Generator Controller Fault Code Override Economics
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Solution Overview
Problem
Power generators face penalties for unanticipated system failures, which can negate savings and require efficient operation to maintain uptime and avoid costly maintenance or shutdowns.
Innovation Solution
A controller system that determines the cost of overriding fault codes to maintain power output versus the cost of utility fines for shutdown, allowing continued operation when fines are higher than repair costs, thereby extending component life and avoiding penalties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the power generator shuts down in response to a fault code, then the reliability and safety of the system are improved, but the productivity and uptime are reduced due to utility fines and contractual penalties
Solution Approach 1:
The control system dynamically changes the operational parameters by adjusting the threshold for fault code response. Instead of immediately shutting down upon detecting a fault code, the system evaluates the cost parameters (utility fines, repair costs, maintenance costs) and determines whether to override the fault code based on economic efficiency criteria, thus changing the decision parameter from binary (shutdown/no shutdown) to a cost-based continuous evaluation
Solution Approach 2:
The system implements a feedback mechanism where the control system continuously monitors fault codes, utility fine structures, repair cost estimates, and maintenance cost data. This feedback loop allows the system to learn from operational history and adjust its fault response strategy to maximize economic efficiency while maintaining acceptable reliability levels
2Productivity
If the power generator overrides the fault code and continues operation, then the productivity and uptime are maintained, but the reliability deteriorates due to potential damage and increased maintenance requirements
Solution Approach 1:
Before overriding a fault code, the control system performs preliminary actions by evaluating and comparing the costs of different responses (shutdown versus continued operation). The system proactively assesses utility fine structures, estimates repair costs, and calculates maintenance implications before making the decision to override the fault code, ensuring that continuation of operation is economically justified
Solution Approach 2:
The system introduces dynamics into the fault response strategy by making the decision to override or honor fault codes flexible and adaptive. Rather than a static shutdown protocol, the control system dynamically adjusts its response based on real-time cost parameters, operational context, and economic efficiency calculations, allowing the reliability-productivity balance to shift according to current conditions
3Loss of time
If the power generator operates through faulty conditions, then the loss of time and productivity are reduced, but the loss of substance increases due to higher maintenance and repair costs
Solution Approach 1:
The control system performs self-service by autonomously evaluating fault conditions, cost parameters, and operational requirements to determine the optimal response. The system independently calculates whether overriding a fault code is economically efficient by comparing utility fines, repair costs, and maintenance implications, eliminating the need for external human judgment and enabling real-time cost-effective decisions
Data Source
AI summary
A method of operating a power generator comprises receiving, a fault code corresponding to an operating condition of the power generator being outside of an acceptable range. A generator controller determines a cost of increased maintenance or repairing damage associated with overriding the fault code and maintaining existing power output from the power generator through the operating condition. A cost of a utility fine or contractual penalty associated with shutting down the power generator is determined in response to the fault code. The generator controller compares the cost of the utility fine or contractual penalty associated with shutting down the power generator with the cost of increased maintenance or damage repair to the power generator associated with overriding the fault code and maintaining existing power output through the operating condition. In response to the comparing, the fault code is overridden continuing operation of the power generator.