CN110307144B - Method for analyzing, monitoring, optimizing and/or comparing energy efficiency in a multi-compressor system - Google Patents

Method for analyzing, monitoring, optimizing and/or comparing energy efficiency in a multi-compressor system Download PDF

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CN110307144B
CN110307144B CN201810231363.4A CN201810231363A CN110307144B CN 110307144 B CN110307144 B CN 110307144B CN 201810231363 A CN201810231363 A CN 201810231363A CN 110307144 B CN110307144 B CN 110307144B
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compressor
energy consumption
specific energy
flow
ideal
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CN110307144A (en
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克里斯蒂安·麦瑞姆
安德斯·肖格伦
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Ensemble Co ltd
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Ensemble Co ltd
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Priority to EP19713392.9A priority patent/EP3768979B1/en
Priority to US16/982,534 priority patent/US11841025B2/en
Priority to PCT/EP2019/056813 priority patent/WO2019180003A1/en
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B41/00—Pumping installations or systems specially adapted for elastic fluids
    • F04B41/06—Combinations of two or more pumps
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
    • F04B49/06—Control using electricity
    • F04B49/065—Control using electricity and making use of computers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B51/00—Testing machines, pumps, or pumping installations

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Computer Hardware Design (AREA)
  • Control Of Positive-Displacement Pumps (AREA)
  • Control Of Positive-Displacement Air Blowers (AREA)

Abstract

The present invention provides a method for analyzing, monitoring, optimizing and/or comparing the energy per mass or volume of compressed gas (specific energy consumption) for generating a common output flow in a multiple compressor system, the method comprising: -collecting measurement data of the common output flow and energy/power usage and calculating specific energy consumption in the multi-compressor system, -identifying which data points of the measured specific energy consumption pertaining to a certain compressor or compressor combination in the multi-compressor system and/or to an operation mode of the multi-compressor system; and-plotting data points of measured specific energy consumption attached to a specific compressor or compressor combination in a multi-compressor system and/or an operation mode of a multi-compressor system and marking the attachment of the data points to the specific compressor or compressor combination and/or operation mode.

Description

Method for analyzing, monitoring, optimizing and/or comparing energy efficiency in a multi-compressor system
Technical Field
The present invention relates to a method for analyzing, monitoring, optimizing and/or comparing the energy (specific energy consumption) per unit mass or volume of compressed gas for generating a common output flow in a multiple compressor system.
Background
Multiple compressor systems are used in a variety of industrial applications. Methods of using such compressors and methods for controlling them are disclosed in several documents. As an example, a method of optimizing the operation of two or more compressors in parallel or in series is disclosed in US 5108263. The method aims at shifting the operating points of each pair of compressors incrementally with respect to each other without affecting the overall operating parameters. The effect of the displacement on the total constraint is monitored and when a change occurs along the optimization direction, movement continues in the same direction. Otherwise, the pressure of the displacement of the operating point will be reversed. The program gradually shifts the compressor to the optimum combination of operating points.
Secondly, US7676283 discloses a method for controlling a compressor installation with at least two compressor units, which method comprises calculating a new switching configuration from a current switching configuration of the compressor units using an optimization calculation.
Furthermore, a method and a device for load balancing between a plurality of compressors are disclosed in EP 0769624. This method implies that the surge parameter S varies in the same direction with the rotational speed during the balancing. Load balancing control involves balancing pressure ratio, speed, or power when the compressor is operating far from surge. Then, when surge is approached, all compressors are controlled so that they arrive at the surge control line at the same time.
Furthermore, in other patent documents, such as US6394120, there are several other methods of controlling a multiple compressor system.
Analyzing existing compressed air systems or preparing for modifications and designing the system from scratch with the aim of optimizing energy use can present a number of difficulties. Compressed air systems consist of a multitude of different components installed by a number of different suppliers, even of the same type and the same compressor, the brands of which vary. Compressor manufacturers rarely provide detailed information on similar parameters, such as design or performance curves, thus making these tasks more difficult.
Compressors are designed for different optimum pressures, and it is not uncommon for a single multi-compressor system to include compressors of different types, tuning methods, manufacturers, and design pressures.
Disclosure of Invention
The present invention relates to a method for analyzing, monitoring, optimizing and/or comparing the energy (specific energy consumption) per unit mass or volume of compressed gas for generating a common output flow in a multiple compressor system. The method includes plotting and visualizing actual data to enable a user to analyze system operation and energy efficiency for optimization purposes.
The above object is achieved by a method for analyzing, monitoring, optimizing and/or comparing the energy (specific energy consumption) per unit mass or volume of compressed gas for generating a common output flow in a multiple compressor system, the method comprising:
-collecting measurement data of the common output flow and energy/power usage and calculating specific energy consumption in a multi-compressor system,
-identifying which data points of measured specific energy consumption pertaining to a certain compressor or compressor combination in a multi-compressor system and/or an operation mode of a multi-compressor system; and is
-plotting data points of measured specific energy consumption attached to a specific compressor or compressor combination in a multi-compressor system and/or an operation mode of a multi-compressor system, and marking said data points as attached to the specific compressor or compressor combination and/or operation mode.
According to one embodiment of the invention, data points are plotted in a chart of specific energy consumption versus common output flow. Furthermore, the method according to the invention may comprise the association of theoretical curves and/or measured data points in any graph to different compressor combinations, operation modes and/or transitions between different operation modes or compressor combinations, and wherein these associations are visualized by markers, such as foreground or background colors, symbols, separation into different sub-graphs or similar markers, in order to be able to analyze the effect of transitions and operation combinations in a multi-compressor system. These and further alternatives are discussed further below in conjunction with the description of the figures.
Detailed description of the invention
Other embodiments of the invention are given below. According to one embodiment of the invention, the method further comprises the steps of:
-constructing from the first compressor an ideal specific energy consumption curve in the first compressor as a function of the output flow of the first compressor; and is
-calculating from the first compressor and the second compressor a combined desired specific energy consumption curve in the first compressor and the second compressor as a function of the combined output flow of the first compressor and the second compressor,
and wherein the method comprises structuring the calculated data to visualize it in an ideal specific energy consumption curve for analysis, monitoring, optimization and/or comparison with corresponding measured data of the multiple compressor system.
From the above it will be appreciated that a multiple compressor system according to the invention comprises at least two compressors, but may of course comprise a plurality of compressors. In this case, it should also be noted that if the expressions "first" and "second" and of course "third" etc. are used, they should not be regarded as a specific order in the multi-compressor system, but as hypothetical numbers for distinguishing different compressors in the multi-compressor system. Thus, for example, the third compressor in a particular multi-compressor system may be the smallest compressor in the system. Thus, the numbering is only a hypothetical number and does not indicate a particular order in the system with respect to location, size, or other factors. The fact that the invention can be used to understand the optimal sequence of operation for a particular multi-compressor system means that it gives advice on which compressor should be put into production first, which compressor should be used in conjunction with the first, or in a system comprising even more compressors, using any kind of combination, e.g. second plus fourth, or second plus third plus fourth, etc. Furthermore, the type of compressor involved may be of any type, in fact also a specific pump, such as a pump or a system with a spill valve or an overpressure valve and which is controlled on demand, however, the method according to the invention is particularly directed to gas compressors, for example air compressors.
