1, 2 or 3 via the
converters 79, 80 and 81. The converters 67, 64, the percentage
setter 35, the comparison unit 70, the amplifier 73, the unit
controller 76, and the converter 79 are common parts of the machine
controller 28, which is associated with the machine unit, which is
formed by the turbine 4 and the compressor 1. The converters 68,
65, the percentage setter 36, the comparison unit 71, the amplifier
74, the unit controller 77, and the converter 80 are common parts
of the machine controller 29, which is associated with the machine
unit, which is formed by the turbine 5 and the compressor 2. The
converters 69, 66, the percentage setter 37, the comparison unit
72, the amplifier 75, the unit controller 78, and the converter 81
are common parts of the machine controller 30, which is associated
with the machine unit, which is formed by the turbine 5 and the
compressor 3.
[0036] The actual value and the set point of the process variable
may be any variables as inputs of the converters 67 through 66.
They are frequently the flow through the compressors, the pressure
before or after the station, but they may also be the load
distribution of the compressors in tandem or parallel operation.
The pressure ratio of the entire station or a temperature or a
liquid level in a tank is also conceivable.
[0037] The essential difference between the state of the art
according to FIG. 3 and the present invention according to FIG. 7
is that the master controller 24 shown in FIG. 3 with the elements
31 through 40 may be eliminated altogether, and its function is
divided among the machine controllers 28, 29, 30, which are present
anyway. The elements 31 through 34 have been eliminated without
replacement and are replaced with three elements 64, 70 and 76; 65,
71 and 77 as well as 66, 72 and 78 each. The converters 38 through
46 are eliminated. However, it is much more essential that the
functionalities being shown are auxiliary functions embodied purely
in software in the machine controllers which are already present
anyway.
[0038] The advantages of the solution according to the present
invention over the state of the art shall be described below based
on an example by comparing the state of the art with the present
invention. Three compressors 1, 2, 3 according to FIG. 2 are
operated with a control system according to FIG. 3 in tandem
operation (state of the art). Each of the compressors 1, 2, 3 shall
operate at the beginning of the control process with a pressure
ratio of 3. The controlled variable shall be the pressure in the
pressure-side bus bar 19. The set point shall be 99 bar and the
actual value 90 bar. The compressors 1 through 3 shall contribute
one third to the total pressure ratio each. The comparison unit 32
detects a deviation of 9 bar and transmits this to the station
controller 34. This station controller 34 increases its power by a
percentage that corresponds to an increase in the pressure ratio by
10% from 90 bar to 99 bar, and an increase in the output signal
from 45% to 50% shall be assumed here as an example. Each of the
three machine units increases its power by the same extent until
the measured actual value corresponds to the set point.
[0039] The function will be the following in a system according to
the present invention according to FIG. 7. The actual value on the
signal line 23 is 90 bar and the set point on the signal line 21 is
99 bar. Via the converters 67 through 69, all three unit
controllers (capacity controllers) 76, 77 and 78 receive the same
deviation of 9 bar. Each of the three unit controllers 76, 77 and
78 reacts in exactly the same way as the master controller 24 in
FIG. 3. Each of the three machine units increases its power by the
same extent until the measured actual value corresponds to the set
point.
[0040] The final pressure is always controlled in the compressors
in tandem operation with variable suction pressure such that the
controlled variable is the pressure ratio over the entire station,
i.e., the tandem connection of all compressors. The ratio of the
pressure ratios of the individual compressors is also the variable
to be controlled for the unit controllers in the case of
compressors in tandem operation, which are run at constant
flow.
[0041] It must be assumed according to the state of the art that
problems may arise if the input controllers for the set point and
the actual value of the individual unit controllers have different
drifts or determine different numerical values for the set point or
the actual value of the individual machine controllers due to the
incremental analog/digital conversion. A deviation of the total
delivery capacity of all compressors from the required power will
arise in this case. According to the state of the art, this
drawback is considered to be reason for the absolute need for a
higher-level master controller. This drawback was pointed out
already in the introduction in connection with the use of three
individual pressure controllers.
