Automated Gas Turbine Water Wash System Controller
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Solution Overview
Problem
Current water wash systems for gas turbine engines are complex, time-consuming, and require multiple operators to perform off-line washes, leading to variability in contaminant removal efficiency and increased shutdown times, which negatively impact engine performance and operating costs.
Innovation Solution
An automated water wash system with a system controller that monitors and controls various operating parameters and valve scheduling to automate the off-line wash process, reducing manual errors and simplifying the process by integrating sensors and automated valves to manage water and detergent flows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual operation of water wash system is used, then flexibility in operation is maintained, but complexity of operation and time consumption increase significantly
Solution Approach 1:
The system performs the wash cycle automatically without requiring continuous manual intervention. The controller autonomously manages valve operations, pump control, and cycle sequencing, allowing the system to serve itself during the wash process while minimizing human involvement and shutdown time.
Solution Approach 2:
Manual mechanical operations are replaced with an automated control system that uses sensors, controllers, and automated valves to manage the wash process. This substitution of manual mechanical control with an automated control system reduces operational complexity and time consumption.
2Reliability
If multiple operators are deployed for manual wash, then monitoring capability is enhanced, but system complexity and operational cost increase
Solution Approach 1:
The system incorporates sensors that continuously monitor wash parameters and provide feedback to the controller. This feedback mechanism ensures consistent wash quality by automatically adjusting operations based on real-time conditions, replacing the need for multiple operators to visually monitor and manually adjust parameters.
Solution Approach 2:
Human operators are replaced with an automated control system that uses electronic sensors and controllers to monitor and manage the wash process. This substitution maintains or improves monitoring capability while reducing system complexity and operational requirements.
3Productivity
If automated control system is implemented, then operational time is reduced, but initial system complexity increases
Solution Approach 1:
The automated control system is designed to perform multiple functions including cycle sequencing, parameter monitoring, valve control, and anomaly detection within a single integrated controller. This multi-functionality reduces the need for separate specialized components, thereby managing system complexity while maintaining high productivity.
Solution Approach 2:
The system uses programmable parameters and settings that can be adjusted to optimize different wash scenarios without requiring hardware changes. This flexibility allows the system to adapt to various conditions through software configuration rather than physical modifications, managing complexity while improving productivity.
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
The automated system significantly reduces shutdown time, operator requirements, and errors in the wash process, ensuring consistent contaminant removal and improved gas turbine engine performance and efficiency.
Implementation Method 1
An automated water wash system with a system controller that monitors and controls various operating parameters and valve scheduling to automate the off-line wash process
Implementation Method 2
integrating sensors and automated valves to manage water and detergent flows
Implementation Method 3
integrating sensors and automated valves to manage water and detergent flows
Data Source
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AI summary
The present application provides a gas turbine engine system (100). The gas turbine engine system includes a gas turbine engine (10), a water wash system (102), and a system controller (104). The gas turbine engine includes a compressor (15), a combustor (25) in communication with the compressor (15), and a turbine (40) in communication with the combustor (25). The water wash system (102) may be in communication with the gas turbine engine (10) and configured to remove contaminants therefrom. The water wash system (104) may include a number of valves configured to control flows through the water wash system, and a number of sensors configured to measure operating parameters of the water wash system. The system controller (102) may be in communication with the valves and the sensors and operable to automatically control the valves upon receiving operating parameter signals from the sensors in order to perform a wash of the gas turbine engine (10).