The present invention has several advantages. Most compressor systems are incorrectly sized. Moreover, the regulation of multiple compressor systems is often far from optimal. These aspects present several problems that are solved or at least minimized by the introduction of the method according to the invention. The method provides visualization of measured data of a multi-compressor system and thus provides the user with the possibility to modify and optimize the system and its operation. The problems mentioned above and visualized according to the invention are systems and their events where the adjustment is not operating as intended, the system is incorrectly designed and its dimensions, the control clearances etc., and how e.g. the miscalculated actual common output flow should match the best mode of compressor combination and operation mode, the latter usually meaning that too many compressors and various disadvantageous compressor combinations are used.
Furthermore, the method according to the invention makes it possible to simulate and optimize a multi-compressor system with great accuracy based on a few parameters, even when there are pressure variations in the system. Manufacturers typically express the single efficiency performance number of their compressors as a specific energy consumption at the optimum design point (ideal flow rate) for the compressor at a specific fixed pressure. Together with the motor name plate nominal value of the motor power (usually in kW or hp) and the knowledge about the type of regulation method used for a particular compressor, with these parameters it is sufficient to create a specific energy characteristic curve for the compressor by very simple calculations, since from the available reference data the optimal design point, the regulation flow range, the ideal specific energy consumption and the maximum possible flow at a particular pressure can be deduced.
In this context, the expression "energy used to produce a unit mass or volume of compressed gas" or "specific energy consumption" is sometimes also referred to in the compressor industry as SEC, which may be taken, by way of example only, in the unit kWh/Nm3Or kWh/kg, or may be expressed as volume per unit energy, e.g. Nm3kWh (where Nm3Expressed in "standard cubic meters", i.e., the volume of gas produced at atmospheric pressure and standard temperature, typically 0 or 15 ℃). Another alternative form of specific energy consumption is specific power consumption (SPC or SP), which is usually expressed in units kW/(Nm & m)3Min), and this and other equivalent expressions may also be used according to the invention. In this case, it can be said that the expression specific energy consumption can refer to: power and/or energy/mass or volume unit produced, and mass or volume unit produced/energy unit or power unit used.
Specific energy consumption varies with pressure, but throughout the literature in the field of thermodynamics, it is well known that the effect of pressure variations on compressor efficiency can be estimated. One common approach is to use an irreversible polytropic compression process to estimate the effect of pressure variations on compressor workload and thus estimate specific energy consumption. The proposed method according to the invention removes the pressure influence from the operational model and is therefore advantageous over other methods, since the reference pressure of the model can be adjusted whether it is set constant or freely variable.
The expression "ideal specific energy consumption" should be taken as the specific energy consumption obtained according to one possible model, to be used according to the invention to compare the possible system efficiencies with the measured data of the efficiency. With reference to the ideal specific energy consumption curve, the following explanation can be made: each compressor or combination of compressors and its mode of operation has an ideal specific energy consumption curve, and at a certain pressure level, i.e. for each total flow, the ideal SEC curve shows the lowest specific energy consumption achievable at that pressure level. The ideal specific energy consumption curve can be adapted to the actual compressor system by taking into account internal imperfections in the compressor installation or control, or external variations in pressure or inlet or outlet temperature. The individual compressors or combinations of compressors may thus have different desired specific energy consumption profiles, depending on internal and external factors. Such an ideal specific energy consumption curve may therefore also include simulation errors or faults. For example, an operating mode that produces the desired specific energy consumption may include a failed discharge valve on one compressor, corresponding to leakage always being 10% open.
In most multi-compressor systems, the output flow is driven by demand, which may include leaks. However, the specific energy consumption depends on the compressor combination and its regulation performance for any fixed output flow. The system efficiency is therefore determined by the system/compressor operating parameters, configuration or combination.
In the method according to the invention, the system can be optimized by varying these combinations, configurations and/or operating parameters based on the analytical measurement data. In order to be able to optimize the system, it must be analyzed and quantified. First, it must be determined whether the system is operating close to its ideal achievable efficiency and whether the available system configuration matches the desired demand/output flow curve. The system may also operate efficiently in certain output flow ranges, but not others. The system may exhibit different behavior over time due to a number of different factors, one of which is which compressors are available (e.g., when certain compressors are manually turned off or on). With the present invention, the collected measurement data is used to visually identify the efficiency performance of the system and to provide a breakdown (sorting of the measurement data according to well-defined categories based on compressor combinations and/or operating modes) that enables the user to see instantly how the system operates under different circumstances. The invention may also use multiple graphs in one or more dimensions and associated visualizations that relate the behavior of each individual compressor to the operating conditions. The present invention thus provides the user with a complete view and in-depth research at the individual compressor level to be able to fully analyze the causes and results of the overall operation of the system and to quantify the manner in which the system operates inefficiently. Based on this analysis, the user can obtain a blueprint of the required changes to achieve individual compressor parameters, as well as the optimal settings and control strategy for the overall system and for all desired flow ranges. The user will then use the same analysis tool according to the present invention to track any changes made to the system or compressor control parameters and/or system design changes to verify the results and continuously monitor system behavior and performance over time.
The ideal specific energy consumption curve constructed according to the invention can then be used as a reference for the structured and decomposed measurement data obtained by analysis according to the method of the invention, in order to facilitate the point-to-point comparison by the user in the optimization work, which can achieve the optimization objective.
These ideal specific energy consumption curves can be viewed as the optimum performance curves for a given output flow range at a particular pressure. In the method according to the invention, ideal specific energy consumption curves are calculated for different combinations of compressors in a multi-compressor system. First an ideal specific energy consumption curve for a single compressor is calculated according to the invention for a specific pressure. Then, an ideal specific energy consumption curve for another combination with the same first compressor and another compressor in the multi-compressor system is calculated for the same specific pressure. It should be noted that the first and second compressors may be any single compressor in a system comprising a plurality of compressors. Furthermore, the combined ideal specific energy consumption profile may also include one or more compressors in unloaded mode, i.e. pressurized standby by running the motor but no flow delivery (recirculation, closed intake, etc., depending on the compressor design). Furthermore, the method may of course also comprise constructing or calculating a desired specific energy consumption curve for a plurality of combinations of different combinations, such as a first compressor, a second compressor and a third compressor combination, or only a second compressor and a third compressor combination, or even more combined compressors, for example, with one or more of the compressors in an unloaded (standby) position. In the latter case, the desired specific energy consumption curve for any compressor combination may be based on a desired specific energy consumption curve for an operating mode with at least one unloaded compressor. The simplest example is for two compressors, where either of the two compressors is in unloaded mode.
Furthermore, the method may of course also comprise the construction of specific energy consumption curves at different reference pressures.
