Gas Turbine Combustor Stabilization via Fuel Flow Split Tuning
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Solution Overview
Problem
Gas turbine engines require frequent manual tuning to maintain optimal performance, which is labor-intensive and inefficient, and existing automatic tuning solutions are not sufficiently efficient or reliable, especially during high-dynamics events where timely adjustments are crucial to prevent hardware damage.
Innovation Solution
A control system that monitors combustion dynamics and emissions by applying a Fourier Transform to pressure signals, adjusting fuel flow splits incrementally to maintain combustion within predetermined limits, allowing for automatic tuning of the gas turbine engine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual tuning is performed to maintain gas turbine engine performance, then the engine can be adjusted to operate within preferred ranges, but the process is labor-intensive and causes extended down-time
Solution Approach 1:
The control system automatically monitors engine parameters and performs tuning adjustments without human intervention. The system self-regulates by detecting when performance drifts outside preferred ranges and autonomously modifies operational parameters to bring them back within specifications, eliminating the need for manual tuning operations.
Solution Approach 2:
The system continuously monitors engine operational parameters and uses this feedback to determine when tuning is needed. Based on the monitored data, the control system automatically adjusts fuel flow splits and other parameters to maintain optimal performance, creating a closed-loop control system that responds dynamically to engine conditions.
2Object-generated harmful factors
If manual tuning is performed to update control system performance, then emissions can be regulated, but operator error and inefficiency occur
Solution Approach 1:
The control system autonomously performs emissions optimization without requiring operator expertise. The system automatically analyzes engine parameters and adjusts fuel flow splits to maintain compliance with emissions regulations, eliminating variability associated with manual operator performance.
Solution Approach 2:
The system replaces manual mechanical tuning operations with automated electronic control. The control system uses software algorithms to calculate optimal fuel flow splits and electronically actuates control valves, substituting human operators with an automated control mechanism that eliminates operator error.
3Extent of automation
If existing automatic tuning solutions are implemented, then some automation is achieved, but they are not sufficiently efficient or reliable during high-dynamics events
Solution Approach 1:
The control system continuously monitors engine parameters and prepares for potential high-dynamics events by maintaining real-time awareness of engine state. When a high-dynamics event is detected, the system has already gathered necessary data and can immediately execute appropriate tuning adjustments without delay, ensuring reliable operation during critical transient conditions.
Solution Approach 2:
The system dynamically adapts its tuning strategy based on real-time engine conditions. During high-dynamics events, the control algorithm adjusts fuel flow splits responsive to changing operational parameters, allowing the system to maintain reliability under varying and transient conditions rather than relying on fixed predetermined settings.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables efficient and reliable automatic tuning of gas turbine engines by consistently adjusting fuel flow splits, reducing processing time and preventing degradation, while minimizing emissions and extending engine life.
Implementation Method 1
a Fourier Transform may be applied to the pressure signals to convert the pressure signals into an amplitude versus frequency format
Implementation Method 2
pressure fluctuations, also called combustion dynamics, may be detected (e.g., utilizing pressure transducers) in each combustor
Implementation Method 3
By altering the fuel flow splits in this manner, the fuel-air mixing within the combustor is changed, thus, affecting the combustion signature
Data Source
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AI summary
An auto-tune controller and tuning process implemented thereby for measuring and tuning the combustion dynamics and emissions of a GT engine, relative to predetermined upper limits, are provided. Initially, the tuning process includes monitoring the combustion dynamics of a plurality of combustors and emissions for a plurality of conditions. Upon determination that one or more of the conditions exceeds a predetermined upper limit, a fuel flow split to a fuel circuit on all of the combustors on the engine is adjusted by a predetermined amount. The control system continues to monitor the combustion dynamics and to recursively adjust the fuel flow split by the predetermined amount until the combustion dynamics and/or emissions are operating within a prescribed range of the GT engine.