[0042] This problem is solved according to the present invention by
the use of a load distribution controller. This load distribution
controller acts in addition to the unit controller 76 through 78
(capacity controller) and uses the same machine controller 28, 29,
30. Only the function of the load distribution controller will be
described below with the use of the prior-art functional groups.
The combination of capacity controller and load distribution
controller will be subsequently described. This load distribution
controller has exactly the same design as the unit controller 76
through 78 (capacity controller) according to FIG. 7. However, the
set point of a load distribution control is the set point of the
load percentage of the compressor and the actual value is the
current load. The distance between the working point and the
stability limit is usually the controlled variable in the case of
compressors in parallel operation, and the pressure ratio is
usually the controlled variable in compressors in tandem operation.
In the case of a load distribution control for tandem operation
according to FIG. 7, the actual value for each machine unit is the
particular pressure ratio of the particular compressor, and the set
point is the set point of the percentage contributed by the
particular compressor to the total pressure ratio. The actual value
of the pressure ratio can be determined by dividing the final
pressure obtained for the surge limit control by the suction
pressure measured for the surge limit control. The total pressure
ratio is calculated by dividing the station's outlet pressure by
the station's inlet pressure. All compressors are usually operated
with the same pressure ratio in tandem operation, so that the set
point is one third of the total station pressure ratio for every
individual load distribution controller. Should the ratio be
different for individual machines, a scaling factor may be taken
into account within the set point formation. Should the load
percentage of the individual machine units depend on additional
process variables, variable scaling factors may be introduced.
[0043] The load distribution algorithm calculates a partial load
for each of the compressors and, in the case of compressors in
parallel operation, e.g., a preset percentage of the total flow. In
tandem operation, the algorithm presets, e.g., a fixed, preset
percentage of the total required pressure ratio. The unit
controller of each compressor now adjusts the individual machine
unit to this value.
[0044] If the actual value processed in the controller deviates
from the actual value at which the compressor is actually operating
in one of the three unit controllers due to a measurement error or
a converter error, all load distribution controllers detect this
alleged deviation from the set point of the load distribution, and
control this deviation by adjusting all three compressors such that
the load distribution controllers will see a uniform load
distribution. If the converter 67 delivers, e.g., a value that is
too high by 10% for the actual value of unit 1, each of the unit
controllers (load distribution controllers) associated with each
compressor notices this deviation and adjusts its downstream
control unit by the preset ratio. In the equalized state, the
machine unit 1 operates in a stable manner with a load that is too
low by 6.66%, and the machine units 2 and 3 operate in a stable
manner with a load that is too high by 3.33%. The consequence of
this is an imbalance of all three compressors. However, this is
smaller than the individual error of the machine unit in
question.
[0045] The system even operates robustly when the set point and the
actual value for each machine unit are determined separately and
there are greater deviations between the set points and the actual
values of the individual controllers as a result. This represents
another advantage of the process according to the present
invention. A disturbance in a common actual value measurement
affects the operation of all machine units in the station. This
also applies to a disturbance in the set point setter. The actual
value measurement can be associated with every individual machine
unit according to this process. FIG. 8 shows, e.g., an arrangement
with individual actual value measurement. Instead of a common
actual value measurement in the pressure-side bus bar 18, the
actual value (final pressure after the compressors, before the
compressors or flow through the compressors) can be measured in the
respective outlet lines 15, 16 and 17 with sensors, which are
connected to converters 90, 91 and 92. The individual actual values
are then sent via the converters 69, 64 and 65 to the comparison
units 70, 71 and 72 according to FIG. 7 and are sent to the machine
controllers 28, 29, 30. It is also possible to preset the set point
individually. Thus, all necessary functionalities are now
individually associated with each machine unit. Conversion errors
of the set point and actual value determination are compensated in
the same manner with the use of the control process according to
the present invention as capacity controllers (flow controllers,
pressure controllers).
[0046] The advantage of such an arrangement is, on the one hand,
that each of the actual value measurements can be associated with
one machine unit, and the converters can be supplied with auxiliary
energy from the control box of the respective associated machine
unit. Furthermore, the corresponding units of the other machine
units are active even in case of total failure of set point or
actual value converters of one machine unit, and they reduce as a
result the negative effects of this failure. It is also possible to
form the set point and the actual value separately for each machine
unit. It is advantageous that there are no common components any
more and only identical machine systems without higher-level system
parts are used.