The method according to the invention provides how the different ideal specific energy consumption curves depend on the output flow of the compressor, i.e. an operation model describing how the system operates. Thus, by constructing an ideal specific energy consumption curve in the first compressor as a function of the output flow of the first compressor, the method provides a means for determining how the ideal specific energy consumption curve in the first compressor depends on the output flow of the first compressor. Likewise, by constructing any other combination of compressors to provide an ideal specific energy consumption curve for that combination, the method according to the invention provides a way to determine how the ideal specific energy consumption curve in that compressor combination depends on the output flow of the compressor combination.
Furthermore, the method according to the invention may comprise constructing/calculating and visualizing one or several ideal specific energy consumption curves of the compressor combination in any combination. Furthermore, the method may comprise constructing/calculating an ideal specific energy consumption curve for one or more fixed system reference pressures, thereby greatly simplifying the calculation and visualization as the model becomes independent of system pressure variations. In addition, other less influential variables such as intake air temperature or pressure may also be considered. Furthermore, according to yet another specific embodiment, the method comprises constructing/calculating and visualizing an ideal specific energy consumption curve for one or more fixed system reference pressures and/or inlet conditions. Furthermore, the method according to the invention can be used for any compressor combination, such as a first compressor plus a third compressor, a second compressor plus a third compressor or a combination of a first compressor, a second compressor and a third compressor, etc.
According to yet another embodiment, the method comprises constructing/calculating one or more ideal specific energy consumption curves for a plurality of combined compressors in any combination, and wherein at least one combination is based on combining adjustable flow ranges of individual compressors. Furthermore, according to yet another specific embodiment of the present invention, the theoretical operating model is based on combining the non-adjustable flow range and the adjustable flow range for each compressor separately to form a single virtual compressor. To combine the non-regulated (non-adjustable) flow range and the regulated (adjustable) flow range separately, the non-regulated flow ranges are first superimposed on top of each other, and then the regulated flow ranges are superimposed on top of each other, as further illustrated in fig. 4. It should also be noted that the present invention can be used in a multi-compressor system having one or more non-adjustable compressors, and where different compressor sizes (flow rates) and specific energy consumption profiles are parameters for improving the operating mode of the multi-compressor system. Further, it should be noted that the ideal specific energy consumption curve within the regulated flow range and the size of the regulated flow range are set based on models of general compressor types, measured values of actual compressors, or manufacturer data.
The possible models used according to the invention can be influenced not only over the range of non-adjustable and adjustable flows of different compressors, but also adjust the pressure to different reference pressures. Further, according to one embodiment, the specific energy consumption curve is calculated with the specific energy consumption set as a constant within the regulated flow range of the compressor, and the ideal specific energy consumption curve is calculated from the constant power usage of the non-regulated flow range of the compressor. Furthermore, according to yet another embodiment, the ideal specific energy consumption curve is adjusted as the efficiency changes within the regulated flow range. Based on the position within the regulation flow range, and based on the particular compressor type and regulation range, efficiency adjustments may be accomplished using a normalization curve.
The range of the regulated flow of the compressor and the efficiency curve within the regulated range vary depending on the type of compressor. The unregulated flow range is typically defined by a compressor or compressed gas system actuating one or more valves to release excess gas produced in the system. These valves are commonly referred to as spill valves, vent valves, BOV valves, waste valves, or the like. These valves can blow the excess gas produced into the atmosphere or recycle it to any intermediate stage on or within the low pressure side of the compressor. The use of a relief valve can result in a significant loss of compressor and/or system efficiency, as the already compressed gas is wasted and all of the energy stored due to the reduced pressure is lost.
The present invention can visualize and quantify the use of turndown capability, mismatch between the turndown compressors and the compressors in the discharge mode, and other inefficiencies associated with a particular compressor combination and/or mode of operation. The present invention can also link how certain compressor combinations and/or operating modes are associated with these visualizations of constructed ideal specific energy consumption curves, visually present the current system operating state as a way to quantify inefficiencies and in comparison to ideally achievable operation, and provide information for optimizing and/or going further down to individual compressor levels.
A common regulation method for compressor regulation is different types of meter-in (for all types of compressors, but most efficient in dynamic compressors such as axial or radial turbocompressors/centrifugal compressors). These different types of meter-in are known by different names, such as butterfly valve, IGV, or DVG. The invention provides a visualization of the system operation and behavior and the operation of a certain compressor combination and/or operating mode in such a way that the use of the system and the state of its adjusting mechanism can be easily understood. The invention can also provide detailed visualization of the status or use of the regulation capacity on the individual compressor level.
Another common method with very good efficiency characteristics, widely used in all types of compressors, is regulation by speed control of the compressor motor. These are commonly referred to as VSDs, variable frequency drives or inverter drives.
Each combination of compressor type (screw, piston, turbine, etc.) and control method creates its own characteristic versus energy consumption curve that is related to the regulating efficiency within the regulating flow range and the size of the available regulating range. The regulated flow range also varies depending on the pressure and compressor design.
Moreover, for most compressor types, a simple model is used according to the invention to compare the possible system efficiency with the total error of the efficiency measurement data being below about 10%, which means that this level already provides information to achieve optimization, especially in the case of compressors that are not adjusted. Systems operating at about 30-40% higher than optimal specific energy consumption are common.
Furthermore, in accordance with yet another embodiment of the present invention, the desired specific energy consumption profile for each compressor is adjusted toward one or more constant pressures in a multiple compressor system. In this case, all specific energy consumption calculations are adjusted towards a constant reference pressure. The reference pressure can of course be adjusted.
The ideal specific energy consumption curve may be calculated based on a design curve using measured or theoretical performance curves for each compressor in a multi-compressor system. Therefore, according to one embodiment of the present invention, the design or performance curves of the individual compressors are used to calculate the ideal specific energy consumption curve. The design curve for each compressor is based on the optimal operating mode ("sweet spot") for each compressor and/or based on information from the manufacturer or using general information well known in the compressor art.
Furthermore, the operational model that can be used according to the invention can also be adapted based on the temporal correlation, thereby using temporal dynamic data. According to a particular embodiment of the invention, the method and thereby the operation model comprises compensating the available flow range for each compressor combination and operation mode based on the time dependence when switching from off-mode to on-mode, from off-load (standby) to on-load (active or delivery mode), and/or based on the measured or estimated rate of change of flow in a multi-compressor system. Now, the model also takes into account the time required to start and shut down each compressor, as well as the time required to change the flow based on demand in a multi-compressor system. The characteristic time parameter may be initially set using knowledge from scratch like a compressor or a combination thereof and later accurately set via machine learning of the measurement data analysis according to the invention.
The invention may involve the steps of modeling and analyzing combinations of compressors and their efficiencies over a range of flow rates available for the combinations of compressors. As the flow demand changes, the required flow may increase beyond the delivery capacity of a certain combination. The compressor combination must then be changed to another combination that may provide the required flow. Switching from one combination to another with a higher capacity requires the activation of additional compressors. This may also involve starting several new compressors and shutting down the compressor currently in operation.
