Gas Turbine Performance Matching for Unmeasured Parameter Prediction

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Solution Overview

Problem

The complex nature of gas turbines makes accurate control and monitoring challenging, leading to incomplete diagnosis and increased operational expenses due to approximations in maintenance planning and failure prediction.

Innovation Solution

A performance characterization method using data from automated systems, matched with physics-based models optimized by a novel solver that performs local and global searches to simulate and predict unmeasured parameters, track engine performance, and simulate virtual scenarios.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If sensors and processing systems are added to monitor gas turbine operation, then real-time data collection capability is improved, but device complexity and operational costs increase

Engineering Contradiction:
Improvereal-time monitoring capabilityVSAvoidsystem complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent creates a virtual copy (digital twin) of the gas turbine that replicates its behavior and performance characteristics. This virtual model serves as a surrogate for physical sensors, allowing prediction of unmeasured parameters without adding physical monitoring hardware. The digital twin is trained on historical sensor data and can simulate turbine behavior under various conditions, providing measurement capabilities without the complexity of additional physical sensor systems.

Inventive Principle:
Principle #26Copying

2Loss of information

If more sensors are installed to measure operating parameters, then measurement coverage is improved, but device complexity and cost increase

Engineering Contradiction:
Improveparameter measurement coverageVSAvoidsensor system complexity
Core Design Contradiction:
Loss of informationVSDevice complexity

Solution Approach 1:

The patent introduces a machine learning model as an intermediary that infers unmeasured parameters from measured ones. Instead of installing sensors for every parameter of interest, the system uses the ML model to act as a mediator that calculates missing information based on correlations learned from training data. This approach provides comprehensive parameter coverage while avoiding the complexity of installing numerous sensors.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Measurement precision

If physics-based models are used to simulate gas turbine behavior, then prediction accuracy for unmeasured parameters is improved, but computational complexity increases

Engineering Contradiction:
Improveparameter prediction accuracyVSAvoidmodel complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent transforms the complex physics-based model into a machine learning model that captures essential relationships in a computationally efficient form. By changing the representation from explicit physics equations to learned parameter relationships, the system maintains prediction accuracy for unmeasured parameters while reducing computational complexity. The ML model learns effective parameters and their relationships from training data, providing accurate predictions without the burden of solving complex differential equations in real-time.

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentUS20250148148A1Enhanced performance model matching, augmentation and prediction
Publication Date: 2025.05.08 NUOVO PIGNONE TECH SRL
  • US20250148148A1 patent drawing
  • US20250148148A1 patent drawing
  • US20250148148A1 patent drawing

AI summary

A simulation method for simulating the operation of a gas turbine (111) is disclosed. The method comprises a global search procedure and an iterative local search procedure, to calculate parameters to simulate the operation of the gas turbine (111). The output parameters can also be used for monitoring the operation of the gas turbine (111) and planning the maintenance. Also disclosed is a characterization system, for characterizing and simulating the operation of a gas turbine (111).