Energy Control Computing Device for Combined Cycle Plant Optimization
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Solution Overview
Problem
Combined cycle power plants face inefficiencies when topping cycle exhaust energy exceeds the capability of the bottoming cycle, requiring additional investments and complex control methods to manage exhaust energy, which can lead to reduced power output and increased costs.
Innovation Solution
An energy control computing device that adjusts steam flow parameters to maximize steam flow to the steam turbine without exceeding operating limits, using sensors and control devices to identify optimal operating modes and direct system components to achieve maximum energy production while respecting equipment limitations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If exhaust gas bypass stack with damper is used to reduce exhaust energy directed to bottoming cycle, then bottoming cycle capability is maintained, but capital investment and device complexity increase significantly
Solution Approach 1:
The patent extracts the control function from complex mechanical bypass systems and implements it through software-based operating mode selection. The controller identifies candidate operating modes and selects optimal modes through computational algorithms, removing the need for physical bypass stacks and dampers while maintaining bottoming cycle capability.
Solution Approach 2:
The patent replaces mechanical control systems (bypass stack with damper) with an electronic control system that uses sensors, a controller, and software algorithms to manage exhaust energy distribution. This substitution eliminates significant capital investment in mechanical infrastructure while achieving the same control objectives.
2Loss of energy
If additional dump condenser or larger system condenser is provided to reduce exhaust energy, then exhaust energy management is improved, but capital investment and device complexity increase
Solution Approach 1:
The patent implements dynamic control of steam flow parameters through operating mode selection, allowing the system to adapt exhaust energy management in real-time based on operating conditions. The controller dynamically identifies candidate modes and selects optimal modes to maximize steam flow within turbine operating limits, replacing static condenser infrastructure with dynamic software-based control.
Solution Approach 2:
The patent changes the control approach from modifying physical infrastructure (condenser size) to adjusting operational parameters (steam flow parameters) through software. The controller modifies steam flow parameters by selecting from candidate operating modes, achieving energy management without additional capital investment in condenser infrastructure.
3Productivity
If steam flow parameters are increased to maximize bottoming cycle output, then power output increases, but steam turbine operating limits may be exceeded
Solution Approach 1:
The patent implements feedback control by continuously monitoring steam turbine operating limits and adjusting steam flow parameters accordingly. The controller receives feedback on current operating conditions, identifies candidate operating modes that satisfy turbine limits, and selects modes that maximize power output while maintaining reliability within established operating boundaries.
Solution Approach 2:
The patent performs preliminary identification of candidate operating modes that satisfy steam turbine operating limits before selecting the optimal mode for maximum power output. This preliminary filtering ensures that reliability constraints are met before optimizing for productivity, preventing exceedance of turbine operating limits.
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
This solution enhances the efficiency of the bottoming cycle by optimizing steam flow and reducing the need for additional emissions reduction equipment, thereby maximizing power output and reducing overall costs.
Implementation Method 1
The hot exhaust gases from the turbine section of the gas turbine are typically directed to a heat recovery steam generator ("HRSG"), which produces steam from the recovered heat
Data Source
AI summary
The present application provides an energy control computing device for adjusting one or more steam flow parameters delivered to a steam turbine from a heat recovery steam generator via a number of control devices. The energy control computing device includes a processor in communication with a memory. The processor is programmed to receive a number of measured operating values, identify steam turbine operating limits, identify a number of candidate operating modes meeting steam turbine operating limits, selecting the candidate operating mode maximizing the steam flow parameters while not exceeding the steam turbine operating limits, and directing the control devices to meet the selected candidate operating mode.