Visualization in accordance with the present invention provides the user with a comprehensive understanding of the curve, behavior, and meaning and location of such transitions. The present invention may also guide the user towards possible transitions to achieve higher energy efficiency levels by using the constructed specific energy curve as a reference for the transitions occurring in current systems. The analysis can be further improved using the time-dependent limitations of the available constructed specific energy consumption curves.
When the compressor is started, there is a time delay before the compressor obtains sufficient speed and pressure to be connectable to the rest of the system. In order to allow sufficient time for the compressor to reach production conditions, the flow range of certain compressor combinations cannot be fully utilized to its maximum value. The size of the restriction, e.g., the combined unusable flow range, is determined by a combination of factors such as the rate of change of the system flow demand and the time required to bring the compressor on-line.
Overcompensation of the required switching point from one combination to another is a common cause of energy efficiency degradation in multi-compressor systems, and the present invention provides a new and accurate tool to optimize this from an energy efficiency perspective.
The most common cause of inconsistency between the measured and desired curves is insufficient synchronization of regulation between different compressors or compressor groups, resulting in a compressor without regulation capacity entering a discharge or standby mode, while other active compressors still have unused regulation capacity. Another related failure in existing plants is not operating the booster compressor at all, or in some combinations of uses, not using the booster compressor within the booster range, which leaves the system without the capacity to be throttled within this flow range. This situation can be conveniently identified by using a plot of individual compressor energy usage versus total flow, wherein such idle turndown capability can be conveniently viewed based on visualizing selected measurement data associated with a single simulated mode of operation.
Measuring a single flow from the compressor is rather difficult, but measuring the power is rather easy. By means of the invention, it is possible to classify unique compressor combinations and/or operating modes of a multi-compressor system and to associate measurement points with constructed ideal specific energy curves, by measuring only the total power and output flow and the activity (mode of the individual compressors). Besides activity, other measurement methods are possible according to the invention, such as voltage/current, on/off signals, variable control signals, IGV and/or BOV values, etc. It should also be noted that the power of the compressor is usually measured indirectly in a sensor by measuring the current and knowing or measuring the voltage. Power is the product of voltage and current and can be output from the sensor as an analog signal. However, typically, power is integrated into the energy and the sensor outputs a pulse when a certain amount of energy is consumed. In this way, the power can be estimated.
As described above, the present invention relates to plotting measured specific energy consumption data points attached to a specific compressor or compressor combination and/or operating mode of a multi-compressor system and marking said data points as attached to the specific compressor or compressor combination and/or operating mode. This is the starting point for the present invention, but many other rendering steps may be performed according to the present invention. According to one embodiment of the invention, the common system pressure and the measurement of the total common output flow are plotted in a single graph and/or the pressure is plotted as an additional axis of a multi-dimensional (3D) graph along with the measured specific energy usage and the common output flow. Stable pressure is a very important parameter in compressed air systems, especially for obtaining good energy efficiency. With the separate graphs as disclosed above, the energy efficiency is linked to the pressure/pressure ripple, which means that the effect of the operation of the compressor (compressor combination/mode) on the pressure can be analyzed. This is for example very advantageous when the measured data points are marked according to the compressor combination.
Furthermore, according to yet another embodiment, the measurement points are attached to a certain compressor or compressor combination and/or operating mode in a multi-compressor system using measured and/or known states of the compressors, voltage on/off, software or hardware controlled compressor switching and/or gas flow from a specific compressor. Furthermore, according to yet another specific embodiment of the present invention, one or more data points having a measured specific energy consumption higher than the ideal specific energy consumption curve for the compressor combination and operating mode are used to indicate that system adjustments may be optimized and/or to select relevant data points for further analysis. According to the invention it is thus also possible to see the cause of the inefficiency, for example by selecting certain points/transitions and then looking at which states (operating modes) the different compressors have, which compressor combinations are involved in a particular state, and the regulation or reaction of the different individual compressors. Further, according to yet another embodiment, one or more data points associated with an ideal specific energy consumption curve are compared to another (other) ideal specific energy consumption curve having another (other) compressor combination and/or operating mode that may produce the same common output flow to indicate whether there is a more efficient compressor combination and/or operating mode for system operation. Also in this case, the selection and highlighting of measurement data points may be used to distinguish between inefficiencies resulting from adjustment errors and inefficiencies resulting from incorrect compressor combinations/operating modes.
Furthermore, according to yet another specific embodiment, the data points of measured specific energy consumption are summed and/or averaged over time with the difference between the ideal specific energy consumption curve to produce a key performance indicator of system inefficiency. These key performance indicators may also be separated by different common output flow ranges or other suitable classifications. Inefficiencies may be associated with a system with too high a specific energy consumption because switching between different compressor combinations or modes of operation occurs at a sub-advantage in flow or not at all. The low efficiency may also involve one or more data points having a measured specific energy consumption that is higher than the specific energy consumption indicated by the associated ideal specific energy consumption curve for a particular flow rate.
Further, the difference between the measured specific energy consumption and the data point for the common output flow and the ideal specific energy consumption curve may be used to detect these inefficiencies in the compressor system, such as incorrect settings set on individual compressors, transition points between different compressor combinations, system design defects, or defective devices. Further, these differences between the measured data points of specific energy consumption and the common output flow from the actual compressors can be compared to an ideal specific energy consumption curve to detect errors in the measurements, such as erroneous conversion factors, sensor errors, or missing data.
Furthermore, the invention relates to a method wherein measured data points of energy consumption, activity and/or other compressor regulation parameters or measurements from individual compressors are plotted in one or more separate graphs with reference to the total same output flow and/or system pressure and/or specific energy consumption in a multi-compressor system to identify the operating mode of each individual compressor in the multi-compressor system.
Furthermore, the method according to the invention may also comprise a visualization of the operation mode of each compressor in the multi-compressor system to indicate whether the compressor is on/off and/or loaded/unloaded and/or within/outside the regulation range or other compressor-specific parameters or operation modes.
Also with reference to the drawings according to the invention, the dimensional viewing angle may vary. According to a particular embodiment of the invention, the method comprises calculating and visualizing an ideal specific energy consumption curve and measurement data, wherein the ideal specific energy consumption curve is adjusted to one common pressure for all compressors in the multi-compressor system, and wherein the ideal specific energy consumption curve is then plotted in 2D for the selected pressure, or wherein the ideal specific energy consumption curve is plotted in 3D for a variable common pressure, to further visualize the pressure dependency, and/or wherein the measurement data and the ideal curve are adjusted towards the same inlet conditions. Furthermore, according to yet another embodiment, the method comprises calculating and visualizing an ideal specific energy consumption curve and measurement data, wherein the measurement data of flow and power/energy consumption adjust the pressure to the same pressure as was used for calculating the ideal specific energy consumption curve and then plotted in 2D together with the ideal specific energy consumption curve, or wherein the ideal specific energy consumption curve is plotted in 3D against the variable pressure axis and the measurement data is plotted in the same 3D-graph using the actual pressure at each measurement point, and/or wherein the measurement data and the ideal curve are adjusted towards the same inlet conditions.