[0047] The above-described case shall be mentioned as an example
with the use of the unit controller as a pressure controller. The
desired final pressure is 99 bar. The compressors 1 through 3 shall
contribute each one third of the total power currently needed. Each
turbine 4 through 6 shall contribute for this 20% of the total
available power each. Now let the actual value measurement fail in
the delivery line 17 of the compressor 3 and furnish an actual
value of 0 bar. The turbine 6 runs up to its maximum power because
of the missing actual value and contributes 33% of the total power
as a result. The pressure rises as a result in the pressure-side
bus bar 18 and so does consequently the final pressure of all
compressors 1, 2 and 3. The two intact measuring means in the
compressor outlet lines 15 and 16 of the compressors 1 and 2 notice
this increase and reduce the power of the compressors 1 and 2 to
the extent that the final pressure of all three compressors 1, 2, 3
will again correspond to the set point of 99 bar. A station that is
controlled according to the state of the art by means of a master
controller brings all compressors to 100% power in this case of
operation. The same thing happens in case of failure of a set
point. A master controller brings all machines to zero and the
entire station ceases to offer any power any longer. In case of a
control according to the present invention, the power of the
compressor whose set point drops to zero will drop the zero, the
other two compressor controls notice this deviation and eliminate
it by increasing their own power, so that the operation of the
station as an entirety is not affected.
[0048] The advantage of the solution according to the present
invention is obvious; the master controller can be eliminated, as a
result of which costs are saved and the availability is increased.
Moreover, this process offers the advantage that a common actual
value measurement and a common set point generation are eliminated
and both the actual value measurement and the set point setting are
associated with each compressor unit. Furthermore, it is very
essential that the availability is increased and the entire plant
is less liable to fault.
[0049] Some variants and embodiments for the distribution of the
load among the individual compressors will be described below.
[0050] It is necessary in many applications to have the possibility
of affecting the percentage contributed by the individual machine
units to the total load. In some cases, the personnel presetting
the operating characteristics of the station may intentionally
affect the load percentage of individual machine units. If, e.g., a
machine unit shall be put out of operation, it is meaningful to
reduce the percentage contributed by that unit to the total load.
This may happen by adding to the summing unit 70, 71 or 72 a fixed
value to offset the equilibrium. The result of this is that the
load distribution controller will no longer load all machine units
uniformly, but differently. An example is as follows: Each of the
three compressors operates with one third of the total pressure
ratio in tandem operation without this offset. If an offset
variable of minus 20% is now added to the summing unit 71 (for the
middle compressor), the three machine controllers will make
adjustments until the pressure ratio of the middle compressor
becomes exactly 20% smaller than that of the other two.
[0051] Another possibility is to preset the set point individually
and differently for the load distribution for each of the
compressors. This may be necessary, e.g., when there is an
asymmetry in the machine units. For example, machine units of
various sizes may operate together in one station. The factor must
be adapted to the size of the machine units in this case.
[0052] Another possibility is for an optimizing algorithm to
determine a combination of the machine load of the individual
machine units that is optimal for the particular working point.
Such optimizing algorithms are described, e.g., in EP-B 0 431 287,
which was mentioned in the introduction. If the present invention
is applied to this prior-art process, a higher-level computer and
master controller may be eliminated even in the prior-art process
if the algorithm is programmed in each machine controller.
[0053] Another need for interfering with the selection of the load
distribution among the individual machine units may also be
encountered, e.g., when a limit of the permissible operating range
is reached at one of the components. If, e.g., gas turbines of
various designs are used as drive machines for compressors, one of
the gas turbines may have reached, e.g., the maximum exhaust gas
temperature, while the other gas turbines still have reserves for
adjustment. The present invention offers two approaches to solving
this problem. One approach is that the factor for the splitting of
the load among the machine units that are not at the limit is
changed such that the factors are increased at the ratio of the
machine units that are no longer available. The factor for the
machine operating at the limit is set to zero as long as the
machine is being operated at the limit. However, the process
according to the present invention also compensates this process
without this intervention. Since the unit being operated at the
limit does not offer any power any longer, the capacity controller
determines a deviation from the set point and increases the power
of the other unit such that the process variable to be controlled
will exactly correspond to the set point. The control unit and the
point of intervention for all these offsetting factors are the
percentage setters 35 through 37 and the addition of a fixed value
to the summing units 70 through 72.
