System and method to improve performance of a compressor device comprising variable diffuser vanes

Abstract

Embodiments of a system and method can modify the position of diffuser vanes to improve performance of a compressor device, e.g., a centrifugal compressor. These embodiments form a feedback loop to manage the position of the diffuser vanes relative to one or more operating parameters on the compressor device. In one embodiment, the system and method measure input power with the diffuser vanes at a first position and a second position. Changes in the input power will identify other positions for the diffuser vanes that optimize performance of the compressor device, e.g., to reduce power consumption and to achieve and maintain peak compressor efficiency within the entire operating envelope of the compressor device.

What is claimed is: 
     
         1 . A system, comprising:
 a compressor device comprising an impeller, a drive unit coupled to the impeller, and a diffuser vane in flow connection with the impeller; and   a controller coupled to the compressor device, the controller comprising a processor, memory, and executable instructions stored on memory and configured to be executed by the processor, the executable instructions comprising instructions for:
 receiving a first signal encoding a first value for an operating parameter for the compressor device with the diffuser vane in a first position; 
 receiving a second signal encoding a second value for the operating parameter of the compressor device with the diffuser vane in a second position; 
 comparing the first value and the second value; 
 selecting an increment by which to move the diffuser vane from the second position, the increment defining the relative position of the second value with respect to the first value; and 
 generating an output encoding instructions to move the diffuser vane from the second position by the increment. 
   
     
     
         2 . The system of  claim 1 , wherein the operating parameter comprises an input power value for the drive unit. 
     
     
         3 . The system of  claim 1 , wherein the operating parameter comprises a power transmission value that measures torque applied to the impeller by the drive unit. 
     
     
         4 . The system of  claim 3 , further comprising a torque coupling secured to at least one of the impeller and the drive unit, wherein the first signal and the second signal encode data collected by the torque coupling. 
     
     
         5 . The system of  claim 1 , wherein the operating parameter comprises a head pressure for the compressor device. 
     
     
         6 . The system of  claim 5 , further comprising a pressure sensor disposed proximate an output of the compressor device, wherein the first signal and the second signal respecting data collected by the pressure sensor. 
     
     
         7 . The system of  claim 1 , further comprising instructions for determining an inlet flow value upstream of the diffuser vane and setting the first position to correspond with the inlet flow value. 
     
     
         8 . The system of  claim 5 , further comprising a flow meter disposed upstream of the diffuser vane, the flow meter providing a third signal that encodes the inlet flow value. 
     
     
         9 . The system of  claim 1 , wherein the increment changes the position of the diffuser vane in a first direction if the second value is larger than the first value, wherein the increment changes the position of the diffuser vane in a second direction if the second value is smaller than the first value, and wherein the first direction is different from the second direction. 
     
     
         10 . The system of  claim 1 , further comprising comparing the second value to a threshold criteria, wherein the threshold criteria defines a maximum value for the operating parameter and a minimum value for the operating parameter, and wherein the increment changes the position of the diffuser vane if the second value is equal to or greater than the maximum value and equal to or less than the minimum value. 
     
     
         11 . The system of  claim 1 , further comprising an actuator coupled to the diffuser vanes, wherein the actuator moves the diffuser vane in response to the output from the controller. 
     
     
         12 . The system of  claim 11 , wherein the increment defines an angular offset of the diffuser vane from the second position. 
     
     
         13 . A compressor device, comprising:
 a drive unit;   an impeller coupled to the drive unit;   a diffuser assembly in flow connection with the impeller, the diffuser assembly comprising an actuator and a diffuser vane coupled to the actuator; and   a controller coupled with the actuator, the controller comprising a processor, memory, and executable instructions stored on memory and configured to be executed by the processor, the executable instructions comprising instructions for:
 receiving a first signal encoding a first value for an operating parameter for the compressor device with the diffuser vane in a first position; 
 receiving a second signal encoding a second value for the operating parameter of the compressor device with the diffuser vane in a second position; 
 comparing the first value and the second value; 
 selecting an increment by which to move the diffuser vane from the second position, the increment defining the relative position of the second value with respect to the first value; and 
 generating an output encoding instructions to move the diffuser vane from the second position by the increment. 
   
     
     
         14 . The compressor device of  claim 13 , further comprising a parameter sensor coupled with the controller, wherein the parameter sensor is in position to measure the operating parameter, and wherein the parameter sensor generates the first signal and the second signal. 
     
     
         15 . The compressor device of  claim 14 , wherein the parameter sensor comprises a flow meter upstream of the impeller. 
     
     
         16 . The compressor device of  claim 14 , wherein the parameter sensor measures input voltage on the drive unit. 
     
     
         17 . The compressor device of  claim 14 , wherein the parameter sensor comprises a torque meter coupled the impeller. 
     
     
         18 . The compressor device of  claim 13 , wherein the diffuser vane has a rotation axis about which the trailing edge rotates about the leading edge when moving from the first position and the second position. 
     
     
         19 . A controller for controlling operation of a compressor device, the compressor device having a diffuser vane with a first position and a second position that is different from the first position, said controller comprising:
 a processor;   memory; and   executable instructions stored on memory and configured to be executed by the processor, the executable instructions comprising instructions for:
 receiving a first signal encoding a first value for an operating parameter for the compressor device with the diffuser vane in a first position; 
 receiving a second signal encoding a second value for the operating parameter of the compressor device with the diffuser vane in a second position; 
 comparing the first value and the second value; 
 selecting an increment by which to move the diffuser vane from the second position, the increment defining the relative position of the second value with respect to the first value; 
 generating an output encoding instructions to move the diffuser vane from the second position by the increment. 
   
     
     
         20 . The controller of  claim 19 , operating parameter comprises an input power value for the drive unit. 
     
     
         21 . A computer program product for improving efficiency of a compressor device, the computer program product comprising a computer readable storage medium having executable instructions embodied therein, wherein the executable instructions comprise one or more executable instructions for:
 receiving a first signal encoding a first value for an operating parameter for the compressor device with the diffuser vane in a first position;   receiving a second signal encoding a second value for the operating parameter of the compressor device with the diffuser vane in a second position;   comparing the first value and the second value;   selecting an increment by which to move the diffuser vane from the second position, the increment defining the relative position of the second value with respect to the first value;   generating an output encoding instructions to move the diffuser vane from the second position by the increment.