Furthermore, according to a further embodiment, at least two ideal specific energy consumption curves are aggregated into one common reference curve, which is visualized in 2D for a common pressure or in 3D for a pressure adjusted towards a variable pressure.
In this case it may also be noted that a possible standard model according to an embodiment of the invention may be pressure dependent. In many compressor systems, it is desirable to avoid varying pressures, and then a reference pressure ("operating pressure") is used throughout the system to analyze specific energy consumption and flow. However, as described above, this reference pressure may be different when performing the simulation test. The varying pressure may be due to demand or the system being unable to maintain a steady pressure for any reason. It is possible to have different pressures so that the pressure dependence is also reflected on each measuring point, so that the specific energy consumption, the pressure and the flow are analyzed together. These three quantities may be plotted in a 3D graph, one or more quantities may be depicted in chromaticity, different symbols, or similar labels, and the pressure dependence in the auxiliary graph is plotted similarly to the other graphs.
Furthermore, according to yet another embodiment, the individual ideal specific energy consumption curves that will form part of the common reference curve are selected by selecting the curve with the lowest specific energy consumption for that flow range based on all available compressor combinations and operating modes. Further, the data for the desired specific energy consumption for one or several common output flows of a plurality of compressor combinations may be individually combined in any combination, structured and plotted on a desired specific energy consumption curve, and wherein the method comprises combining the desired specific energy consumption curves to establish and/or measure the control gap based on insufficient overlap of the modulation flow ranges between the different desired specific energy consumption curves.
The control clearance represents a range of flow where the system and possible compressor combinations do not have the capability to adjust. These regions may imply high specific energy consumption and risk of system disturbances in the form of pressure fluctuations, and it is therefore advantageous to avoid this. According to the present invention, these regions can be identified by analyzing whether the adjustable flow ranges in different compressor combinations overlap each other using the constructed ideal specific energy curve (see fig. 6). As described above, this may be performed with or without temporal dynamics analysis. In addition, it is also possible to use this method to identify the presence of possible flow rates of the control gap when comparing with actual measurement data and to analyze the influence of these flow rates on the pressure and pressure fluctuations.
Further, according to a specific embodiment, the energy level (power) for the maximum energy (power), the off position, the standby position, the turndown range, the lowest specific energy consumption position, and/or other key compressor performance values are plotted in a compressor energy (power) chart. Furthermore, according to yet another embodiment, any pressure, flow, power (energy), specific energy measurement data or other measurement values from a multi-compressor system are plotted against time, and wherein each measurement point is associated to a different compressor combination, operating mode and/or a different operating mode or a transition between compressor combinations, and wherein these associations are visualized in the graph by markers such as foreground or background colors, symbols, separation into different sub-graphs or similar markers in order to analyze the effect of transitions and operating combinations in the multi-compressor system.
Further, according to a particular embodiment, rather than plotting individual measurement points individually, measurement data points are partitioned and/or grouped in different ranges and visualized as contour plots, heat maps, histograms, or similar plotting techniques. This feature according to the invention also enables visualization of large amounts of data, for example months or years, to find deviations and changes of the system over time. Further, the identified control gaps may be marked with colors, different foreground or background colors, limiting lines, symbols, or similar indicia in any of the other figures described above.
Further, according to yet another specific embodiment, the method includes calculating an available flow range for each compressor combination and operating mode based on the time required to create the increase or decrease in the common output flow versus the rate of change of flow measured in the multiple compressor system differing between the compressor combinations or operating modes, and marking the available and/or unavailable portion of each ideal specific energy consumption curve in a plot of ideal specific energy consumption versus common output flow. The method may further include calculating an available flow range for each compressor combination and operating mode based on the time required to create an increase or decrease in the common output flow relative to the rate of change of flow measured in the multi-compressor system being different from one compressor combination or operating mode to another, and calculating the most efficient compressor combination or operating mode to switch to, and flagging a flow point for optimal switching from one compressor combination or operating mode to another.
Furthermore, according to a particular embodiment of the invention, the analysis method comprises selecting one or more measurement points, either alone or using one or more polygonal areas or one or more volumes, wherein the respective measurement points that have been selected are marked or otherwise identified with highlighting, color, symbols or similar effects in any other visualization graph. According to the invention and using such methods and features, it is possible to further isolate different "events" and how these events are associated with the behaviour of the individual compressors and the behaviour of the whole system. One example is how this occurs in time when switching between different compressor combinations/operating modes based on measured data.
The method according to the invention can be used for compressors and certain pumps, such as the pumps described above. According to one embodiment of the invention, the multiple compressor system is a compressed gas compressor system and the compressor is a compressed gas compressor. Some applications that may be of interest are given as examples, such as natural gas storage and distribution or industrial compressed air (for N)2And/or O2Cylinders, pneumatic devices, clean, compressed air, etc. generated, etc.). Also, any type of compressor is possible according to the invention. A compressed air compressor system is a particularly advantageous type in connection with the present invention. Furthermore, both open-loop and closed-loop systems are possible according to the invention. An open-loop system is a system that depressurizes and injects a gas into the atmosphere after use. A typical example is a compressed air system. A closed loop system is a system that recirculates used gas to the compressor inlet after use. Typical examples are refrigeration systems and heat pumps.
Furthermore, the invention relates to a computer unit arranged for performing the method according to the invention, wherein the computer unit is arranged for structuring and visualizing data.
Drawings
The drawings are described below.
Fig. 1 shows a schematic diagram of a multiple compressor system with a common output flow. In this case, there are three different compressors in the system. The compressors are individually regulated and the total input power is distributed over the different compressors accordingly. The multiple compressor system provides a common output flow, whether this is in a mixing point directly after the compressors or, for example, after a common expansion tank.
The compressors may be connected to a loop or distribution line and the flow may be divided into different end-use zones in such a way that there is no single measurement point (through which all combined flows from all compressors flow). The combined end use is then a common output flow. The common outgoing traffic must then be measured as aggregated traffic from individual measurements throughout the system and/or in the distribution network.
Any compressor system having a certain point in the system where compressor interconnections achieve cross flow may be considered a multiple compressor system with a common output flow. Typically, the air flow from the compressors may also be directed such that air from certain compressors is lost from, for example, an air dryer connected to only a portion of the compressors. Losses that occur during this process will become part of the total output flow (and/or be compensated for in the performance adjustment). This loss can be measured or calculated by a model and/or other parameters, such as pressure. One such example is a compressor unit sold with an integrated dryer unit that can be connected into a system with a compressor with an external air dryer, and the air from both types of compressors is mixed after the dryer.
Fig. 2 shows a further embodiment according to the invention. In different cases, the curve in the range of the regulated flow for a certain compressor setting is adjusted according to the diagram shown in fig. 2. The adjustment may be performed using one or more linear compensations, mathematically adjusted curves, or curves based on certain decision points (see last alternative).
