EP1844236B1 - System und verfahren zur steuerung der leistung eines schraubenverdichters - Google Patents

System und verfahren zur steuerung der leistung eines schraubenverdichters Download PDF

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Publication number
EP1844236B1
EP1844236B1 EP06711366A EP06711366A EP1844236B1 EP 1844236 B1 EP1844236 B1 EP 1844236B1 EP 06711366 A EP06711366 A EP 06711366A EP 06711366 A EP06711366 A EP 06711366A EP 1844236 B1 EP1844236 B1 EP 1844236B1
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EP
European Patent Office
Prior art keywords
capacity
motor
compressor
speed
bypass valve
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Not-in-force
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EP06711366A
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English (en)
French (fr)
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EP1844236A1 (de
Inventor
Rajepandhare Nahesh
Pandurangan Ramesh
Kuppachi Venu Mahdav
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ELGI EQUIPMENTS Ltd
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ELGI EQUIPMENTS Ltd
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C28/00—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids
    • F04C28/24—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids characterised by using valves controlling pressure or flow rate, e.g. discharge valves or unloading valves
    • F04C28/26—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids characterised by using valves controlling pressure or flow rate, e.g. discharge valves or unloading valves using bypass channels
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C18/00—Rotary-piston pumps specially adapted for elastic fluids
    • F04C18/08—Rotary-piston pumps specially adapted for elastic fluids of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing
    • F04C18/12—Rotary-piston pumps specially adapted for elastic fluids of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing of other than internal-axis type
    • F04C18/14—Rotary-piston pumps specially adapted for elastic fluids of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing of other than internal-axis type with toothed rotary pistons
    • F04C18/16—Rotary-piston pumps specially adapted for elastic fluids of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing of other than internal-axis type with toothed rotary pistons with helical teeth, e.g. chevron-shaped, screw type
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C28/00—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids
    • F04C28/08—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids characterised by varying the rotational speed

