Granted Patent B2

US 12,378,970 · App. 17/933,237 · Granted Aug 5, 2025

Inventors: Michael D. Oakley (Dayton, OH); Michael M. Perevozchikov (Tipp City, OH); Matthew J. Swallow (Versailles, OH)

Assignee: Copeland LP

F04D27/001F04D17/12F04D29/30

Abstract

Claims (83)

1. A system comprising:

a dynamic compressor operable to compress a working fluid, the dynamic compressor comprising an impeller, a motor operably connected to the impeller, a variable frequency drive (VFD) coupled to the motor, and a variable inlet guide vane (VIGV); and

a controller connected to the dynamic compressor, the controller comprising a processor and a memory, the memory storing:

a map of a plurality of predetermined operating points of the dynamic compressor, each predetermined operating point including a mass flow of the dynamic compressor at that predetermined operating point; and

instructions that program the processor to:

operate the dynamic compressor to compress the working fluid by controlling a position of the VIGV and controlling a speed of the motor driving the impeller using the VFD;

determine, while operating the dynamic compressor, a current operating point of the compressor;

calculate a mass flow for the current operating point from the map of the plurality of predetermined operating points; and

continue to operate the dynamic compressor to compress the working fluid based at least in part on the calculated mass flow for the current operating point by inputting the calculated mass flow into a control algorithm that calculates an operating point value based at least in part on the calculated mass flow and controlling an unloading device of the dynamic compressor based on the operating point value and a margin.

2. The system of claim 1 , wherein the instructions stored in the memory program the processor to calculate the mass flow for the current operating point from the map of the plurality of predetermined operating points by:

retrieving the mass flow from the map when the current operating point is one of the predetermined operating points; and

determining the mass flow for the current operating point by interpolating between a plurality of the predetermined operating points when the current operating point is not one of the predetermined operating points.

3. The system of claim 1 , wherein the instructions stored in the memory program the processor to calculate the mass flow for the current operating point from the map of the plurality of predetermined operating points by:

identifying a subset of the predetermined operating points;

determining distances between the current operating point and each predetermined operating point in the subset of the predetermined operating points; and

calculating the mass flow of the current operating point as a function of the determined distances and the mass flow of each predetermined operating point in the subset of the predetermined operating points.

4. The system of claim 1 , wherein each predetermined operating point and the current operating point are defined by the speed of the motor and an operating pressure ratio of the compressor.

5. The system of claim 1 , wherein each predetermined operating point and the current operating point are defined by the speed of the motor, an operating pressure ratio, and the position of the VIGV.

6. The system of claim 5 , wherein the instructions stored in the memory program the processor to calculate the mass flow for the current operating point from the map of the plurality of predetermined operating points by:

identifying a first subset of the predetermined operating points, the first subset of predetermined operating points having a same first VIGV position that is less than a current VIGV position of the current operating point;

determining distances between the current operating point with the current VIGV position replaced with the first VIGV position and the predetermined operating points in the first subset;

calculating a first intermediate mass flow of the current operating point with the current VIGV position replaced with the first VIGV position as a function of the determined distances and the mass flow of each predetermined operating point of the first subset;

identifying a second subset of the predetermined operating points, the second subset of predetermined operating points having a same second VIGV position greater than the current VIGV position of the current operating point;

determining distances between the current operating point with the current VIGV position replaced with the second VIGV position and the predetermined operating points of the second subset;

calculating a second intermediate mass flow of the current operating point with the current VIGV position replaced with the second VIGV position as a function of the determined distances and the mass flow of each predetermined operating point of the second subset; and

calculating the mass flow of the current operating point as a function of the first intermediate mass flow, the second intermediate mass flow, and distances between the current VIGV position and the first and second VIGV positions.

7. The system of claim 1 , wherein the memory further stores a map of a plurality of predetermined surge points, a surge point mass flow for each predetermined surge point, a map of a plurality of predetermined choke points, and a choke point mass flow for each predetermined choke point, and the instructions stored in the memory program the processor to:

determine a current surge point for the current operating point based on the map of the plurality of predetermined surge points;

determine a current choke point for the current operating point based on the map of the plurality of predetermined choke points;

calculate a surge point mass flow for the current surge point from the map of the plurality of predetermined surge points; and

calculate a choke point mass flow for the current choke point from the map of the plurality of predetermined choke points.

8. The system of claim 1 , wherein the dynamic compressor does not include a mass flow sensor.

9. A controller for a dynamic compressor without a mass flow sensor, the dynamic compressor including an impeller, a motor operably connected to the impeller, a variable frequency drive (VFD) coupled to the motor, and a variable inlet guide vane (VIGV), the controller comprising:

a processor; and

a memory, the memory storing:

a map of a plurality of predetermined operating points of the dynamic compressor, each predetermined operating point including a mass flow of the dynamic compressor at that predetermined operating point; and

instructions that program the processor to:

operate the dynamic compressor to compress the working fluid by controlling a position of the VIGV and controlling a speed of the motor driving the impeller using the VFD;

determine, while operating the dynamic compressor, a current operating point of the compressor;

calculate a mass flow for the current operating point from the map of the plurality of predetermined operating points; and

continue to operate the dynamic compressor to compress the working fluid based at least in part on the calculated mass flow for the current operating point by inputting the calculated mass flow into a control algorithm that calculates an operating point value based at least in part on the calculated mass flow and controlling an unloading device of the dynamic compressor based on the operating point value and a margin.

10. The controller of claim 9 , wherein the instructions stored in the memory program the processor to calculate the mass flow for the current operating point from the map of the plurality of predetermined operating points by:

retrieving the mass flow from the map when the current operating point is one of the predetermined operating points; and

determining the mass flow for the current operating point by interpolating between a plurality of the predetermined operating points when the current operating point is not one of the predetermined operating points.

