Fan Optimization Module for Gas Turbine Cooling Water Systems
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Solution Overview
Problem
Gas turbine engine components face challenges in withstanding increasingly high temperatures without deterioration, and existing cooling systems are inefficient, acting as a parasitic drain on overall performance.
Innovation Solution
A method and system for optimizing fan usage in a closed loop cooling water system, involving a heat exchanger, fans, and a fan optimization module to calculate and balance the number of fans turned on or off based on thermal energy requirements, aiming to reduce energy consumption and extend component lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If all fans are run continuously at base load to ensure adequate cooling, then cooling reliability is improved, but energy consumption increases
Solution Approach 1:
The system dynamically adjusts fan operation based on real-time cooling requirements. The optimization module continuously monitors cooling fluid temperature, heat transfer capabilities, and thermal energy requirements to determine the minimum number of fans needed, allowing the system to adapt between continuous operation and reduced operation modes
Solution Approach 2:
The system changes operational parameters by adjusting the number of active fans based on calculated thermal energy requirements. The optimization module modifies fan operation parameters (on/off states) according to varying thermal conditions, converting the cooling system from static continuous operation to dynamic parameter-adjusted operation
2Use of energy by moving object
If fans are operated selectively to reduce energy consumption, then energy efficiency is improved, but cooling performance may deteriorate
Solution Approach 1:
The optimization module implements a feedback mechanism by continuously monitoring actual cooling fluid temperature, comparing it with target temperature, and using the temperature difference feedback to adjust fan operation. The system calculates heat transfer capabilities and thermal energy requirements based on real-time conditions, ensuring cooling performance is maintained while optimizing energy usage
Solution Approach 2:
The system performs preliminary calculations of heat transfer capabilities and thermal energy requirements before making fan operation decisions. By pre-calculating the minimum number of fans needed based on current thermal conditions, the system ensures adequate cooling is maintained before reducing fan operation, preventing performance deterioration
3Device complexity
If fans are used unevenly to reduce operational complexity, then system complexity is reduced, but fan lifespan and performance uniformity deteriorate
Solution Approach 1:
The system implements periodic action by cycling fans through on/off states in a balanced manner. The optimization module distributes operating hours evenly among available fans, ensuring each fan receives comparable usage over time. This periodic rotation of fan operation maintains performance uniformity and extends overall system lifespan while managing operational complexity
4Reliability
If cooling fluid temperature is reduced to improve cooling effectiveness, then cooling effectiveness is improved, but make-up fluid usage increases
Solution Approach 1:
The system changes temperature parameters by optimizing cooling fluid temperature based on actual thermal energy requirements rather than maintaining a fixed low temperature. The optimization module adjusts the target temperature parameter dynamically, allowing higher temperatures when full cooling effectiveness is not needed, thereby reducing make-up fluid usage while maintaining adequate cooling
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 approach reduces parasitic energy consumption, balances fan running hours for uniform performance, determines maintenance priorities, and minimizes make-up fluid usage, thereby enhancing the efficiency and longevity of gas turbine engine components.
Implementation Method 1
a heat exchanger to cool a cooling fluid
Implementation Method 2
a number of fans positioned about the heat exchanger
Data Source
AI summary
The present application provides a method of optimizing fan usage in a cooling water system having a number of fans with a heat exchanger to cool a cooling fluid for use with a number of gas turbine subsystems. The method may include the steps of running all of the fans at base load, calculating a heat transfer capability of each fan at base load, calculating a temperature difference between an actual temperature and a target temperature of the cooling fluid, selecting a minimum target temperature of the cooling fluid, calculating a target thermal energy of the cooling fluid for the minimum target temperature, calculating a number of the fans to be turned on or off by dividing the target thermal energy with the heat transfer capability of each fan, and turn on or off the calculated number of fans in a predetermined manner with an objective of balancing the running hours of each fan.