[0054] FIGS. 9 through 11 show three parallel-connected compressors
of the low-pressure stage (LP-A, LP-B, LP-C) with three
parallel-connected compressors of the medium-pressure stages (MP-A,
MP-B, MP-C) and three parallel-connected compressors of the
high-pressure stage (HP-A, HP-B, HP-C) connected in tandem. The
control system for the compressor MP-B is enlarged in FIGS. 10 and
11. The usual compressors are equipped with an identical control
system. Each compressor is provided with a surge limit control,
which was already described in connection with FIG. 6. Furthermore,
a machine controller 85 is associated with each machine unit
comprising a compressor and a turbine.
[0055] A sensor for determining the actual value of the final
pressure of the station is arranged in the pressure-side bus bar
18. The measured value is sent to a converter 86, which is
connected to a comparison unit 88 via a signal line 87. In
addition, the set point of the final pressure is sent to this
comparison unit 88 by the set point presetter.
[0056] Furthermore, a sensor for determining the actual value of
the flow of the station is arranged in the pressure-side bus bar
18. The measured value is sent to a converter 89, which is
connected to a comparison unit 91 via a signal line 90. In
addition, the set point of the flow is sent to this comparison unit
91 by the set point presetter.
[0057] A sensor for determining the actual value of the suction
pressure of the station is arranged in the suction-side bus bar 13.
The measured value is sent to a converter 92, which is connected to
a comparison unit 94 via a signal line 93. In addition, the set
point of the suction pressure is sent to this comparison unit 94 by
the set point presetter.
[0058] The signal line 93 of the suction pressure and the signal
line 87 of the final pressure are led to a computing site 95, in
which the total pressure ratio is calculated. The pressure ratio
may be additionally rated with a fixed factor or even a factor that
depends on other variables. The factor is 1/3 in the first
approach, i.e., all three compressors are loaded equally. A signal
line 96, which is led to a computing site 97, is branched off after
the converter 62 for the final pressure of the compressor MP-B. A
signal line 98, which is likewise led to a computing site 97, is
branched off after the converter 61 for the suction pressure of the
compressor MP-B. The pressure ratio of an individual compressor is
determined in the computing site 97. The computing sites 95 and 97
are connected to a comparison unit 99, in which the individual
pressure ratio of this compressor MP-B is compared with its
percentage set point relative to the total pressure ratio (which is
rated with a factor).
[0059] A signal line 100 is led from the surge limiter 59 to a
computing site 101. The signal line 100 carries a signal containing
the distance of the working point of an individual compressor. In
addition, the corresponding signals of the other parallel-connected
compressors are sent to the computing site 101. The mean value of
the distance of the working points is determined in the computing
site 101. The mean value of the distances is compared with the
individual value of a compressor in a comparison unit 102. The
comparison units 88, 91, 94 are connected to a summing unit 104 via
signal lines, in which a changeover switch 103 each is arranged.
The comparison units 99, 102 are connected to a summing unit 106
via signal lines, in which a changeover switch 105 each is
arranged. The summing units 104 are also connected to the summing
unit 106.
[0060] Via a signal line 107, in which a manual intervention means
108 is arranged, the summing units 104, 106 are connected to the
machine controller 85, which belongs to a machine unit and performs
the functions of a capacity, final pressure, suction pressure, flow
and load distribution controller.
[0061] The control system shown in FIG. 11 also contains
additionally a maximum selection means 109 and a minimum selection
means 110 in order to limit the speed and the load of the drive
machine or other variables.