Definitions

  • the present invention relates to a rotary screw compressor and more particularly to a system and a method to control the discharge capacity of the screw compressor by using a combination bypassing the compressed medium and by varying the speed of the motor of the compressor.
  • Screw compressors are widely used for various industrial applications due its simplicity of operation, reliable & consistent performance over its life span.
  • a screw compressor generally includes a male screw rotor and a female screw rotor in engagement with each other. These rotors are rotated by a prime mover like an electric motor, engine etc. to compress an intake air/gas to be supplied to an equipment, appliance or a process requiring compressed air or any other gas for its operation or functioning.
  • a screw compressor is normally designed for operating at a particular speed for optimum performance but most of the time it does not operate at the designed speed due to lack of demand of compressed air or any other gas from the dependent equipment or appliance or process, which requires supply of compressed air or any other gas for its operation or functioning.
  • the part load operation of the screw compressor results into degradation of the performance and energy efficiency of the same.
  • a compression system should operate in such a way that the compressor flow delivery is always in line with the demand without causing any additional energy & efficiency losses.
  • capacity control in a screw compressor is performed by means of sliding valve mechanism, in which a sliding valve operated through suitable control mechanism is used to control the opening area of the bleeding port.
  • This method offers unlimited capacity control over its capacity control range. But involvement of various sliding parts makes unsuitable due to problems related to maintenance.
  • the capacity control operation is performed by a suction throttle, wherein controlling the valve at the compressor suction controls air mass entering into the compressor.
  • the throttling of air through this valve causes pressure losses and corresponding increase in total pressure ratio and there by power input which offsets the gains of capacity control.
  • the capacity control of a rotary compressor motor is also performed by using multi-pole electric motor (Two Pole/Four Pole/Six Pole motors), which is not a dynamic type ,as disclosed in DE 4 221 494 A1 , considered to represent the closest prior art document.
  • the capacity Control of Compressor is performed by varying the speed of the motor, by variable speed frequency drives. This method is efficient as it has a control over the capacity control process.
  • the major drawbacks of this method are high cost and power reduction is not in proportional to capacity reduction with decrease in rotational speed of the equipment.
  • a screw compressor for accommodating low compression ratio and pressure variation is described, which is intended to be achieved by varying the internal volume ratio by means of positioning of an internal volume ratio control valve at a pre-determined position. Further a bypass valve is arranged which operates between discharge and suction zones of the compressor.
  • VFD Variable Frequency Drives
  • the dependent systems like screw compressors operates most efficiently at an optimum speed and running a screw compressor at lower speeds than the optimum or designed speed, degrades its performance due to various losses generated because of operating at lower speeds like reduced volumetric efficiency at lower speeds etc. So apparently even if the system's supply and demand matches well, the energy efficiency of the complete system is very poor.
  • the primary object of the present invention is to provide a system and a method for a screw compressor with in-built bypass flow arrangement and driven by a multi-speed or multi-capacity (speed and power) electric motor to generate, regulate the flow or delivery of the compressed air or gas.
  • An object of the present invention is to provide a system and method where no variable frequency drive (VFD) is used.
  • VFD variable frequency drive
  • the present invention provides a system and a method for implementing capacity control in a screw compressor, said system comprising; a screw compressor, said compressor driven by a multi-capacity (speed and power)motor to compress air or gas medium, a bypass inlet member with a bypass valve, extending from the high pressure zone to the low pressure zone of the screw compressor to recirculate the gaseous medium, a bypass valve controller functionally connected to said bypass valve, a motor controller functionally connected to the motor to effect multi-capacity (speed and power) operations, a main processing control unit disposed to control the bypass valve and multi-capacity (speed and power) operations, measuring means disposed on the compressed medium passage for measuring the changes in the pressure and/or temperature changes in the form of signals, a signal converter functionally connected to the main processing unit and the measuring means to receive the signals, and said motor controller and bypass valve controller are functionally connected to the main processing unit to perform the capacity control of the screw compressor.
  • the present invention provides a rotary screw compressor system and a method to control the discharge capacity of the screw compressor by using a combination of bypassing the compressed air or gas and by varying the speed of the motor of the compressor.
  • the constructional features of the system of the present invention are described by referring to Fig 1-3 .
  • Fig 1 is a schematic diagram of the compression system of the present invention, wherein a rotary screw compressor 1 is driven by a multi-capacity (speed and power) motor 2 to compress a gas or air medium and to discharge the compressed medium.
  • a multi-capacity (speed and power) motor 2 to compress a gas or air medium and to discharge the compressed medium.
  • the screw compressor 1 comprises rotor housing in which male rotor 11 and female rotor 12 rotates in continuous engagement.
  • the gaseous medium air or gas enters into the rotor housing through the upstream pipe or intake pipe 13 and thereafter compressed to the desired pressure level during its transportation from suction end to discharge end of the rotor housing.
  • This compressed air or gas is then transported to the end applications 6 through the network of various sub-components of a compression system hereinafter described.
