Method and apparatus for controlling a fluid medium compressor system
The present invention relates to a method according to claim 1 for controlling a fluid medium compressor system. The invention also concerns an apparatus suited for controlling a fluid medium compressor system.
In the art, compressor system control equipment are used having a sensor device for measuring the fluid pressure and means for controlling the compressor units on the basis of the output signal of said sensor device so that, when the fluid line pressure falls below a preset lower limit, the compressor system duty capacity is increased by issuing a load command to the compressor unit. In the case that the fluid line pressure does not rise above the preset lower limit with a preset delay period, the compressor system duty capacity is further increased by issuing a new load command to another compressor unit, and so forth. As soon as the fluid line pressure rises above the preset lower limit, the control equipment issues an unload command to one of the running compressor units. If the fluid line pressure after a preset delay period still remains above the preset lower limit, the compressor system duty capacity is further reduced in the same fashion.
Large compressor systems comprise a plurality of compressor units, often located at a great distance from each other. The pressure level varies in the different sections of the system depending on the air consumption and the pressure differential between the compressors and the point of air demand. Hence, sensing the line pressure at one point of a large network does not render all the points of the network capable of securing the critical minimum line pressure level required for the desired function of pneumatic equipment, whereby the only
solution is to elevate the line pressure lower limit to quite a high level .
Furthermore, if a system having the compressor units located wide apart from each other is controlled on the basis of a single pressure signal measured at one point of the compressed-air network, a risk of compressor overload arises as the line pressure on the discharge side of the compressors may rise higher than 'the design value of compressor discharge pressure. Typically, the cause of such an overload condition can be traced to the air- conditioning equipment which is placed downstream from a compressor unit or compressed-air station and whose pressure loss may increase substantially according to the air consumption and degree of filter contamination.
The rate of pressure deviations and basic level of line pressure in a compressed-air system vary dynamically depending on air consumption. The practice of using constant delay periods in the control of compressor units either causes an excessively slow response of the control system not capable of keeping the pressure level within preset limits or forces the system to overreact, whereby compressors are started or loaded unnecessarily.
Therefore, conventional control systems do not lend themselves to such a control of compressed-air systems that could keep the line pressure above a desired minimum level in all desired sections of the compressed-air network in an economical manner without being handicapped by energy losses due to the use of an unnecessarily high basic level of line pressure level.
Moreover, prior-art control systems are incapable of sensing the line pressure levels of distributed compressor systems so as to avoid unnecessarily high
compressor discharge pressure levels in situations where the line pressure falls below the preset minimum level.
Besides, the connection of widely apart located compressors to conventional control equipment involves a plenty of wiring, because the cable to each compressor must have one control line for each desired function. This causes high installation costs and, moreover, elevates the failure rate of the compressed-air system.
A method and apparatus for controlling a compressor system is disclosed in the international patent application WO 96/16271. It is a broad object of the present invention to improve said prior-art system and it is a particular object of the invention to provide a method and apparatus suited for the needs of large compressed- air systems.
The invention is characterized by what is stated in the appended claims.
By virtue of the invention, the input power of a system used for compressing a fluid medium can be kept at the lowest possible level irrespective of the area of the compressor system and the number of compressor units and/or compressor unit groups (compressed-air station) connected thereto. The pressure losses caused by postprocessing equipment connected to the network downstream after the compressor units do not affect the function of the control system in a detrimental manner.
The control system reacts with a desired degree of control gain to the sensed pressure level deviation in each section of the compressed-fluid system. Thus, the demand- point pressure levels of the compressed- fluid system can be kept at their lowest possible values and the no-load idle periods of the compressor units minimized no matter
how massive the extent of the compressed-fluid system. By virtue of the apparatus according to the invention, the installation of the compressed-fluid system is simplified and the operating reliability of the compressed-fluid system is increased.
By virtue of the invention, it will be possible to achieve greater than 30 % energy savings over compressed- fluid systems controlled by conventional means. Even as compared to systems that are controlled by more advanced prior-art logic-controller-steered systems, the margin of potential cost savings is better than 10 %.
Since the subcontroUer units according to the invention are capable of independent control of the line pressure downstream after the compressor units, as well as the line pressure at desired points of a compressed-air network, most advantageously in the vicinity of a compressor station, the self-contained fault diagnostics secure a continuous function of the compressor units irrespective of the status of the individual fluid medium post-processing devices occurring as the plugging of filters, for instance.
In the following, the invention will be examined in more detail with reference to an exemplifying embodiment illustrated in the attached drawing in which is shown a compressor system utilizing the method and apparatus according to the invention.
A control method and apparatus for a compressed-fluid system representing the basic construction details of the present method and apparatus are described in cited patent publication WO 96/16271.
The method and apparatus disclosed in this application are principally intended for use in large compressor
networks of a fluid medium, particularly in compressed- air systems. This type of network involves a plurality of compressor units and/or compressor groups, typically located at a distance from each other.
With reference to the diagram, the present invention relates to a method of controlling a fluid medium compressor system, said compressor system including a plurality of compressor units 1, 1', 1'' and/or groups of compressor units suitable for compressing a fluid medium and means 2 for distributing said compressed fluid medium to at least one point of demand 3 , 4. According to the method, the allowable minimum and maximum pressure levels at said at least one point of demand 3, 4 are defined, the discharge pressure of said compressor unit 1, 1', 1'' is monitored, the line pressure at said point of demand 3, 4, or alternatively, at a desired point along the distribution piping of said medium is monitored, the directions of pressure level changes at said points of the network are monitored, and at least one compressor unit 1, 1', 1 ' ' is controlled by means of a main control unit and/or at least one subcontroUer unit 9, 10 on the basis of at least one of the monitored parameters defined above .
