Method for analyzing, monitoring, optimizing and/or comparing energy efficiency in a multiple compressor system
11841025 · 2023-12-12
Assignee
Inventors
Cpc classification
F04C28/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04C23/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B2203/0208
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04C2270/80
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D25/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D27/001
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F04D25/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04C23/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04C28/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
The present invention provides a method for analyzing, monitoring, optimizing and/or comparing energy used for producing a unit of mass or volume of compressed gas (Specific Energy Consumption) in relation to a common output flow in a multiple compressor system, said method comprising: —collecting measured data of common output flow and energy/power use and calculating the specific energy consumption in the multiple compressor system, —identifying which data points of measured specific energy consumption that affiliate to a certain compressor or compressor combination in the multiple compressor system and/or operating mode(s) of the multiple compressor system; and —plotting the data points of measured specific energy consumption that affiliate to a certain compressor or compressor combination in the multiple compressor system and/or operating mode of the multiple compressor system and marking affiliation of said data points to the certain compressor or compressor combination and/or operating mode.
Claims
1. A method for analyzing, monitoring, optimizing and/or comparing energy used for producing a unit of mass or volume of compressed gas (Specific Energy Consumption) in relation to a common output flow in a multiple compressor system, said method comprising: collecting measured data of common output flow and energy/power use and calculating the specific energy consumption in the multiple compressor system, identifying which data points of the specific energy consumption that affiliate to a certain compressor or compressor combination in the multiple compressor system and/or operating mode(s) of the multiple compressor system; plotting the data points of the specific energy consumption that affiliate to a certain compressor or compressor combination in the multiple compressor system and/or operating mode of the multiple compressor system and marking affiliation of said data points to the certain compressor or compressor combination and/or operating mode, wherein an ideal specific energy consumption curve(s) is plotted and each ideal specific energy consumption curve is complemented with another curve visualizing the working limit for each certain compressor or compressor combination in the multiple compressor system, and wherein the curves together form a working area for each certain compressor or compressor combination in the multiple compressor system and adapting the multiple compressor system based on the data points of the specific energy consumption.
2. The method according to claim 1, wherein plotting the data points is performed in a chart of specific energy consumption vs common output flow.
3. The method according to claim 1, wherein said method also comprises from a the first compressor, constructing an ideal specific energy consumption curve in the first compressor as a function of the output flow of the first compressor; and from a first compressor and a second compressor, calculating a combined ideal 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 calculated data to be visualized in ideal specific energy consumption curves, to analyze, monitor, optimize and/or compare with measured data for a corresponding multiple compressor system.
4. The method according to claim 1, wherein constructed curves and/or measurement data points in the plots are linked to different compressor combinations, operation modes and/or transitions between different operation modes or compressor combinations and where the links are visualized by markings such as front- or background colors, symbols, separation into different sub-plots or similar to enable analysis of the effects of transitions and operating combinations in the multiple compressor system.
5. The method according to claim 3, wherein the method involves constructing and visualizing the ideal specific energy consumption curve(s) for one or more fixed system reference pressure(s) and/or inlet conditions.
6. The method according to claim 3, wherein the method involves constructing and visualizing one or several ideal specific energy consumption curve(s) for compressor combination(s), in any combination(s).
7. The method according to claim 3, wherein the method involves constructing and visualizing one or several ideal specific energy consumption curves(s) for compressor combination(s), in any combination(s), and wherein at least one combination is based on combining adjustable flow ranges of individual compressors.
8. The method according to claim 3, wherein the calculation of ideal specific energy consumption curves is based on combining non-adjustable flow ranges and adjustable flow ranges for individual compressors separately to form one single virtual compressor.
9. The method according to claim 3, wherein the ideal specific energy consumption curve(s) is calculated with specific energy consumption set as a constant or close to constant within a compressor(s) regulating flow range and where ideal specific energy consumption is calculated from a constant power use for a compressor(s) non-regulating flow range.