  • a bypass line 14 extending from a bypass port 18 is provided with a bypass valve 10, said bypass line 14 extending from the high-pressure zone to the low-pressure zone of the screw compressor to recirculate the gas or air medium.
  • the bypass valve of the present invention either a vertically operated or a rotary valve, which is known in the art to provide a controlled flow of the medium.
  • the valve controller 7 is a stepper motor or any suitable mechanical device that can drive or transmit the driving functions to the bypass valve 10.
  • the bypass arrangement of the present can also be implemented by adapting a sliding valve mechanism.
  • the suitable power transmission mechanism 19 includes a direct coupling of the shaft of motor 2 with male rotor 11 or a gear drive or a belt pulley arrangement.
  • the multi-capacity (speed and power) 2 is generally equipped with an in-built electrical winding network suitable to operate the multi-capacity (speed and power) motor 2 at different pole configurations e.g. 2-pole, 4-pole, 6-pole etc.
  • the pole configuration of the motor 2 is configured to run at a particular speed by activation of the particular pole configuration.
  • a motor controller device 9 is connected the motor 2 to provide activation of the required winding configuration.
  • the motor controller 9 is a stepper motor or any suitable mechanical device or electrical contactors that can drive or transmit the driving functions to the motor 2.
  • An oil separator tank 3 is disposed to collect the compressed discharge from the compressor 1 to filter the residual oil that is carried by the discharge gas or air during the compression operations. However, it is understood here that this requirement of having an oil separator tank may not be necessary if an oil-free screw compressor is used in place of oil-flooded screw compressors.
  • a storage container 5 is generally used as a temporary storage device, for storing the compressed gas or air and to further supply to end applications 6, wherever there is requirement of compressed air or gas supply
  • a non-return valve 4 is disposed between the oil separator tank 3 and the storage container 5, to facilitate unidirectional flow of the compressed air or gas.
  • a plurality of sensing means is disposed on the storage container 5.
  • the sensing means can also be disposed on any location of the discharge passage between compressor outlet 13a and end applications 6.
  • the sensing means are pressure transducers, the can sense a change in the pressure levels and transmit the same as analog signals 15.
  • sensing is performed by using pressure transducers.
  • a temperature transducer or a combination of pressure and temperature transducers can also be used. It is also within purview of this invention to use a flow transducer to measure the flow rate of the discharged compressed gas or air to generate corresponding signals 15.
  • a signal converter interface unit 20 is disposed to convert the analog signals 15 generated from the sensing means to convert the same in to digital signals.
  • the digital signals thus converted are further transmitted to main processing unit 8, which is hereinafter described.
  • Main processing control unit 8 of the present invention is a micro-controller based device having an instruction set to control the various connected devices including motor control unit 9, bypass control unit 7.
  • the micro controller used in the present invention is a device, which is generally used to perform the control operations of this nature.
  • Main processing control unit 8 is connected by means of an electrically conductive material to bypass controller 7 and motor controller 9.
  • the process steps of the present invention is described by referring to various phases of operation that the compressor of the present invention undergoes to control the bypass flow of the compressed air or gas and the multi-capacity (speed and power) of the motor 2 to generate and regulate the flow or delivery of the compressed air or gas.
  • the screw compressor 1 along with the controlling elements and other devices as explained above is energized to carry out the process of compression of air or gas.
  • the main processing control unit 8 which is a micro-controller based is loaded with an instruction set to control the operational aspects of the system.
  • a three-speed electric motor 2 with required number of poles and electrical windings/configurations for achieving these three speeds (N1, N2 & N3) is used to perform the capacity control of the screw compressor 1 of the present invention.
  • N1 is always maximum, which is generally the maximum value of the speed provided to the motor during fabrication.
  • N2 & N3 are used as input data for the main processing control unit 8 to enable the control unit 8 in regulating the desired rpm of the motor 2 at various stages of operation of the screw compressor 1.
  • N values can vary from N1 to Nn .
  • the value of discharge pressure at a given point of time is designated as MP.
  • the screw compressor 1 After the screw compressor 1 starts functioning, the constantly monitored MP pressure value is compared with the pressure values SP1, SP2 and SP3 for finding the matching values.
  • the motor control unit 9 Effect the change in the motor speed, by selecting the rpm from any one of the N1, N2 or N3 values, which correspond to SP1 or SP2 or SP3.
  • active pole configuration of the motor 2 is suitable to run the motor 2 at a maximum speed available i.e. the motor 2 runs at speed value N1.
  • the bypass valve 10 is completely closed, since the normal pressure conditions are experienced in the initial stages of the operation.
  • the pressure value SP1 is designates as a normal working pressure of the screw compressor 1.
  • the main processing control unit 8 will run the motor 2 at speed N1 with bypass control valve 10 in completely closed condition until the continuously monitored discharge pressure value MP is equal to SP1.
  • the capacity control phase starts after completion of the working pressure built-up phase.
  • the screw compressor 1 is required to be operated in capacity control phase whenever there is a reduction in the demand of the compressed air or gas from the end applications 6.
  • the pressure sensing elements sense the pressure of the compressed air or gas and generates the signal 15, in the form of an analog signal as an input to the analog-to-digital converter (ADC) 20 and thereafter supplied to the main processing control unit 8 for further processing.
