Gas Turbine Model-Based Control for Real-Time Tuning

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Solution Overview

Problem

Current schedule-based gas turbine control systems sacrifice performance and flexibility due to rigid operational boundaries, inability to adapt to component deterioration, and inflexible tuning, which can lead to inefficiencies and potential failures.

Innovation Solution

Implementing a model-based control system that uses operational boundary models and scheduling logic algorithms to adjust turbine control effectors in real-time, allowing for more accurate and efficient operation by minimizing error terms and accommodating changing conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If strict turbine compliance with schedule-based control systems is enforced, then operational safety is improved, but performance is sacrificed at many operating conditions

Engineering Contradiction:

Improveoperational safetyVSAvoidperformance

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The control system transitions from rigid, pre-defined schedules to dynamic, real-time control boundaries that adapt to actual turbine component conditions. The boundaries are continuously updated based on measured operating parameters and component health status, allowing the turbine to operate closer to true performance limits while maintaining safety.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system implements feedback mechanisms by continuously monitoring operating parameters and component conditions, then using this information to adjust control boundaries in real-time. This closed-loop approach allows the system to learn from actual turbine behavior and optimize performance while maintaining safety margins.

Inventive Principle:

Principle #23Feedback

2Reliability

If rigid schedule-based control systems are used, then operational boundaries are protected, but the system cannot identify and incorporate component deterioration

Engineering Contradiction:

Improveoperational boundary protectionVSAvoidcomponent deterioration detection

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The control system performs self-diagnosis by continuously monitoring its own component conditions and automatically adjusting control boundaries based on detected deterioration. The system serves itself by identifying component health issues and adapting control strategies without external intervention, maintaining protective boundaries while incorporating deterioration information.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces traditional mechanical/schedule-based control approaches with model-based control that uses computational models and sensor data to detect component deterioration. This substitution enables the system to identify and respond to component degradation through data analysis rather than rigid pre-programmed schedules.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If schedule-based control systems are used, then operational limits are defined, but the system cannot effectively accommodate changing conditions such as gas quality and ambient conditions

Engineering Contradiction:

Improveoperational limit definitionVSAvoidchanging conditions accommodation

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The control system dynamically changes operational parameters based on real-time measurements of gas quality, ambient conditions, and component state. Rather than fixed schedules, the system adjusts control boundaries by modifying key parameters such as temperature limits, pressure ratios, and flow rates to accommodate varying operating conditions while maintaining reliability.

Inventive Principle:

Principle #35Parameter changes

4Ease of operation

If schedule-based control systems are used, then control inputs are managed, but coupling between different turbine control effectors creates inflexible tuning

Engineering Contradiction:

Improvecontrol input managementVSAvoidcoupling between control effectors

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent segments the coupled control effector problem into independent, decoupled control boundaries for each effector. By defining separate control limits for fuel flow, inlet guide vanes, and other effectors based on individual component characteristics and interactions, the system simplifies tuning and control while accounting for inter-effector relationships through the model-based approach.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS9043118B2Methods and systems for model-based control of gas turbines

Publication Date: 2015.05.26 GE INFRASTRUCTURE TECH LLC

AI summary

Embodiments of systems and methods for tuning a turbine are provided. In one embodiment, a method may include receiving at least one of a measured operating parameter or a modeled operating parameter of a turbine during operation; and tuning the turbine during operation. The turbine may be tuned during operation by applying the measured operating parameter or modeled operating parameter or parameters to at least one operational boundary model, applying the measured operating parameter or modeled operating parameter or parameters to at least one scheduling algorithm, comparing the output of the operational boundary model or models to the output of the scheduling algorithm or algorithms to determine at least one error term, and closing loop on the one error term or terms by adjusting at least one turbine control effector during operation of the turbine.