10. The method according to claim 3, wherein the ideal specific energy consumption curve(s) is adjusted for efficiency variations within a regulating flow range compared to a constant specific energy consumption and/or wherein the ideal specific energy consumption curve(s) is calculated employing design or performance curves of tho individual compressors.
11. The method according to claim 1, wherein data points outside of the working area(s) for each certain compressor or compressor combination in the multiple compressor system are identified and/or indicated as measuring errors or system or equipment faults.
12. The method according to claim 1, wherein the working limit curve is constructed and plotted as an ideal specific energy consumption curve independent of regulating capabilities of any of the compressors involved in the compressor combination.
Description
DETAILED DESCRIPTION OF THE DRAWINGS
(1) Below, the drawings are described.
(2) In
(3) The compressors may be connected to a ring-line or distribution line and the flow may be split into different end-usage areas in a way that there is no single measurement point where all the combined flow from all compressors passes. The combined end-usage is then the common output flow. The common output flow must then be measured as an aggregated flow from individual measurements throughout the system and/or over the distribution network.
(4) Any compressor system where there at some point in the system is an interconnection between the compressors enabling a cross-flow can be considered as a multi compressor system with a common output flow. It is also common that the air flow from the compressors may be directed in such a way that there are losses of air from certain compressors from e.g. air dryers that are only connected to part of the compressors. The losses occurred in such a process will then be a part of the total output flow (and/or compensated for in the performance adjustments). Such losses can either be measured or calculated from models and/or other parameters such as pressure. One such example is compressor units sold with an integrated dryer unit which may be connected into a system with compressors with external air dryers and where the air from the two types is mixed after dryers.
(5) In
(6) With reference to
(7) In
(8) In
(9) In
(10) In
(11) The uppermost plot shows the available regulating ranges of the different compressor combinations (1, 1 plus 2, 1 plus 2 plus 3) and the non-usable part if the regulating range is marked separately. The non-usable part of the regulating range has been set by taking account of the systems desired capability in handling fast flow changes as well as the needed start-up time for an individual compressor.
(12) The middle plot shows the aggregated ideal specific efficiency curve constructed from the three separate ideal specific energy curves for the three different compressor combinations. The non-usable part of each curves regulating range has been excluded while performing the aggregation. The bottom plot shows a visualization of where the regulating gaps for the system is present based on the aggregated curve shown in the middle plot. 100% on the y-axis show that the system has full regulating capability and thus can operate efficiently and stable. 0% on the y-axis show that the system lack regulating capability for those flow ranges and thereby indicates the position of the systems regulating gaps.
(13) In
(14) In
(15) In
(16) In
(17) The areas used in the three plots are “production” which corresponds to the compressor contributing to the common output flow, “Unload”, where the compressor is in unloaded state and does not provide any contribution to the common output flow and finally “Off”, where the compressor is completely shut down. There are many different options of area classifications that can be used such as separation of the production range into smaller segments and/or presentation of expected IGV position.
(18) In
(19) In
(20) Based on the above, according to one specific embodiment of the present invention, the ideal specific energy consumption curve(s) is plotted and each of them is complemented with another curve visualizing the working limit for each certain compressor or compressor combination in the multiple compressor system, and wherein the curves together form a working area for each certain compressor or compressor combination in the multiple compressor system. Furthermore, according to yet another specific embodiment of the present invention, data points outside of the working area(s) for each certain compressor or compressor combination in the multiple compressor system are identified and/or indicated as measuring errors or system or equipment faults. Moreover, and as hinted above, according to yet another embodiment of the present invention the working limit curve is constructed and plotted in the same way as an ideal specific energy consumption curve but assuming that none of the compressors involved in the compressor combination is using any of their regulating capabilities.
CONCLUSIONS
(21) The present invention provides a model for analyzing an existing multiple compressor system to find the optimal operation mode based on real measurement data.