According to the invention, the pressure level of the fluid medium is monitored at multiple points 7, 7', 7'' of demand or along the fluid distribution piping.
Further, the discharge pressure measurement data from at least one compressor unit 1', 1'' and/or from at least one point of demand 3, 4 are transmitted to a subcontrol- ler unit 9, 10, the measurement data are processed in the subcontroUer unit as required, and the processed or raw data are transmitted from said subcontroUer unit 9, 10 to a main control unit 8.
Still further, the information related to the control of the compressor units, such as compressor unit control commands, control parameters and pressure level set data are transmitted from the main control unit 8 to the subcontroUer units 9, 10.
The main control unit 8 regulates the basic line pressure level of the compressed-medium system to a desired level by controlling the compressor units 1, 1', 1'' either directly or via the subcontroUer units according to a specific control scheme.
In the diagram is illustrated an apparatus according to the invention suited for controlling a fluid medium compressor system, whereby said compressor system may comprise a plurality of compressor units 1, 1', 1'' and/or groups of compressor units suitable for compressing a fluid medium and means 2 for distributing said compressed fluid medium to at least one point of demand 3, 4. The apparatus further includes a main control unit and at least one subcontroUer unit, both of which being connected to the operating control system 15, 15', 15'' of at least one compressor unit 1, 1', 1'' and both of which further being connected via data transfer means 13, 13', 13'', 14, 14', 14" to at least one first pressure sensor element 6, 6', 6'' adapted to measure the pressure status of the fluid medium in the vicinity of said compressor unit or compressor unit group 1, 1', 1'' and to at least one second pressure sensor element 7, 7', 7'' adapted to measure the pressure status of the fluid medium at at least one point of demand 3 , 4 and/or a desired point of the distribution piping 2 of the compressed fluid medium.
The first pressure sensor element 6, 6', 6'' is placed upstream preceding the fluid post-processing equipment 5
and the second pressure sensor element 7, 7', 7'' is placed downstream after said post-processing equipment 5.
The main control unit 8 and at least one subcontroUer unit 9, 10 are adapted connectable to each other via data transfer means 11, 12. In this embodiment, the main control unit 8 and at least one subcontroUer unit 9, 10 are connected to each other via a serial interface data transfer bus 12.
In the embodiment illustrated in the drawing, the compressor system includes one main control unit 8 and two subcontroUer units 9, 10. To the main control unit 8 and the subcontroUer units 9, 10 are taken the output sig- nals from pressure sensors 6, 6', 6'' adapted to measure the discharge pressure of the compressors, as well as from a desired number of pressure sensors 7, 7', 7'' adapted to measure the line pressure of the compressed- air network 2. From the main control unit and the subcontroUer units, control signal cabling is passed to the compressor units 1, 1', 1'' and connections are made to the dedicated control systems 15, 15', 15'' of the compressor units. The main control unit and a desired number of the subcontroUer units are connected to each other via a pair cable or similar signal transfer means.
The main control unit reads the serial data transmitted from the subcontroUer units via the pair cable, whereby the transmitted information contains the pressure data gathered and processed from pressure sensor elements 6', 6'', 7', 7'' of the subcontroUer units, as well as the operating status data of the compressor units.
On the basis of pressure data obtained from the pressure sensors 6, 7 connected directly to the main control unit and the status data obtained from the subcontroUer units 9, 10, the main, control unit 8 controls the basic line
pressure level of the compressed-medium system to a proper value by steering the operation of the compressor units 1, 1', 1'' according to a programmed operating system. Furthermore, the main control unit 8 is allowed to decide, on the basis of the measured pressure levels, which sections of the network appear to need an increase of local compressor duty capacity.
Via an operator interface, the main control unit 8 is programmed with operating parameters related to the compressor-specific control scheme. The functions of such an operator interface may be provided by, e.g., a programming terminal, a remote-control room computer, a graphic terminal with a touch panel, or simply, a display terminal with a keyboard.
By virtue of the data transmitted over the serial interface bus, the main control unit is continuously furnished with updated information on the pressure levels at all the pressure measurement points and on the directions of pressure changes at said points, as well as on the pressure rate-of-change at said points. The control unit may be programmed with the criticality of the dynamic pressure level value at each pressure measurement point in regard to the function of the plant that uses the compressed-air supply. Consequently, the main control unit can always select an optimal control scheme suitable for securing the desired pressure set value using the minimum possible compressor input power.
The control system operating parameters may be selected from the group of the compressor-specific delay time values that characterize the capability of each compressor unit to respond in a given time to the control commands issued by the control system. The delay time required to respond to a control command issued by the main control unit is a critical factor which determines
the system capability of keeping the line pressure within its set values. Thus, the control scheme does not require any system-specific parameters to be known in beforehand from the compressed-air system (e.g., the pressure vessel volumes) , which makes the installation and commissioning of the novel control system easy.
As the pressure information processing is distributed to occur at the compressor unit/station level, even a large control system can be implemented using a relatively cost-efficient equipment combination.
Over the serial interface bus, the compressor control commands can be transferred from the main control unit to the subcontroUer units that then implement the commands. Additionally, the bus may be used for transmitting data of allowable maximum and minimum pressure levels, for instance .
The main control unit performs functional status monitoring of subcontroUer unit, and in the case of a possible fault, controls the compressors to manual operating mode. Should a fault of the main control unit occur, the sub- controller units can assume a self-contained running mode, where "tilting" of the entire control system is made almost impossible. This property is a most important benefit, because a fall of line pressure to an insufficiently low level causes almost invariably the shutdown of the process utilizing compressed air.
To those versed in the art it is obvious that the invention is not limited by the exemplifying embodiments described above, but rather, can be varied within the scope of the invention defined in the appended claims.