  • ADC analog-to-digital converter
  • the main processing control unit 8 will not generate any signal for motor control unit 9 and for bypass control unit 7 so the motor keeps on running at N1 with bypass valve 10 in completely closed state.
  • the main processing control unit 8 will generate signal 17 for the bypass control unit 7 and no signal will be generated for motor control unit 9 to enable the motor to run at the maximum speed N1.
  • the bypass control unit 7 opens up the bypass valve 10 till the value of MP is equal to the value of SP1.
  • the main processing control unit 8 In the event where the continuously monitored pressure value of MP is equal to SP2, the main processing control unit 8 generates signals 16 and 17. In response to the signal 17, the bypass control unit 7, closes the bypass valve 10 completely. After this closure of the valve 10 in response to signal 17, the motor control unit 9 changes motor 2 speed value to N2 i.e. motor 2 starts running at N2.
  • the main processing control unit 8 does not generate the signal 16 and generates only the signal 17.
  • the bypass control unit 7 opens-up the bypass valve 10 till the value of MP is equal to SP1.
  • the main processing control unit 8 In the event where the continuously monitored pressure value of MP is equal to SP3, the main processing control unit 8 generates the signals 16 and 17. In response to signal 17 the bypass control unit 7, closes the bypass valve 10 completely and there after in response to signal 17, the motor control unit 9 changes the motor speed to speed value N3 i.e. motor 2 starts running at N3.
  • the main processing control unit 8 In the event where the continuously monitored pressure value MP is greater than SP3 , the main processing control unit 8 generates only the signal 17 and no signal 16 is generated. In response to signal 17, the bypass control unit 7 , opens up the bypass valve 10 till the MP is equal to SP1.
  • the system of the present invention can also be implemented by dispensing with the bypass inlet member, which is used to bypass the intermediately compressed air or gas.
  • the multi-capacity (speed and power) of the motor is achieved by step-control arrangement. In such an arrangement the capacity control will be in stages.
  • the compressor of the present invention where VFD is not used is much more efficient than the compressors run with VFD. For instance if the capacity reduction required is 80 %, in case of compressors with VFD, the same need to be run at 20 % of the desired speed. However, in the compressor of the present invention for the same capacity reduction of 80%, the compressor is run at the 50% of the designed speed.
  • Fig 6 is a graphical representation of the sequence of operations/method of capacity control of the rotary screw compressor of the present invention for a 50Hz frequency power supply condition. The same method can be made applicable for other frequency conditions such as 60Hz frequency condition.
  • the sequence of operations or the method of capacity control is explained in Fig.6 .
  • the point "A" in this figure corresponds to the 100% capacity of the compressor.
  • the multi-capacity motor 2 operates at its maximum design speed and the by pass valve 10 is fully closed.
  • bypass valve gradually opens based on the capacity control requirement.
  • the capacity at "B” with full opening of bypass valve 10 will be corresponding to the capacity of the compressor at next designed speed of motor at Point "C” with by-pass valve fully closed.
  • B-C motor speed changes to next design speed of motor and at closes the bypass valve completely.
  • the above sequence follows between C-D and D-E and so on.
  • the present invention provides a system for implementing capacity control in a screw compressor, said system comprising; a screw compressor, said compressor driven by a multi-capacity (speed and power) motor to compress a medium, a bypass inlet member with a bypass valve, extending from the high pressure zone to the low pressure zone of the screw compressor to recirculate the gaseous medium, a bypass valve controller functionally connected to said bypass valve, a motor controller functionally connected to the motor to effect multi-capacity (speed and power) operations, a main processing control unit disposed to control the bypass valve and multi-capacity (speed and power) operations, measuring means disposed on the compressed medium passage for measuring the changes in the pressure and/or temperature changes in the form of signals, a signal converter functionally connected to the main processing unit and the measuring means to receive the signals, and said motor controller and bypass valve controller are functionally connected to the main processing unit to perform the capacity control of the screw compressor.
  • the system wherein the measuring means is pressure or temperature transducers.
  • the system wherein the bypass inlet member on the compressor where pressure of the air or gas moving through the screw compressor has a positive pressure.
  • the present invention also provides a method for method for capacity control in a screw compressor as claimed in claim 1, said method comprising the steps of; setting a plurality of pressure values along with corresponding motor capacity (speed and power) values for the compressor, measuring discharge pressure of the compressor, comparing the discharge pressure value with the pre-set pressure value, running initially the multi-capacity (speed and power) motor at a maximum speed with bypass valve closed, to deliver the compressed medium, when the discharge pressure value is equal to pre-set pressure value, and controlling the compressor capacity by relative regulation of the bypass valve and the speed of multi-capacity (speed and power) motor, through the main processing unit, to achieve the desired capacity of the compressor.
  • the method wherein the controlling of the compressor capacity is performed by; measuring the discharge pressure, comparing the discharged pressure with pre-set pressure value, running the motor at the motor speed value corresponding to the pre-set pressure value, and controlling the bypass valve to achieve the desired capacity of the compressor.
  • the method wherein the initial motor speed value is varied to the corresponding pre-set pressure value whenever the discharge pressure value is equal to pre-set pressure value.
  • the method wherein the opening of the bypass valve is regulated when the discharge pressure value is not equal to pre-set pressure value.

