Compressor Operating Limit Control Based on Mass Flow Loss
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Solution Overview
Problem
Conventional gas turbine systems overprotect compressors by maintaining a higher operating limit threshold due to difficulties in accurately measuring mass flow rate, leading to reduced operational efficiency and power output, especially in new compressors.
Innovation Solution
A system that uses sensors and computational modules to accurately measure and adjust the operating limit threshold of a compressor based on mass flow loss, dynamically adjusting the margin between the operating limit and surge thresholds to optimize compressor performance and reduce fouling risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the operating limit threshold is maintained at a higher level to protect degraded compressors, then the risk of compressor surge is reduced, but the operational efficiency and power output are reduced
Solution Approach 1:
The operating limit threshold is made dynamic rather than static. The system continuously monitors compressor health parameters and adjusts the operating limit threshold in real-time based on the actual compressor condition. This allows the threshold to be higher for healthy compressors (improving efficiency) and lower for degraded compressors (maintaining protection), resolving the contradiction between reliability and productivity
Solution Approach 2:
The system implements feedback control by monitoring compressor performance parameters and using this information to adjust the operating limit threshold. The feedback loop enables the system to adapt the protection level based on actual compressor health, allowing optimal efficiency when the compressor is healthy while maintaining adequate protection when degradation occurs
2Productivity
If the operating limit threshold is lowered to improve operational efficiency, then power output increases, but the risk of compressor surge increases
Solution Approach 1:
The operating limit threshold dynamically adapts to compressor health status. When the compressor is healthy, the threshold can be lowered to allow higher power output while maintaining safety. When degradation is detected, the threshold automatically increases to prevent surge, resolving the contradiction between productivity and reliability
3Reliability
If new compressors are operated with the same conservative threshold as degraded compressors, then protection is ensured, but operational efficiency is reduced
Solution Approach 1:
The system performs preliminary assessment of compressor health status and sets appropriate operating limits before degradation occurs. For new or healthy compressors, the system preemptively allows higher operating thresholds, maximizing efficiency. The conservative threshold is only applied when actually needed based on detected degradation, eliminating unnecessary efficiency loss
Data Source
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AI summary
Systems (10), program products, and methods for adjusting operating limit (OL) thresholds (144B, 144D) for compressors (12) of gas turbine systems (11) based on mass flow loss (130) are disclosed herein. The systems (10) may include at least one computing device (100) in communication with the gas turbine system (11), sensor(s) (106) measuring operational characteristic(s) of the gas turbine system (11), and a pressure sensor (104) measuring an ambient fluid (20) pressure surrounding the gas turbine system (11). The computing device(s) (100) may be configured to adjust operational parameters of the gas turbine system (11) by performing processes including determining a mass flow loss (130) between an estimated, first mass flow rate (124) and a calculated, second mass flow rate (128) for the compressor (12) of the gas turbine system (11), and adjusting an OL threshold (144, 144A, 144C) for the compressor (12) of the gas turbine system (11) based on the mass flow loss (130). The OL threshold (144, 144A, 144C) for the compressor (12) may be below a predetermined surge threshold (140) for the compressor (12).