Gas Turbine Auto-Tuning via Fuel-Flow Split Adjustment
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Solution Overview
Problem
Gas turbine engines require frequent manual tuning to maintain optimal operating conditions, which is labor-intensive and inefficient, and may not be possible during high-dynamic events, leading to potential hardware damage and inefficiencies.
Innovation Solution
A control system that dynamically monitors and adjusts fuel-flow splits within the combustor to automatically tune the engine by selecting and incrementally adjusting fuel-flow splits based on real-time data and predefined limits, using a scanning order table to prioritize corrective actions that minimize negative impacts on other parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual tuning is performed frequently to maintain optimal operating conditions, then engine performance and emissions are improved, but labor intensity and operational inefficiency increase
Solution Approach 1:
The control system automatically monitors engine parameters and performs tuning adjustments without human intervention. The system self-diagnoses out-of-tune conditions and autonomously modifies fuel-flow splits to restore optimal performance, eliminating the need for manual tuning operations while maintaining engine reliability
Solution Approach 2:
The system continuously monitors engine parameters such as emissions and combustion dynamics, compares them against optimal ranges, and uses this feedback to automatically adjust fuel-flow splits. This closed-loop control ensures engine performance is maintained without requiring manual intervention
2Reliability
If manual tuning is performed during high-dynamic events, then potential hardware damage is prevented, but tuning operations cannot be performed during these critical windows
Solution Approach 1:
The automatic tuning system operates continuously without requiring scheduled maintenance windows or human presence. It can detect and respond to out-of-tune conditions during high-dynamic events, ensuring hardware protection is maintained at all times regardless of operational conditions
Solution Approach 2:
The system continuously monitors parameters and is ready to perform tuning adjustments immediately when needed, including during high-dynamic events. By being pre-positioned and automated, it eliminates the delay associated with scheduling manual tuning operations
3Reliability
If multiple parameters are monitored and adjusted simultaneously, then comprehensive engine tuning is achieved, but system complexity and difficulty of implementation increase
Solution Approach 1:
The system monitors multiple engine parameters but addresses them in a prioritized sequence rather than simultaneously. By segmenting the tuning process into ordered steps, it manages complexity while maintaining comprehensive coverage of all critical parameters
Solution Approach 2:
The system uses a scanning order table that defines a specific sequence for addressing out-of-tune parameters. This parameterized approach to tuning allows comprehensive multi-parameter control while simplifying implementation through predefined adjustment sequences
Data Source
AI summary
Tuning processes implemented by an auto-tune controller are provided for measuring and adjusting the combustion dynamics and the emission composition of a gas turbine (GT) engine via a tuning process. Initially, the tuning process includes monitoring parameters, such as combustion dynamics and emission composition. Upon determining that one or more of the monitored parameters exceed a critical value, these “out-of-tune” parameters are compared to a scanning order table. Upon comparison, the first out-of-tune parameter that is matched within the scanning order table is addressed. The first out-of-tune parameter is then plotted as overlaid slopes on respective graphs, where the graph represents a fuel-flow split. Typically, the slopes are plotted as a particular out-of-tune parameter against a particular fuel-flow split. The slopes for each graph are considered together by taking into account the combined impact on each out-of-tune parameter when a fuel-flow split is selected for adjustment.