Gas Turbine Compressor Threshold Adjustment Using Mass Flow Loss
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Solution Overview
Problem
Conventional gas turbine systems operate compressors at lower efficiency due to overprotective measures against compressor surge, as accurate mass flow rate measurement is difficult, leading to an exaggerated operating limit margin, which reduces efficiency and output, especially in new compressors.
Innovation Solution
A system that adjusts operational parameters of a gas turbine system by estimating and calculating mass flow rates based on measured operational characteristics and ambient fluid pressure, determining mass flow loss, and dynamically adjusting the operating limit threshold below a predetermined surge threshold to optimize compressor operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the operating limit threshold is set lower to ensure protection against compressor surge, then the reliability of the compressor is improved, but the operational efficiency and power output deteriorate
Solution Approach 1:
The operating limit threshold is made dynamic rather than static. The control system continuously monitors compressor conditions and adjusts the operating limit threshold in real-time based on actual mass flow rate measurements and compressor degradation state, allowing the threshold to adapt between conservative (when degraded) and optimized (when new) settings
Solution Approach 2:
The system implements feedback by measuring actual mass flow rate and using this information to adjust the operating limit threshold. The control system receives feedback on compressor performance and modifies the threshold accordingly, creating a closed-loop control that resolves the contradiction between protection and efficiency
2Reliability
If the operating limit threshold is set lower to account for measurement uncertainties, then the reliability against surge is improved, but the operational efficiency deteriorates
Solution Approach 1:
The system replaces conservative mechanical/operational margins with intelligent measurement and calculation systems. By implementing accurate mass flow rate measurement and sophisticated calculation algorithms that account for uncertainties, the system can use smaller safety margins while maintaining reliability, thus improving efficiency
Solution Approach 2:
The system changes the parameter of operating limit threshold from a fixed conservative value to a dynamically adjusted value based on actual measurements and uncertainty analysis. This parameter change allows optimization of the threshold to balance reliability and efficiency
3Reliability
If the control system operates the compressor as if it was fully degraded, then the reliability protection is improved, but the operational efficiency deteriorates
Solution Approach 1:
The system performs preliminary assessment of compressor condition through mass flow rate measurement and comparison with baseline values. By determining the actual degradation state in advance, the system can set appropriate operating limits tailored to the specific compressor condition rather than assuming full degradation
Solution Approach 2:
The system applies different operating strategies to different operational phases of the compressor. New compressors receive optimized operating limits that allow higher efficiency, while degraded compressors receive conservative limits. This local quality approach matches the protection level to the actual condition
Data Source
AI summary
Systems, program products, and methods for adjusting operating limit (OL) thresholds for compressors of gas turbine systems based on mass flow loss are disclosed herein. The systems may include at least one computing device in communication with the gas turbine system, sensor(s) measuring operational characteristic(s) of the gas turbine system, and a pressure sensor measuring an ambient fluid pressure surrounding the gas turbine system. The computing device(s) may be configured to adjust operational parameters of the gas turbine system by performing processes including determining a mass flow loss between an estimated, first mass flow rate and a calculated, second mass flow rate for the compressor of the gas turbine system, and adjusting an OL threshold for the compressor of the gas turbine system based on the mass flow loss. The OL threshold for the compressor may be below a predetermined surge threshold for the compressor.