(22) The method according to the present invention may be directed to different types of usage. For instance, the method may be directed to regulation of a multiple compressor system as such. Moreover, the operation model according to the present invention may also be used only as a simulation model or mathematical model for analyzing an existing multiple compressor system. By use of the model as such, a multiple compressor system may be evaluated and improvements may be implemented. Furthermore, this also implies that the operation model according to the present invention may be used as a type of virtual multiple compressor. Regardless, the main direction of the present invention is a modelling method, implemented directly into a multiple compressor system or used indirectly off-site only on collected data.
(23) The present method is directed to visualize ideal specific energy consumption curves for different compressor combinations and operating modes in the multiple compressor system. This is different when comparing to other existing systems today. Moreover, another clear difference is the fact that the present invention provides both disaggregation and visualization of measurement data into different compressor combination, operating modes, individual compressor operation and system pressure as well as direct comparison of the measurement data with simulated system performance. Other known methods, are limited to comparison only with static reference levels of specific energy usage and/or time average/accumulated key performance indicators, whereas the invention enables the use of key performance indicators measuring efficiency while at the same time taking ideal system performance into consideration thereby providing a much more accurate measurement and base for further analysis. Other known methods are also limited to plotting the systems measured or calculated values in time based plots or in some cases in flow profiles (i.e. histograms), and thereby not providing the analyzing user with any associations between the measured data and the systems operational mode and thereby severely limiting the possibility to find the causes of problems and in many cases to identify the existence of the problems or inefficiencies altogether. The possibility to analyze the system in a time independent manner enable analysis over long periods of time as well as the possibility to compare with an operational model that is directly associated to the data to provide the user with advantage over other available analyzing methods.
(24) To summarize, the method according to the present invention has several advantages in comparison to existing analysis methods for compressed air systems and other multiple compressor systems. Firstly, it provides disaggregation and association of the measured data into unique compressor combinations and system operating modes, enabling identification of problems as well as visualizing the cause. Secondly, real data may be compared directly to a simulation model matching the associated data enabling identification of improvement potential as well as possible improvements to the system set-up, control or operation. Moreover, the present invention provides the tool for a full analysis of an existing multiple compressor system without the need of deep expert knowledge and skill through indication and visualization of both inefficient or unstable operation as well as means to visualize and find the causes and also indicate the possible solution by comparing with simulation of optimal system operation.
(25) To give a guidance of the possible level of improvement when using the present invention, a possible value of specific energy consumption as kWh/Nm.sup.3 at around 0.09 or 0.1 in the widely used pressure band of 6-8 bar may be obtainable using large size screw or turbo compressors, which may be compared to a level of anywhere from 0.15 and upwards which is a common level for a reference multiple compressor system running without proper optimization and/or regulating capability. To lower the specific energy consumption value of this magnitude is of course of great interest. To simplify the process so that non-expert users can perform such system optimizations as well as providing expert users tools to find further earlier unrealized optimization potential is also of great value.
(26) As described above, measured data of common output flow and energy/power use can be collected using different types of sensors, e.g. the power of the compressor can be measured by measuring current and measuring voltage, if not being set at a constant value. By continuously collecting data related to the common output flow of energy/power use as well as determining, or in other words calculating, the specific energy consumption in the multiple compressor system, it is made possible over time to collect data that can be used for increasing the understanding of how to control the system in an energy efficient manner.
(27) Further, it can be identified which data points of measured specific energy consumption, collected by using the sensors, that affiliate to a certain compressor or compressor combination in the multiple compressor system and/or operating mode(s) of the multiple compressor system. Put differently, a specific data point can be associated with the compressor or compressor combination used when the specific data point was collected as well as the operating mode(s) the compressor or compressor combination was set to when the data point was collected. Information of the compressor or the compressor combination used when collecting the data point can be retrieved from the compressors themselves or alternatively from a control unit connected to and controlling the compressors.