[0062] In the control system being shown for the tandem or parallel
operation, the capacity control and the load distribution control
of the station are performed by a single machine controller each
which is associated with each machine unit. Deviations for the
capacity control, the load distribution control in parallel
operation and the load distribution control in tandem operation are
formed by the machine controller. Three different capacity control
algorithms (flow control, final pressure control after the
high-pressure compressor and suction pressure control before the
low-pressure compressor) can be selected in this control system.
Since the capacity controller can control only one variable, the
other two deviations of the capacity control are switched to zero
via the switches 103. A mutual interlocking is meaningful here. If,
e.g., the flow control shall be active, the deviation for the
suction pressure control and the final pressure control is switched
to zero. As an alternative, the set point for the non-active
controller may also be switched to the actual value. This also
causes the deviation to become zero.
[0063] The same thing happens if one of the load distribution
controllers is to be deactivated. The corresponding deviation is
simply switched to zero. This can be done in an elegant manner by
switching the optimizing variable (actual value of the load
distribution) to the set point. The same thing also happens when a
compressor is out of operation. The load distribution controllers
of the other compressors simply assume that the compressors that
are out of operation are optimized and therefore do not affect the
load distribution among the other compressors.
[0064] It is also possible to operate the machines exclusively by
manual operation. All deviations are switched to zero for this
purpose, i.e., all controllers are switched off. The manual
intervention means shown in FIGS. 10 and 11 can be used to impose
an artificial deviation as an actuating variable in a manually
controlled manner. The particular machine controller follows this
difference as long as the variable is present. Since the controller
usually also has an integral behavior (PI--proportional, integral
or PID--proportional, integral, differential controller), the
integral part of the controller responds to this fixed deviation in
the input by continuously adjusting the output. In a special
embodiment, this manual adjustment can act only on the integral
part of the controller, so that the proportional (P) and the
differential percentage (D) do not respond to this manual
intervention. As an alternative, the manual adjustment may also be
performed by switching the controller 85 to "Manual."
[0065] An example shall be described below for illustration. The
compressors in tandem are called the low-pressure (LP) compressor,
medium-pressure (MP) compressor and high-pressure compressor (HP).
The parallel-connected compressors are called A, B, C. It shall be
assumed that the plant is in the flow control mode and all
compressors are in operation.
[0066] The flow set point shall be 2% greater in parallel operation
than the actual value, and compressor LP-A shall deliver exactly
1/3 of the total mass flow, compressor LP-B 5% too little, and
compressor LP-C 5% too much. Compressor MP-A and compressor MP-B
shall deliver 30% of the mass flow and compressor MP-C shall
deliver 40%. Each of the HP compressors shall deliver an equal mass
flow.
[0067] In tandem operation, compressor LP-A shall be loaded 2% too
low, compressor MP-A shall be loaded correctly, and compressor HP-A
shall be loaded 2% too high. Compressor LP-B is loaded correctly,
compressor MP-B is loaded 3% too high, and compressor HP-B 3% too
low. Compressor LP-C shall be loaded at a rate of 29%, MP-C at 36%,
and HP-C at 35%.
[0068] The following deviations become established on the summing
units:
1 Summing unit of compressor MP-B HP-A HP-B HP-C Capacity +2 +2 +2
Parallel +2 0 -2 Tandem -2 +3 -1.7 MP-A MP-B MP-C Capacity (104) +2
+2 +2 Parallel (102) +3.3 +3.3 -6.6 Tandem (99) 0 -3 -3.3 LP-A LP-B
LP-C Capacity +2 +2 +2 Parallel 0 0 0 Tandem +2 0 +5.1
[0069] The control algorithm now forms the resulting deviation
before the controllers. The following is obtained from this:
2 HP-A HP-B HP-C Capacity +2 +2 +2 Parallel +2 0 -2 Tandem -2 +3
-1.7 Sum +2 +5 -1.7 Capacity +2 +2 +2 Parallel +3.3 +3.3 -6.6
Tandem 0 -3 -3.3 Sum +5.3 +2.3 -7.9 Capacity +2 +2 +2 Parallel 0 0
0 Tandem +2 0 +5.1 Sum +4 +2 +7.1
[0070] Despite the sometimes conflicting requirements of the
individual control tasks (the capacity controller requires an
increase in power, the load distribution controller a reduction),
each machine controller receives an unambiguous adjusting command
in the necessary direction in order to reach the optimum. An
interaction between the different requirements is ruled out by
design.