11. The controller of claim 10 , wherein each predetermined operating point and the current operating point are defined by the speed of the motor, an operating pressure ratio, and the position of the VIGV, wherein the instructions stored in the memory program the processor to calculate the mass flow for the current operating point from the map of the plurality of predetermined operating points by:

identifying a first subset of the predetermined operating points, the first subset of predetermined operating points having a same first VIGV position that is less than a current VIGV position of the current operating point;

determining distances between the current operating point with the current VIGV position replaced with the first VIGV position and the predetermined operating points in the first subset;

calculating a first intermediate mass flow of the current operating point with the current VIGV position replaced with the first VIGV position as a function of the determined distances and the mass flow of each predetermined operating point of the first subset;

identifying a second subset of the predetermined operating points, the second subset of predetermined operating points having a same second VIGV position greater than the current VIGV position of the current operating point;

determining distances between the current operating point with the current VIGV position replaced with the second VIGV position and the predetermined operating points of the second subset;

calculating a second intermediate mass flow of the current operating point with the current VIGV position replaced with the second VIGV position as a function of the determined distances and the mass flow of each predetermined operating point of the second subset; and

calculating the mass flow of the current operating point as a function of the first intermediate mass flow, the second intermediate mass flow, and distances between the current VIGV position and the first and second VIGV positions.

12. The controller of claim 9 , wherein the instructions stored in the memory program the processor to calculate the mass flow for the current operating point from the map of the plurality of predetermined operating points by:

identifying a subset of the predetermined operating points;

determining distances between the current operating point and each predetermined operating point in the subset of the predetermined operating points; and

calculating the mass flow of the current operating point as a function of the determined distances and the mass flow of each predetermined operating point in the subset of the predetermined operating points.

13. The controller of claim 9 , wherein each predetermined operating point and the current operating point are defined by the speed of the motor and an operating pressure ratio.

14. The controller of claim 9 , wherein the memory further stores a map of a plurality of predetermined surge points, a surge point mass flow for each predetermined surge point, a map of a plurality of predetermined choke points, and a choke point mass flow for each predetermined choke point, and the instructions stored in the memory program the processor to:

determine a current surge point for the current operating point based on the map of the plurality of predetermined surge points;

determine a current choke point for the current operating point based on the map of the plurality of predetermined choke points;

calculate a surge point mass flow for the current surge point from the map of the plurality of predetermined surge points; and

calculate a choke point mass flow for the current choke point from the map of the plurality of predetermined choke points.

15. A method of determining a mass flow of a dynamic compressor that is compressing a working fluid and does not include a mass flow sensor, the dynamic compressor including an impeller, a motor operably connected to the impeller, a variable frequency drive (VFD) coupled to the motor, and a variable inlet guide vane (VIGV), the method comprising:

operating the dynamic compressor to compress the working fluid by controlling a position of the VIGV and controlling a speed of the motor driving the impeller using the VFD;

determining, while operating the dynamic compressor, a current operating point of the compressor;

calculating the mass flow for the current operating point from a map of a plurality of predetermined operating points, each predetermined operating point including a mass flow of the dynamic compressor at that predetermined operating point; and

continuing to operate the dynamic compressor to compress the working fluid based at least in part on the calculated mass flow for the current operating point by inputting the calculated mass flow into a control algorithm that calculates an operating point value based at least in part on the calculated mass flow and controlling an unloading device of the dynamic compressor based on the operating point value and a margin.

16. The method of claim 15 , wherein calculating the mass flow for the current operating point from the map of the plurality of predetermined operating points comprises:

identifying a subset of the predetermined operating points;

determining distances between the current operating point and each predetermined operating point in the subset of the predetermined operating points; and

calculating the mass flow of the current operating point as a function of the determined distances and the mass flow of each predetermined operating point in the subset of the predetermined operating points.

17. The method of claim 15 , wherein each predetermined operating point and the current operating point are defined by the speed of the motor, an operating pressure ratio, and the position of the VIGV, and calculating the mass flow for the current operating point from the map of the plurality of predetermined operating points comprises:

identifying a first subset of the predetermined operating points, the first subset of predetermined operating points having a same first VIGV position that is less than a current VIGV position of the current operating point;

determining distances between the current operating point with the current VIGV position replaced with the first VIGV position and the predetermined operating points in the first subset;

calculating a first intermediate mass flow of the current operating point with the current VIGV position replaced with the first VIGV position as a function of the determined distances and the mass flow of each predetermined operating point of the first subset;

identifying a second subset of the predetermined operating points, the second subset of predetermined operating points having a same second VIGV position greater than the current VIGV position of the current operating point;

determining distances between the current operating point with the current VIGV position replaced with the second VIGV position and the predetermined operating points of the second subset;

calculating a second intermediate mass flow of the current operating point with the current VIGV position replaced with the second VIGV position as a function of the determined distances and the mass flow of each predetermined operating point of the second subset; and

calculating the mass flow of the current operating point as a function of the first intermediate mass flow, the second intermediate mass flow, and distances between the current VIGV position and the first and second VIGV positions.

18. The method of claim 15 , further comprising determining a current surge point for the current operating point based on a map of a plurality of predetermined surge points, wherein the map includes a surge point mass flow for each predetermined surge point;

determining a current choke point for the current operating point based on a map of the plurality of predetermined choke points, wherein the map includes a choke point mass flow for each predetermined choke point;

calculating a surge point mass flow for the current surge point from the map of the plurality of predetermined surge points; and

calculating a choke point mass flow for the current choke point from the map of the plurality of predetermined choke points.

Assignments (6)