Gas Turbine Auto-Tune Controller for Emissions Compliance
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Solution Overview
Problem
Gas turbine engines face inefficiencies due to mechanical degradation and operational changes, leading to increased emissions and dynamic issues, which require frequent manual tuning, causing labor-intensive processes and potential downtime.
Innovation Solution
A computerized method for automated extended turndown of a gas turbine engine, adjusting fuel flow splits and load reduction, combined with incremental tuning, to maintain emission and dynamics within predetermined limits, using a control system that monitors and adjusts fuel flow splits and load to optimize performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual tuning is performed to maintain emissions and dynamics within limits, then emissions and dynamics are maintained, but labor intensity increases and downtime occurs
Solution Approach 1:
The control system automatically monitors operating conditions and performs tuning adjustments without human intervention. The system self-diagnoses when emissions or dynamics exceed limits and autonomously modifies fuel flow splits and other parameters to restore compliance, eliminating the need for manual tuning operations and associated downtime.
Solution Approach 2:
The system continuously monitors emissions levels and combustion dynamics parameters, comparing them against predetermined limits. When deviations are detected, the control system automatically adjusts fuel flow splits and operating parameters to bring measurements back within limits, creating a closed-loop feedback mechanism that maintains compliance without manual intervention.
2Reliability
If manual tuning is performed frequently to address mechanical degradation, then performance is maintained, but labor costs and operational inefficiency increase
Solution Approach 1:
The control system autonomously monitors performance parameters and automatically executes tuning adjustments in response to detected deviations. This eliminates the need for operators to perform repeated manual tuning tasks, freeing them for higher-value activities and eliminating the labor costs and operational disruptions associated with frequent manual interventions.
Solution Approach 2:
The system provides continuous monitoring and adjustment capability, maintaining optimal performance without interruption. By automatically detecting and correcting performance deviations as they occur, the system ensures continuous useful action rather than periodic manual interventions that cause operational discontinuity.
3Power
If the load on the gas turbine is increased to meet power demand, then electricity output increases, but emissions and dynamics may exceed limits
Solution Approach 1:
The control system dynamically adjusts fuel flow splits and other operating parameters in real-time based on current load conditions and measured emissions/dynamics. As load increases, the system automatically modifies parameter settings to maintain compliance, and vice versa, creating a dynamic adaptation mechanism that preserves both power output capability and emissions compliance across varying operating conditions.
Solution Approach 2:
The system changes operating parameters such as fuel flow splits, air-fuel ratios, and combustion timing in response to varying load conditions. These parameter adjustments are automatically calculated and implemented to maintain emissions and dynamics within limits while accommodating the requested power output level.
4Duration of action of stationary object
If the gas turbine operates beyond preferred ranges due to degradation, then continuous operation is maintained, but emissions exceed regulated limits
Solution Approach 1:
The control system continuously monitors emissions levels and compares them against regulated limits. When degradation causes emissions to approach or exceed limits, the system automatically detects this condition and adjusts operating parameters to bring emissions back into compliance, enabling continuous operation while preventing harmful emissions exceedances.
Solution Approach 2:
The system proactively detects trends toward emissions exceedance caused by mechanical degradation and performs preventive adjustments before limits are violated. By monitoring parameter drift and predicting future compliance issues, the system takes preliminary corrective action to maintain emissions within limits throughout continuous operation.
Data Source
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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.