(28) Time stamps may be used for affiliating the data points to the compressor or compressor combination as well as the operating mode. When measuring the common output flow and energy/power a time stamp may be added to the measured data. In a similar manner, a compressor or compressor combination being used, as well as the operating mode being used, may be logged with a time stamp. By having time stamps both for the measured data and the compressor and compressor combination, as well as operating mode(s), it is possible to affiliate these to each other.
(29) Having data points collected over time from the compressors and having these affiliated with different compressors or compressor combinations, and also to different operating mode(s) it is made possible to analyze, monitor, optimize or compare different alternatives for producing a unit of mass or volume of compressed gas (Specific Energy Consumption) in terms of energy used. This can be achieved in different ways. For instance, data points related to a specific alternative may be color coded such that when the data points are presented to the user, sometimes also referred to the operator, the different alternatives can be easily kept apart. Still an option is to configure a computer, or a control unit, such that based on the data points a most energy efficient can be chosen and the multiple compressor system adapted accordingly.
(30) The approach above may be described as below:
(31) A method for controlling a multiple compressor system, wherein the multiple compressor system comprises a number of compressors together providing a common output flow, said method comprising
(32) receiving power/energy usage measurement data from a number of sensors connected to the number of compressors, respectively, over a period of time such that a power/energy usage measurement data set covering several compressor combinations and/or operating modes is provided,
(33) receiving, in parallel with receiving the power/energy usage measurement data, system operation data related to operational compressor combination(s) and operating mode(s) from the number of compressors such that system operation data set is provided,
(34) processing the power/energy usage measurement data set and the system operation data set by using a control unit such that data points, related to the power/energy usage measurement data set, are affiliated to operational compressor combination(s) and operating mode(s) by using the system operation data set, such that a measured specific energy consumption data set comprising power/energy usage measurement data for different compressor combinations and operating mode(s) is provided,
(35) selecting, based on the measured specific energy consumption data, a selected compressor combination, and
(36) configuring the multiple compressor system according to the selected compressor combination.
(37) The power/energy usage measurement data may comprise measurement data of flow and power/energy consumption or estimated flow associated with the measured power/energy consumption.
(38) Alternatively, if one system is used for collecting and processing data and another system is used for controlling the multiple compressor system, the approach may be described as below:
(39) A method for monitoring a multiple compressor system, wherein the multiple compressor system comprises a number of compressors together providing a common output flow, said method comprising
(40) receiving power/energy usage measurement data from a number of sensors connected to the number of compressors, respectively, over a period of time such that a power/energy usage measurement data set covering several compressor combinations and/or operating modes is provided.
(41) receiving, in parallel with receiving the power/energy usage measurement data, system operation data related to operational compressor combination(s) and operating mode(s) from the number of compressors such that system operation data set is provided,
(42) processing the power/energy usage measurement data set and the system operation data set by using a control unit such that data points, related to the power/energy usage measurement data set, are affiliated to operational compressor combination(s) and operating mode(s) by using the system operation data set, such that a measured specific energy consumption data set comprising power/energy usage measurement data for different compressor combinations and operating mode(s) is provided,
(43) such that, based on the measured specific energy consumption data, a selected compressor combination may be selected, and the multiple compressor system configured according to the selected compressor combination.
(44) The power/energy usage measurement data may comprise measurement data of flow and power/energy consumption or estimated flow associated with the measured power/energy consumption.
(45) The different features and advantages mentioned above with reference to the method set forth in claim 1 are also applicable to the methods above.
(46) As illustrated in
(47) In addition, the server 1302 can comprise a control unit 1312, comprising a processor 1314, and a transceiver 1316. By using the transceiver 1316, data can be exchanged with multiple compressor systems 1318a, 1318b, 1318c communicatively connected to the server 1302. More particularly, power/energy use measurement data 1320a, 1320b, 1320c and system operation data 1322a, 1322b, 1322c may be transferred from the multiple compressor systems 1318a, 1318b, 1318c to the server 1302, and from the server 1302 configuration data 1324a, 1324b, 1324c may be transferred to the multiple compressor systems 1318a, 1318b, 1318c.