Referring to fig. 2, there are several parameters worth calculating or knowing. First, Specific Energy Consumption (SEC) at 100% output flow. Second, the specific energy consumption at the optimum output flow, i.e., the minimum specific energy consumption, and the optimum output flow in percent. Finally, the specific energy consumption at the beginning of the regulation, and the output flow expressed as a percentage at the beginning of the regulation. This is of course beneficial if more data is available. The upper left curve is quadratic in shape and may be, for example, any type of nth order polynomial curve. Other types are also possible, such as gaussian, bezier or other forms of parametric, cosine or sine curves. The left lower curve is two first order curves. In this case, the curve is a piecewise function of any type, where the function is divided into different flow ranges. Finally, the lower right curve is also a variation of the piecewise function, where it has been assumed that the flow ranges are approximately the same. This is one possible assumption, but many other assumptions are possible.
Fig. 3 shows system measurement data specific to energy use and common output flow, which are sorted into different compressor combinations, which are shown in the graph with different symbols. An ideal Specific Energy Consumption (SEC) curve for a combination matched to the plotted compressor combination according to one embodiment of the present invention has also been plotted in the figure. It is noted that the first curve on the left is the ideal specific energy consumption curve for a compressor. When used as the only compressor in operation, the "first" compressor may be any compressor in a multi-compressor system. As described above, the desired specific energy consumption curve for the first compressor is calculated as a function of the output flow of the first compressor and then plotted. The next curve is the combined desired specific energy consumption curve for the first compressor and the second compressor, and in general, may be any two compressors of the system. The last curve thus shows the ideal specific energy consumption for three compressors in continuous operation, i.e. 1, 1 plus 2 plus 3 derived from the combinations used in the plotted measurement data. This example is an example of two non-regulated screw compressors and one frequency-regulated screw compressor. The data points measured are from 4 different compressor combinations. I.e. 1 compressor, 2 compressors, 3 compressors and 4 compressors are plotted with different symbols and covered with four corresponding ideal specific energy consumption curves matched to different compressor combinations. It should be noted that it is also possible to construct and visualize a curve of the unloaded combination, and that the measurement data of the unloaded combination may be marked with different symbols. It is worth noting that most of the actual measured data points are not on the (SEC) curve that provides as low a specific energy consumption as possible for a specific flow rate. Furthermore, many measurement points are not located directly on or near the (SEC) curve, which is located at a higher specific energy consumption than when located on the ideal (SEC), further showing that there is room for improvement in operating this particular multi-compressor system in a more efficient manner than is currently performed. The graph shows that the measured system only operates at near optimum efficiency in the highest flow range and when operating four compressors.
Figure 4 shows a model according to a specific embodiment of the invention. First, the unregulated and regulated flow ranges associated with the flow rates of the respective compressors are shown. According to a particular embodiment of the invention, the theoretical operating model is based on combining the non-adjustable flow range and the adjustable flow range for each compressor separately to form a single virtual compressor. Such a single virtual compressor is shown below, where it can be seen how different parts of the single compressor are added to form the virtual compressor. Thus, this embodiment provides a single virtual compressor with an unregulated flow range and a regulated flow range associated with the total flow as a model for use in evaluating a multi-compressor system. Fig. 4 shows the modulation flow ranges of two compressors modeled in sequential order, such that only one compressor is modulated at a time and the next compressor starts modulation when the previous compressor reaches its modulation flow range limit. The regulated flow ranges of the combined compressors can also be modeled as being regulated in parallel over a common regulated flow range, or in a combination of sequential and parallel. The parallel-regulated compressors will be simultaneously regulated throughout their collective regulation flow range.
Fig. 5 shows a specific embodiment according to the present invention, wherein at least two ideal Specific Energy Consumption (SEC) curves are aggregated into one common reference curve (referred to as composite curve in fig. 5). Furthermore, actual measured data from two different compressor combinations has been plotted in the graph, and based thereon, the measured inefficiency in incremental specific energy consumption at a particular system flow rate can be calculated. Each desired efficiency curve may also be adjusted prior to aggregation based on the reduced regulated flow range taking into account system dynamic time constraints.
FIG. 6 shows three graphs of ideal specific energy curves for a three compressor system including one VSD screw compressionA machine, and two loading/unloading screw compressors, all three of similar size. The upper two graphs show SEC (kWh/Nm)3) With a common output flow (Nm)3Min), the bottom graph shows the system regulation capacity for different common output flows.
The uppermost graph shows the available adjustment ranges and the unusable parts (if the adjustment ranges are individually indicated) for the different compressor combinations (1, 1 plus 2 plus 3). The unusable part of the regulation range is set by taking into account the capacity of the system required when dealing with rapid flow variations and the start-up time required for the individual compressors.
The middle curve shows the ideal specific efficiency curve for a polymerization constructed from three separate ideal specific energy curves for three different compressor combinations. When performing polymerization, unusable portions of each curve adjustment range have been excluded. The bottom graph shows the position of the adjustment gap of the system based on the aggregate graph shown in the middle graph. 100% on the y-axis indicates that the system has full turndown capability and therefore can operate efficiently and stably. 0% on the y-axis indicates that the system is not capable of adjusting enough in these flow ranges, indicating the position of the system adjustment gap.
Fig. 7 shows a schematic diagram of a method and steps therein according to an embodiment of the invention.
FIG. 8 shows five separate correlation graphs for a four compressor system, where the various measurement points for each detected compressor combination are identified with a unique symbol, according to one embodiment of the present invention. The upper graph shows the measured SEC versus the common output flow, the lower left graph shows the system pressure versus the common output flow, and the lower right three graphs show the energy usage of a single compressor versus the common output flow of the three system compressors.
The pressure versus common output flow for a multiple compressor system is plotted in fig. 9 and the various measurement points are identified as two distinct categories depending on whether all compressors are operating within regulation range or whether one or more compressors are operating outside of their regulation range, i.e. with an open discharge valve and thus in a less energy efficient state. This graph is used as a complement to the other graphs described in the specification herein, and the same classification and labeling may be used in any other graph, such as a graph of specific energy versus common output flow. The graph may also be part of a larger multi-dimensional (3D) graph.
FIG. 10 shows three graphs, where each graph corresponds to a single compressor energy usage versus common output flow. The graph is segmented in the Y-axis direction and labeled in different regions according to the compressor operating mode within the specific energy usage range.
The area used in these three graphs is "production", corresponding to the contribution of the compressor to the common output flow, "unloading", in which the compressor is in an unloaded state and does not provide any contribution to the common output flow, and finally "shut down", in which the compressor is completely shut down. There are many different options for area classification that may be used, such as dividing the production area into smaller sections and/or presenting the intended IGV locations.
In fig. 11 it is visualized how a subset of the collected measurement data is selected in a graph of pressure versus common output flow by using polygon selection according to the present invention, and where the measurement points corresponding to the selected measurement points are highlighted in the auxiliary graph. The selection process and highlighting may be used in any of the graphs mentioned in the present invention and the highlighting may be performed simultaneously in any graph and any number of graphs. The selection can be further refined by using the same polygon tool or by selecting a smaller subset of previously selected points by selecting individual measurement points.