[0071] In another embodiment, additional algorithms may be added as
well. The drive machines of one or more compressors may reach,
e.g., a power limit. This can be additionally processed in the
algorithm such that the deviation of the machine controllers of the
drive machines, which are being operated at the limit, are brought
to zero (as in manual operation). These drive machines will then
not participate in a further power increase any longer. To
compensate this effect, the difference between the optimal
adjusting difference according to the above table and the actual
effective difference can be added to the deviation of the other
parallel and tandem compressors. This intervention is thus
optimally compensated as well. The process also functions, of
course, for a plurality of limiting controllers per machine
unit.
[0072] In another embodiment, the limiting controllers may be
switched, as is shown in FIG. 11, via an extreme value selection
means (maximum selection or minimum selection means). In addition
to the above-described deviations, deviations for the distances of
the working points from the limits are formed, e.g., from the
maximum speed and the minimum speed in FIG. 11. In addition, the
formation of another deviation each for a maximum limitation and a
minimum limitation are shown. The deviations for limitations to
maxima are switched to a minimum selection, and the deviations for
a minimum limit act on a maximum selection. The effective deviation
for the machine controller is thus either the deviation according
to the above algorithm or the distance of the working point from
the limit when this distance is shorter. When a limit is exceeded,
the output of the max/min selection means 109/110 also always
controls the machine unit in case of conflicting requirements of
capacity or load distribution controllers primarily such that the
limit is not exceeded in steady-state operation.
[0073] According to the above example, the power of compressor LP-C
shall be increased by a deviation of 6.3%. However, the drive
turbine shall be 3% below the maximum operating speed. The
effective deviation is thus limited to 3%. As soon as the turbine
has reached the maximum operating speed, the deviation of the speed
limiting control becomes zero and prevents any positive deviation
on the machine controller via the minimum selection. Only negative
deviations in the direction of a speed reduction can occur. When
the maximum speed is exceeded, the controller of the unit reduces
the speed.
[0074] It may be occasionally necessary for the individual control
circuits (pressure controller, flow controller, load distribution
controller in tandem, load distribution in parallel) to be set to
different control parameters, because the path time behavior of the
control system is different for the individual controlled
variables. This can be achieved in a simple manner by imposing
different gain factors on the particular deviations. If, e.g., the
deviation of the pressure controller is multiplied by a factor of
1, the deviation of the flow controller by a factor of 2, and that
of the load distribution controller by a factor of 3, this causes
the circuit gain of the load distribution controller to become 3
times that of the pressure controller.
[0075] If the controller adjustment time is to be adapted
individually, this can be achieved in a simple manner. The variable
that is the leading variable can be identified from a comparison of
the individual inputs of the maximum and minimum selection with the
output. The position of the changeover switch for the deviations of
the capacity controllers and the load distribution controllers
makes it possible to determine which of these controllers is in
operation. A selection matrix can now determine which controller
adjustment time shall be effective at which controller combination.
The controller time constant effective in the machine controller
can now be accurately adjusted adaptively as is required by the
selection matrix.
[0076] FIG. 11 shows an application with a total of nine control
circuits. If such a system were composed of nine individual
controllers according to the state of the art, extensive
adjustments and mutual interlocking, which would prevent individual
non-active controllers from running into saturation, would be
necessary. Furthermore, there is a risk that the nine controllers
will mutually dynamically affect each other. All these drawbacks
are circumvented according to the present invention. There is only
one machine controller per machine unit. Any adjustment can be
eliminated, and an interaction between controllers cannot occur,
either. The machine controllers of the other compressors cannot
mutually affect each other, because all machine controllers are set
to the same parameters for the same controlled variables. Since all
load distribution controllers are optimized with the same
parameters, they have the same time characteristic. Consequently,
it cannot happen that individual machines run in different
directions and consequently against each other.
[0077] While specific embodiments of the invention have been shown
and described in detail to illustrate the application of the
principles of the invention, it will be understood that the
invention may be embodied otherwise without departing from such
principles.
* * * * *