Gas Turbine Auto-Tune Controller for Extended Turndown
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Solution Overview
Problem
Gas turbine engines face inefficiencies due to manual tuning processes, which are labor-intensive and often unavailable during critical conditions, leading to extended downtime and potential hardware damage.
Innovation Solution
An automatic extended turndown (AET) system with incremental tuning adjusts fuel flow splits and load reduction to maintain emission and dynamics within preferred ranges, using a control system to monitor and adjust combustor conditions, applying Fourier Transform to pressure signals for real-time feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual tuning is used to maintain emissions and dynamics, then tuning accuracy can be achieved, but labor intensity increases and downtime extends
Solution Approach 1:
The control system automatically performs tuning operations without human intervention. The processor monitors operating conditions and autonomously adjusts fuel flow splits and other parameters to maintain emissions and dynamics within specified ranges, eliminating the need for manual tuning and thereby reducing downtime while maintaining reliability
Solution Approach 2:
The system continuously monitors emissions and dynamics parameters and uses this feedback to automatically adjust operating parameters. The processor compares actual measurements with target values and makes real-time adjustments to fuel flow splits, creating a closed-loop control system that maintains reliability without requiring manual intervention
2Reliability
If manual tuning is performed frequently to maintain optimal performance, then emissions and dynamics are maintained, but labor costs and operational inefficiency increase
Solution Approach 1:
The control system performs self-tuning by automatically monitoring emissions and dynamics parameters and adjusting fuel flow splits without human intervention. This eliminates the need for operators to perform manual tuning tasks, reducing labor costs and improving operational efficiency while maintaining reliable emissions and dynamics performance
Solution Approach 2:
The automatic tuning system operates continuously without interruption to engine operation. The processor constantly monitors parameters and makes adjustments as needed, ensuring continuous optimal performance without the stoppages and inefficiencies associated with periodic manual tuning interventions
3Adaptability or versatility
If load is reduced to extend operational range, then adaptability improves, but combustion stability and emissions control deteriorate
Solution Approach 1:
The system automatically adjusts fuel flow splits and other operating parameters in response to load changes. When load is reduced to extend operational range, the processor compensates by modifying fuel distribution and combustion parameters to maintain stable combustion and controlled emissions, thereby preserving reliability across the extended operational range
Solution Approach 2:
The system applies different fuel flow splits to different combustors or combustion zones based on local conditions. This allows optimized combustion control in each zone, maintaining stability and emissions control even when overall load is reduced to extend operational adaptability
4Productivity
If automatic tuning is implemented to reduce manual intervention, then productivity increases, but system complexity increases
Solution Approach 1:
The control system performs multiple functions using a single integrated processor. It monitors emissions, dynamics, and operating conditions; automatically adjusts fuel flow splits; and manages tuning operations all through one multi-functional control unit, increasing productivity without proportionally increasing system complexity
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
The AET system enables continuous operation within optimal parameters, reducing manual intervention, lowering maintenance costs, and preventing hardware damage by automatically adjusting fuel flow splits and load to maintain stable combustion dynamics and emissions.
Implementation Method 1
applying Fourier Transform to pressure signals for real-time feedback
Data Source
AI summary
An auto-tune controller and tuning process implemented thereby for measuring and tuning the combustion dynamics and emissions of a GT engine, relative to predetermined upper limits, are provided. Initially, the tuning process includes monitoring the combustion dynamics of a plurality of combustors and emissions for a plurality of conditions. Upon determination that one or more of the conditions exceeds a predetermined upper limit, a fuel flow split to a fuel circuit on all of the combustors on the engine is adjusted by a predetermined amount. The control system continues to monitor the combustion dynamics and to recursively adjust the fuel flow split by the predetermined amount until the combustion dynamics and/or emissions are operating within a prescribed range of the GT engine. Additionally, a method of automated extended turndown of a GT engine to find a minimum load is provided.