Conclusion
The present invention provides a model for analyzing existing multi-compressor systems to find the best mode of operation based on actual measurement data.
The method aims at visualizing ideal specific energy consumption curves for different compressor combinations and operating modes in a multi-compressor system. In contrast to other existing systems today. In addition, another significant difference is that the present invention provides for decomposing and visualizing the measurement data into different compressor combinations, operating modes, individual compressor operation and system pressures, and directly comparing the measurement data to the simulated system performance. Other known methods are limited to comparison with static reference levels and/or time averaged/accumulated key performance indicators of specific energy usage, and the present invention is able to use the key performance indicators to measure efficiency while taking into account the desired system performance, thereby providing a more accurate measurement and basis for further analysis. Other known methods are also limited to plotting system measurements or calculations in a time-based graph, or in some cases in a flow curve (i.e., a histogram), so as not to provide the analyzing user with any correlation between the measurement data and the system operating mode, thereby severely limiting the likelihood of finding the cause of the problem, and in many cases collectively identifying the problem or inefficiency that exists. The possibility of analyzing the system in a time-independent manner enables analysis over a long time and comparison with operational models directly associated with the data, thereby providing the user with advantages over other available analysis methods.
In summary, the method according to the invention has several advantages compared to existing analytical methods for compressed air systems and other multi-compressor systems. First, it decomposes and correlates the measurement data to unique compressor combinations and system operating modes, enabling problems to be identified and causes to be visualized. Second, the actual data can be directly compared to the simulation model that matches the relevant data, thereby enabling identification of the potential for improvement and possible improvement in system setup, control, or operation. Furthermore, the present invention provides a tool for comprehensive analysis of existing multi-compressor systems without requiring extensive expertise and skills by indicating and visualizing inefficient or unstable operation and ways to visualize and find causes and indicate possible solutions by comparison with simulations of optimal system operation.
To give guidance to possible improvements in the use of the invention, it is possible to use large-size screw or turbo-compressors, obtaining a pressure band of about 0.09 or 0.1 in kWh/Nm in the widely used pressure band of 6 to 8 bar3Can be compared to a level of 0.15 and higher, which is a common level when operating without proper optimization and/or turndown capabilities with reference to multiple compressor systems. It is of course very important to reduce the specific energy consumption of this order. Simplifying the process so that non-expert users can perform such system optimizations, and providing expert users with tools to find earlier unrealized optimization possibilities is also very valuable.

Claims (40)

1. A method for analyzing, monitoring, optimizing and/or comparing specific energy consumption, representing energy used to produce a unit mass or volume of compressed gas, related to a common output flow in a multiple compressor system, comprising:
-collecting measurement data of common output flow and energy/power usage and calculating the specific energy consumption in the multi-compressor system,
-identifying which data points of measured specific energy consumption pertaining to a certain compressor or compressor combination in the multi-compressor system and/or one or more operation modes of the multi-compressor system; and
-plotting said data points of measured specific energy consumption attached to a specific compressor or compressor combination and/or an operation mode of said multi-compressor system and marking the attachment of said data points to said specific compressor or compressor combination and/or operation mode.
2. The method of claim 1, wherein plotting the data points is performed in a graph of specific energy consumption versus common output flow.
3. The method of claim 1, wherein the method further comprises
-constructing, from a first compressor, an ideal specific energy consumption curve in said first compressor as a function of said output flow of said first compressor; and
-calculating, from a first compressor and a second compressor, a combined ideal specific energy consumption curve in the first compressor and the second compressor as a function of a combined output flow of the first compressor and the second compressor,
and wherein the method comprises structuring the calculated data to visualize it in an ideal specific energy consumption curve for analyzing, monitoring, optimizing and/or comparing with measured data of a corresponding multi-compressor system.
4. The method of claim 2, wherein the method further comprises
-constructing, from a first compressor, an ideal specific energy consumption curve in said first compressor as a function of said output flow of said first compressor; and
-calculating, from a first compressor and a second compressor, a combined ideal specific energy consumption curve in the first compressor and the second compressor as a function of a combined output flow of the first compressor and the second compressor,
and wherein the method comprises structuring the calculated data to visualize it in an ideal specific energy consumption curve for analyzing, monitoring, optimizing and/or comparing with measured data of a corresponding multi-compressor system.
5. The method according to any of claims 1-4, wherein the construction curves and/or measurement data points in any graph are correlated to different compressor combinations, operation modes and/or transitions between different operation modes or compressor combinations, and wherein the correlation is visualized by markers to enable analysis of the effect of transitions and operation combinations in the multi-compressor system.
6. The method according to claim 3, wherein the method involves constructing and visualizing one or more ideal specific energy consumption curves for one or more fixed system reference pressures and/or inlet conditions.
7. The method according to claim 4, wherein the method involves constructing and visualizing one or more ideal specific energy consumption curves for one or more fixed system reference pressures and/or inlet conditions.
8. The method according to claim 5, wherein the method involves constructing and visualizing one or more ideal specific energy consumption curves for one or more fixed system reference pressures and/or inlet conditions.
9. The method according to any one of claims 3-4 and 6-8, wherein the method involves constructing and visualizing one or more ideal specific energy consumption curves for one or more compressor combinations in any combination.
10. The method according to any one of claims 3-4 and 6-8, wherein the method involves constructing and visualizing one or more ideal specific energy consumption curves for one or more compressor combinations in any combination, and wherein at least one combination is based on combining adjustable flow ranges for individual compressors.
11. The method according to any of claims 3-4 and 6-8, wherein the calculation of the ideal specific energy consumption curve is based on combining the non-adjustable flow range and the adjustable flow range for each compressor separately to form a single virtual compressor.
12. The method according to any one of claims 3-4 and 6-8, wherein the one or more ideal specific energy consumption curves are calculated by setting the specific energy consumption at or near a constant over a regulated flow range of the one or more compressors, and wherein the ideal specific energy consumption is calculated from a constant power usage of a non-regulated flow range of the one or more compressors.
13. The method according to any of claims 3-4 and 6-8, wherein said one or more ideal specific energy consumption curves are adjusted for efficiency variation over an adjusted flow range of the compressor compared to a constant specific energy consumption, and/or wherein said one or more ideal specific energy consumption curves are calculated by using a design or performance curve of the respective compressor.
14. The method according to any of claims 1-4 and 6-8, wherein the common system pressure is plotted in a separate graph with the measurements of the total common output flow, and/or wherein the pressures are plotted as additional axes of a multi-dimensional graph, together with the measured specific energy usage and the common production flow.
15. The method according to any of claims 1-4 and 6-8, wherein the measured and/or known state, power/energy consumption, current consumption, voltage on/off, software or hardware controlled compressor switching and/or gas flow from a specific compressor of a compressor is used to attach a measurement point to a certain compressor or compressor combination and/or one or more operation modes in the multi-compressor system.
