Gas Turbine Auto Testing System Using Closed-Loop Control
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Solution Overview
Problem
Conventional industrial gas turbine engines require manual operation for test sequences, which do not accurately reflect real-world conditions due to differences in climate, elevation, and fuel composition, leading to deviations in measured operating parameters.
Innovation Solution
An automatic testing method using a closed-loop control system with a gas turbine system comprising a control unit, sensor device, comparative unit, and data acquisition system, which includes a thermodynamic model unit to calculate and adjust parameters like combustor outlet temperature and normalized speed to achieve target performance parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual operation is used for test sequences, then operators can control the gas turbine engine, but the test sequences do not accurately reflect real-world conditions due to deviations in measured operating parameters
Solution Approach 1:
The system continuously compares actual operating parameters with reference values from a database and automatically adjusts control parameters based on the deviations detected, enabling the test sequence to adapt to real-world conditions while maintaining measurement accuracy
Solution Approach 2:
The system dynamically modifies test parameters based on detected deviations from reference values, adjusting operating parameters in real-time to compensate for environmental differences and maintain both accuracy and adaptability
2Extent of automation
If automatic testing is implemented, then the need for manual operation is reduced, but the system complexity increases
Solution Approach 1:
A database storing reference operating parameters serves as an intermediary between the sensor device and control unit, enabling automatic testing by providing reference values for comparison without requiring complex decision-making logic in the control system
Solution Approach 2:
The system replaces manual mechanical operation with automated electronic control, using software-based parameter comparison and adjustment instead of manual operator intervention, thereby increasing automation while managing complexity through information processing
3Stability of the object's composition
If predefined test cycles are used, then test sequences can be executed systematically, but the test cycles do not coincide with actual operating parameters values and environmental parameters
Solution Approach 1:
The test system transitions from static predefined cycles to dynamic adaptive testing, where control parameters are continuously adjusted based on real-time comparison with reference values, maintaining procedural consistency while ensuring representativeness of test results
Data Source
AI summary
A gas turbine system has a gas turbine engine, control unit, a data acquisition system including a thermodynamic model unit and a test sequence unit, sensor device coupled to the engine for measuring performance parameter of the engine, and comparative unit. The thermodynamic model unit generates computed performance parameter based on mechanical and thermodynamic models of the engine. The test sequence unit generates test sequence data including set point operating data and time schedule data with which a test cycle of the engine is runnable. The data acquisition system generates test control data based on the test sequence data, and is coupled to the control unit for providing test control data thereto to control the engine. The comparative unit is coupled to the data acquisition system such that the measured performance parameter measured by the sensor device is comparable with the computed performance parameter.