Gas Turbine Controller Using 2D Operating Area for Flexible Load Management
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Solution Overview
Problem
Combined cycle power plants face challenges in flexible control due to frequent start-ups and shut-downs driven by variable electricity demand, leading to inefficiencies and increased wear on equipment, particularly in managing gas turbine operations and emissions.
Innovation Solution
A system and method utilizing a controller to manage gas turbine operations within a defined 2-dimensional control area, allowing independent control of air flow and fuel flow to achieve specific setpoints and rates, prioritizing equipment life, emissions, and startup efficiency, while adhering to operational constraints such as emissions standards and HRSG limitations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the combined cycle power plant operates with frequent start-ups and shut-downs to meet variable electricity demand, then the adaptability to grid demand increases, but the equipment wear increases and startup efficiency decreases
Solution Approach 1:
The control system dynamically adjusts operating parameters (fuel flow, air flow, valve positions) in real-time during startup and operation. The system transitions from static control to dynamic control, allowing continuous adaptation to changing grid demand while optimizing startup sequences to minimize thermal stress and equipment wear.
Solution Approach 2:
The system changes multiple operating parameters simultaneously and in a coordinated manner during startup. By pre-planning and executing coordinated changes in fuel flow rate, air flow, turbine inlet temperature, and valve positions, the system achieves faster startups while maintaining equipment integrity through controlled parameter transitions.
2Productivity
If traditional control methods are used for gas turbine operations, then the device complexity remains low, but the startup time increases and operational efficiency decreases
Solution Approach 1:
The startup process is segmented into distinct phases (cold startup, warm startup, hot startup) with predefined control sequences for each phase. This segmentation allows the complex startup process to be managed through modular, phase-specific control routines, reducing the perceived complexity while enabling optimized startup paths for each condition.
Solution Approach 2:
The control system pre-calculates and pre-plans optimal startup sequences before actual startup occurs. By pre-establishing control parameter trajectories and valve timing sequences based on the selected startup type, the system eliminates real-time decision delays and achieves faster, more consistent startup times.
3Object-generated harmful factors
If emissions control is prioritized during operation, then emissions compliance improves, but the operational flexibility and load adjustment capability decrease
Solution Approach 1:
The control system continuously monitors emissions parameters (NOx, CO, unburned hydrocarbons) and uses this feedback to dynamically adjust fuel-air mixture ratios, combustion timing, and aftertreatment system operation. This closed-loop control maintains emissions compliance while allowing flexible load adjustments within the emissions constraint boundary.
Solution Approach 2:
The system dynamically balances emissions control with operational flexibility by continuously adapting combustion parameters based on load conditions. During transient operations, the system prioritizes stable combustion to control emissions, while during steady-state operation, it allows greater flexibility for load following within emissions 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
Enables flexible and efficient operation of combined cycle power plants, reducing start-up times, improving equipment life, and enhancing emissions control by allowing precise management of gas turbine load and exhaust temperature within defined operational boundaries.
Implementation Method 1
the gas turbine systems combust a fuel-air mixture to create torque that drives a load
Implementation Method 2
the combined cycle power plants use the thermal energy in the gas turbine system exhaust gases to create steam
Implementation Method 3
The steam travels through a steam turbine system creating torque that drives a load such as an electrical generator
Data Source
AI summary
Systems, methods, and tangible non-transitory machine readable medium are provided. A system includes a gas turbine system configured to produce power by combusting a fuel. The system further includes a controller configured to control the gas turbine system via an operating 2-dimensional surface area and a setpoint, wherein the operating 2-dimensional surface area comprises a plurality of limits defining bounds for the operating 2-dimensional surface area, and wherein the setpoint is configured to be disposed inside the operating 2-dimentionsal surface area or on the limits.