Claims (6)

  1. Ein System zur Durchführung einer Leistungssteuerung in einem Schneckenverdichter mit:
    (a) einem von einem Mehrfachleistungsmotor angetriebenen Schneckenverdichter mit einer gleich bleibenden Leistung entsprechend der jeweils gewählten Drehzahl, zum Verdichten eines gasförmigen Mediums, wobei der Verdichter eine Verdichtungszone zwischen einem Ansaugrohr und einem Auslasskanal aufweist,
    (b) einer zwischen dem Ansaugrohr und einem Bereich in der Verdichtungszone angeordneten Bypass-Zone, in der ein etwas höherer Druck als am Ansaugrohr herrscht,
    (c) einer Bypass-Leitung mit einem Bypass-Ventil, die zur Rückführung des gasförmigen Mediums von der Bypass-Zone zu dem Ansaugrohr verläuft,
    (d) einer Hauptprozesssteuerungseinheit,
    (e) einer in einem verdichtetes Medium führenden Kanal des Verdichters angeordneten Messeinrichtung zum Messen der Druckänderungen und/oder Temperaturschwankungen in Form von Signalen,
    (f) einem funktional mit der Hauptprozesseinheit und der Messeinrichtung verbundenen Signalumwandler zum Empfangen von Signalen,
    (g) einem funktional mit dem Bypass-Ventil verbundenen Bypass-Ventilregler,
    (h) einem funktional mit dem Motor verbundenen Motorregler zur Durchführung von Mehrfachleistungsvorgängen, wobei der Bypass-Ventilregler und der Motorregler funktional mit der Hauptprozesseinheit verbunden ist,
    (i) der Hauptprozesssteuerungseinheit, die derart angeordnet ist, dass das Bypass-Ventil bei Empfang der Signale zur Steuerung der Verdichterleistung mittels des Bypass-Ventilreglers schrittweise geöffnet wird, sowie
    (j) der Hauptprozesseinheit, die weiterhin derart angeordnet ist, dass die Motordrehzahl durch die Motorsteuerung bei Empfang der Signale zur Steuerung der Verdichterleistung auf die nächste eingestellte Drehzahl umgeschaltet wird, indem das Bypass-Ventil geschlossen wird, wenn die Verdichterleistung der Leistung in der nächsten eingestellten Motordrehzahl entspricht.
  2. System gemäß Anspruch 1, wobei die Messeinrichtung aus Druck- und Temperaturwandlern besteht.
  3. Verfahren zur Leistungssteuerung in einem Schneckenverdichter gemäß Anspruch 1, wobei das Verfahren folgende Schritte umfasst:
    (a) Einstellen einer Vielzahl von Druckwerten zusammen mit entsprechenden Motordrehzahlwerten für den Verdichter,
    (b) Messen des Förderdrucks des Verdichters,
    (c) Vergleichen des Förderdruckwertes mit dem voreingestellten Druckwert,
    (d) anfängliches Regeln des Mehrfachleistungsmotors bei maximaler Drehzahl mit dem Bypass-Ventil in geschlossenem Zustand, um das verdichtete Medium zuzuführen, wenn der Förderdruckwert dem voreingestellten Druckwert entspricht, und
    (e) Steuern der Verdichterleistung durch relative Regulierung des Bypass-Ventils und der Drehzahl des Motors mit mehreren Geschwindigkeiten über die Hauptprozesseinheit, um die gewünschte Leistung des Verdichters zu erreichen.
  4. Verfahren gemäß Anspruch 3, wobei die Steuerung der Verdichterleistung durchgeführt wird durch
    (a) Messen des Förderdrucks,
    (b) Vergleichen des Förderdrucks mit dem voreingestellten Druckwert,
    (c) Betreiben des Motors mit einem Motordrehzahlwert entsprechend dem voreingestellten Druckwert und
    (d) Steuern des Bypass-Ventils, um die gewünschte Leistung des Verdichters zu erreichen.
  5. Verfahren gemäß Anspruch 4, wobei der Ausgangswert der Motordrehzahl auf den entsprechenden voreingestellten Druckwert geändert wird, wenn der Förderdruckwert dem voreingestellten Druckwert entspricht.
  6. Verfahren gemäß Anspruch 4, wobei die Öffnung des Bypass-Ventils reguliert wird, wenn der Förderdruckwert nicht dem voreingestellten Druckwert entspricht.
EP06711366A 2005-02-02 2006-02-01 System und verfahren zur steuerung der leistung eines schraubenverdichters Not-in-force EP1844236B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN85CH2005 2005-02-02
PCT/IN2006/000038 WO2006095364A1 (en) 2005-02-02 2006-02-01 A system and a method for capacity control in a screw compressor

Publications (2)

Publication Number Publication Date
EP1844236A1 EP1844236A1 (de) 2007-10-17
EP1844236B1 true EP1844236B1 (de) 2011-04-06

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US (1) US20080286087A1 (de)
EP (1) EP1844236B1 (de)
CN (1) CN100562666C (de)
AT (1) ATE504743T1 (de)
DE (1) DE602006021137D1 (de)
HK (1) HK1116852A1 (de)
WO (1) WO2006095364A1 (de)

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US6527522B2 (en) 2001-07-03 2003-03-04 Yen Sun Technology Corp. Heat dissipation fan structure

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EP1844236A1 (de) 2007-10-17
ATE504743T1 (de) 2011-04-15
DE602006021137D1 (de) 2011-05-19
WO2006095364A1 (en) 2006-09-14
US20080286087A1 (en) 2008-11-20
CN101163885A (zh) 2008-04-16
HK1116852A1 (en) 2009-01-02
CN100562666C (zh) 2009-11-25

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