16. The method according to any one of claims 3-4 and 6-8, wherein one or more data points having a measured specific energy consumption higher than said ideal specific energy consumption curve for the compressor combination and operating mode are used to indicate that system adjustments can be optimized and/or to select relevant data points for further analysis.
17. The method of any of claims 3-4 and 6-8, wherein one or more data points associated with an ideal specific energy consumption curve are compared to another ideal specific energy consumption curve having another compressor combination and/or one or more operating modes capable of producing the same common output flow to indicate whether there is a more efficient compressor combination and/or operating mode for operation of the multi-compressor system.
18. The method according to any of claims 3-4 and 6-8, wherein the data points of measured specific energy consumption are summed with the difference between one or more ideal specific energy consumption curves and/or averaged over time to produce a key performance indicator of low efficiency of the multi-compressor system.
19. The method of any of claims 1-4 and 6-8, wherein measured data points of energy consumption, activity and/or other compressor regulation parameters or measurements from individual compressors are plotted in one or more separate graphs with reference to a total of the same output flow and/or system pressure and/or specific energy consumption in the multi-compressor system to identify the operating mode of each separate compressor in the multi-compressor system.
20. The method of claim 19, wherein the method further involves including visualizing an operating mode of each compressor in the multi-compressor system to indicate that the compressor is on/off and/or loaded/unloaded and/or within/outside a regulation range.
21. The method according to any one of claims 1-4, 6-8 and 20, wherein said method involves calculating and visualizing one or more ideal specific energy consumption curves and measurement data, wherein one or more ideal specific energy consumption curves are adjusted to one common pressure for all compressors in said multi-compressor system, and wherein ideal specific energy consumption curves are then plotted in 2D for the selected pressure, or wherein one or more ideal specific energy consumption curves are plotted in 3D for a variable common pressure, to visualize pressure correlations as well, and/or wherein measurement data and ideal specific energy consumption curves are adjusted towards the same inlet conditions.
22. The method according to any one of claims 3-4, 6-8 and 20, wherein the method involves calculating and visualizing one or more ideal specific energy consumption curves and measurement data, wherein the measurement data of flow and power/energy consumption are pressure adjusted to the same pressure as has been used for calculating the ideal specific energy consumption curve and then plotted in 2D together with the ideal specific energy consumption curve, or wherein one or more ideal specific energy consumption curves are plotted in 3D on a variable pressure axis, and wherein the measurement data are plotted in the same 3D graph using the actual pressure of each measurement point, and/or wherein measurement data and ideal specific energy consumption curves are adjusted towards the same inlet conditions.
23. The method according to any one of claims 3-4, 6-8 and 20, wherein at least two ideal specific energy consumption curves are aggregated into one common reference curve, which is visualized in 2D against a common pressure, or adjusted towards a variable pressure and visualized in 3D.
24. The method according to claim 23, wherein by selecting said curve having the lowest specific energy consumption of a flow range based on all available compressor combinations and operating modes, a separate ideal specific energy consumption curve is selected which will form part of said common reference curve.
25. The method according to any of claims 3-4 and 6-8, wherein in any combination said data of ideal specific energy consumption for one or several common output flows of multiple compressor combinations are individually combined, structured and plotted in an ideal specific energy consumption curve, and wherein the method involves combining ideal specific energy consumption curves to establish and/or measure control clearances based on insufficient overlap of the regulating flow ranges of the compressors between different ideal specific energy consumption curves.
26. The method according to any one of claims 12, wherein in any combination, said data of ideal specific energy consumption for one or several common output flows of multiple compressor combinations are individually combined, structured and plotted in an ideal specific energy consumption curve, and wherein the method involves combining ideal specific energy consumption curves to establish and/or measure control clearances based on insufficient overlap of the regulating flow ranges of the compressors between different ideal specific energy consumption curves.
27. The method of claim 25, wherein the maximum energy level, the off position, the standby position, the turndown range, the lowest specific energy consumption position, and/or other critical compressor performance values are labeled in a compressor energy map.
28. The method of claim 26, wherein energy levels of maximum energy, off positions, standby positions, turndown ranges, lowest specific energy consumption positions, and/or other critical compressor performance values are labeled in a compressor energy map.
29. The method of any of claims 1-4, 6-8, 20, 24, and 26-28, wherein any pressure, flow, power, specific energy measurement data or other measurement from the multi-compressor system is plotted against time, and wherein each measurement point is associated to a different compressor combination, operating mode, and/or a different operating mode or transition between compressor combinations, and wherein these associations are visualized in one or more graphs by markers to enable analysis of the effects of transitions and operating combinations in the multi-compressor system.
30. The method of claim 1, wherein measurement data points are partitioned and/or grouped in different ranges and visualized as contour plots, heat maps, histograms, or similar mapping techniques, rather than plotting individual measurement points individually.
31. The method of claim 19, wherein the measurement data points are partitioned and/or grouped in different ranges and visualized as contour plots, heat maps, histograms, or similar mapping techniques, rather than plotting individual measurement points individually.
32. The method of any of claims 1-4, 6-8, 20, 24, 26-28, and 30-31, wherein the identified control gaps are marked with a color, a different foreground or background color, a limit line, a symbol, or the like in any other graph.
33. The method of any of claims 3-4, 6-8, 24, and 26, wherein the method involves calculating an available flow range for each compressor combination and operating mode based on the time required to create the increase or decrease in the common output flow as a function of the measured rate of change of flow in the multi-compressor system, and marking an available portion and/or an unavailable portion of each ideal specific energy consumption curve in the graph of ideal specific energy consumption versus one or more common output flows.
34. The method of any of claims 1-4, 6-8, 20, 24, 26-28, and 30-31, wherein the method involves varying between compressor combinations or operating modes one from another based on the time required to create the increase or decrease in the common output flow relative to the rate of change of flow measured in the multi-compressor system, calculating an available flow range for each compressor combination and operating mode, and calculating the most efficient compressor combination or operating mode to switch to, and marking flow points for optimal switching from one compressor combination or operating mode to another.
35. The method of any of claims 1-4, 6-8, 20, 24, 26-28, and 30-31, wherein the method involves selecting one or more measurement points in any other graph, alone or with one or more polygonal areas or one or more volumes, wherein corresponding measurement points that have been selected are marked or otherwise identified with highlighting, color, symbols, or similar effects in any other graph.
36. The method of any of claims 1-4, 6-8, 20, 24, 26-28, and 30-31, wherein the multiple compressor system is a compressed gas compressor system and the compressor is a compressed gas compressor.
37. The method of any of claims 1-4, 6-8, 20, 24, 26-28, and 30-31, wherein the multi-compressor system is a compressed air compressor system and the compressor is a compressed air compressor.
38. The method of claim 5, wherein the marker is a foreground or background color, a symbol, a separation into different sub-graphs, or a similar marker.
39. The method of claim 29, wherein the marker is a foreground or background color, a symbol, a separation into different sub-graphs, or the like.
40. A computer unit arranged to perform the method according to any of claims 1-39, wherein the computer unit is arranged to structure and visualize data.
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