Genset Cold Start Reduction via Preheating and Turbo Spinning
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Solution Overview
Problem
Cold starting a genset, especially after a prolonged shutdown, results in significant time delays and power output issues due to low thermal and kinetic energy in the turbocharger, leading to turbo lag and inefficient power production.
Innovation Solution
The method involves preheating the lubricant and coolant to specific temperatures before startup, continuously ramping the engine speed to target without idling, synchronizing genset electrical parameters with the utility grid within a short time, and adjusting fueling rate and spark timing based on power production, while using a turbine nozzle ring to enhance turbocharger performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the genset is cold started after prolonged shutdown, then the genset can be quickly brought online, but significant time delays occur due to turbocharger thermal and kinetic energy deficiencies
Solution Approach 1:
The patent applies preliminary action by pre-heating the lubricant and coolant systems before engine startup, and pre-spinning the turbocharger using an electric motor to build thermal and kinetic energy reserves. This prepares the system in advance to eliminate delays during actual cold starting.
Solution Approach 2:
The patent introduces an electric motor as an intermediary device to spin the turbocharger before startup, and uses pre-heated lubricant and coolant as thermal intermediaries to quickly bring engine components to operating temperature, bridging the gap between cold shutdown and hot operation.
2Productivity
If the engine speed is rapidly ramped to target speed, then power delivery is faster, but turbo lag increases due to insufficient thermal energy in the turbocharger
Solution Approach 1:
The turbocharger is pre-spun and pre-heated before engine startup using an electric motor and hot coolant circulation. This preliminary action builds the thermal and kinetic energy needed to eliminate turbo lag during rapid power ramping.
Solution Approach 2:
The patent changes the operational parameters of the turbocharger by controlling its rotational speed and thermal state independently of engine speed during the startup phase, allowing the turbo to be ready before the engine reaches full power demand.
3Temperature
If the genset is allowed to idle at low speed to warm up, then component temperatures increase, but startup time increases due to pausing at lower speeds
Solution Approach 1:
The lubricant and coolant systems are pre-heated before startup, and the turbocharger is pre-spun to operating temperature and speed. This eliminates the need for post-startup idling to warm components, allowing immediate high-speed operation.
Solution Approach 2:
The patent enables continuous engine acceleration from idle to target speed without pauses or idling periods. The pre-heated systems maintain continuous useful action throughout the startup sequence, eliminating wasted time at low speeds.
4Speed
If the lubricant is cold at startup, then the engine can start immediately, but insufficient lubrication occurs during the first few seconds
Solution Approach 1:
The lubricant is pre-heated to operating temperature and circulated through the engine before startup. This preliminary action ensures proper viscosity and flow characteristics are established, providing immediate reliable lubrication when the engine starts.
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
This approach significantly reduces cold start time to less than 75 seconds, ensures quick power delivery, and maintains high efficiency by minimizing turbo lag and power overshoot, allowing gensets to meet load demands promptly.
Implementation Method 1
The lubricant is heated to a predetermined lubricant temperature using an external heating system
Implementation Method 2
A high temperature coolant of the genset is heated to greater than a predetermined high temperature coolant temperature
Implementation Method 3
The turbine nozzle ring is structured to provide a pressure drop thereacross sufficient to cause the turbocharger system to produce a target power output
Data Source
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AI summary
A method of reducing cold startup time of a genset includes providing a lubricant to the genset at predetermined time intervals before a genset startup. The lubricant is heated to a predetermined lubricant temperature using an external heating system. A high temperature coolant of the genset is heated to greater than a predetermined high temperature coolant temperature. The speed of the engine is ramped to a target speed continuously without pausing at a speed lower than the target speed. Genset electrical parameters of the genset are synchronized to utility grid or load electrical parameters of the utility grid or load. The genset is electrically coupled to the utility grid or load such that the synchronizing and electrically coupling are performed within a predetermined synchronization time. A fueling rate and a spark timing is adjusted based on a power being produced by the genset.