Gas Turbine Clearance Control via Simulation Thresholds
Solution Overview
Problem
Existing gas turbine systems face challenges in automatically controlling the position of the rotor to minimize gaps between the rotor and housing efficiently, as permanent gap measurement is technically difficult and expensive, necessitating a Hydraulic Clearance Optimization (HCO) logic that optimally uses gap settings during load changes.
Innovation Solution
A method using a simulation program to create a data set that determines the dependence of gap size on operating parameters, setting threshold values, and activating/deactivating gap minimization based on actual parameter values within defined ranges, allowing for continuous optimization without active gap measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If continuous measurement of the operating clearance is implemented, then the control precision of gap minimization is improved, but the device complexity and cost increase significantly
Solution Approach 1:
The patent creates a simulated measurement system that copies the behavior of a physical clearance measurement system. Instead of measuring actual clearance continuously, the system uses simulation data that replicates clearance characteristics based on operating parameters, eliminating the need for complex physical measurement infrastructure while maintaining control precision
Solution Approach 2:
The patent replaces the mechanical/physical clearance measurement system with a computational model. The simulation program substitutes direct physical measurement with mathematical calculations based on operating parameters, transforming a complex mechanical measurement problem into a simpler computational solution
2Loss of energy
If the gap minimization is activated during all operating conditions, then the gas turbine efficiency is maximized, but the reliability decreases due to excessive wear during transient phases
Solution Approach 1:
The patent implements dynamic control of gap minimization by adjusting the rotor position based on real-time operating conditions. The system activates gap minimization only during steady-state high-load operation and deactivates it during transient phases or low-load conditions, optimizing the balance between efficiency and component protection
Solution Approach 2:
The patent changes the operational parameters of the gap minimization system based on operating conditions. By monitoring operating parameters and adjusting the minimization activation state accordingly, the system adapts to different operational phases, maintaining efficiency during appropriate conditions while protecting components during vulnerable phases
3Loss of energy
If the rotor position is adjusted frequently to minimize gaps, then the gas turbine efficiency is improved, but the device complexity increases due to continuous hydraulic adjustment
Solution Approach 1:
The patent performs preliminary simulation and analysis to determine optimal gap minimization strategies before actual operation. By pre-calculating the relationship between operating parameters and optimal rotor positions, the system eliminates the need for complex real-time control algorithms, reducing control system complexity while maintaining efficiency
Solution Approach 2:
The system uses readily available operating parameter data from the gas turbine's normal operation to control gap minimization, rather than requiring separate complex measurement and control systems. The existing operational data serves the dual purpose of controlling both power output and clearance optimization
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 results in precise activation of the HCO function, increasing operational efficiency by optimizing gap settings and reducing complexity, while being independent of active gap measurement, thus enhancing gas turbine performance.
Implementation Method 1
a gap-adjusting device, in particular a hydraulic one
Data Source
Figure 1~2
AI summary
The invention relates to a method for controlling a gap minimization for an adjustable gap between a rotor and a housing of a gas turbine. This is carried out on the basis of a correlation extracted from simulation data. If the actual value (PI) lies below the lower threshold (PU), the gap minimization is deactivated, whereas if the actual value lies above the upper threshold (PO), the gap minimization is activated. The gap minimization is activated between the thresholds (PU, PO) if the actual value lies above the threshold (PG) but is deactivated if the actual value (PI) lies below the threshold (PG).