(48) The approach described above, in the form of the server 1302, can be described as below:
(49) The server 1302 configured to control the multiple compressor system 1318a, 1318b, 1318c, wherein the multiple compressor system comprises a number of compressors together providing a common output flow, said server comprising
(50) the transceiver 1316 configured to receive:
(51) the power/energy use measurement data 1320a, 1320b, 1320c from a number of sensors connected to the number of compressors, respectively, over a period of time such that a power/energy usage measurement data set covering several compressor combinations and/or operating modes is provided;
(52) the system operation data 1322a, 1322b, 1322c related to operational compressor combination and operating mode(s) from the number of compressors such that a system operation data set is provided,
(53) the control circuit 1312 configured to execute:
(54) the affiliation function 1306 configured to process the power/energy usage measurement data set and the system operation data set such that data points, related to the power/energy usage measurement data set, are affiliated to operational compressor combination and operating mode(s) such that a measured specific energy consumption data set comprising power/energy usage measurement data for different compressor combinations and operating mode(s) is provided,
(55) the compressor combination selection function 1308 configured to select, based on the measured specific energy consumption data, the selected compressor combination, and
(56) the configuration function 1310 configured to configure the multiple compressor system 1318a, 1318b, 1318c according to the selected compressor combination using configuration data 1324a, 1324b, 1324c,
(57) wherein the transceiver is further configured to transfer:
(58) the configuration data 1324a, 1324b, 1324c to the multiple compressor system 1318a, 138b, 1318c.
(59) The power/energy usage measurement data may comprise measurement data of flow and power/energy consumption or estimated flow associated with the measured power/energy consumption.
(60) Alternatively, as discussed above, if two or more systems are used the server may instead be described as below:
(61) The server configured to monitor the multiple compressor system 1318a, 1318b, 1318c, wherein the multiple compressor system comprises a number of compressors together providing a common output flow, said server comprising
(62) the transceiver 1316 configured to receive:
(63) the power/energy use measurement data 1320a, 1320b, 1320c from a number of sensors connected to the number of compressors, respectively, over a period of time such that a power/energy usage measurement data set covering several compressor combinations and/or operating modes is provided;
(64) the system operation data 1322a, 1322b, 1322c related to operational compressor combination and operating mode(s) from the number of compressors such that a system operation data set is provided,
(65) a monitoring circuit configured to execute:
(66) the affiliation function 1306 configured to process the power/energy usage measurement data set and the system operation data set such that data points, related to the power/energy usage measurement data set, are affiliated to operational compressor combination and operating mode(s) such that a measured specific energy consumption data set comprising power/energy usage measurement data for different compressor combinations and operating mode(s) is provided,
(67) wherein the transceiver is further configured to transfer
(68) the measured specific energy consumption data to other devices configured to execute the compressor combination selection function 1308 configured to select, based on the measured specific energy consumption data, the selected compressor combination, and the configuration function 1310 configured to configure the multiple compressor system 1318a, 1318b, 1318c according to the selected compressor combination using configuration data 1324a, 1324b, 1324c.
(69) The power/energy usage measurement data may comprise measurement data of flow and power/energy consumption or estimated flow associated with the measured power/energy consumption.
(70) The different features and advantages mentioned above with reference to the method set forth in claim 1 are also applicable to the servers above. Further, as illustrated, several multiple compressor systems may be connected to the server. In addition to reducing hardware costs, this also provides an advantage in that information from different multiple compressor systems may be compared and aligned. Thus, for instance, a positive side effect of using the server for assuring energy efficient operation for a plurality multiple compressor systems is that maintenance or service needs may be detected at an early stage by comparing the different multiple compressor systems to one another such that inconsistencies can be detected.