Genset Feed-Forward Control for Quick Cold Start Power Ramping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Cold starting a genset, which has been shut down for an extended period, results in significant time delays and power output issues due to low turbo pressure boost and thermal energy limitations, leading to inefficiencies and potential power overshoot during rapid power ramping.
Innovation Solution
The method involves preheating the lubricant and high-temperature coolant, continuously ramping the engine speed to target, synchronizing genset electrical parameters with the grid within a short time, and adjusting fueling rate and spark timing based on power output, while using a turbine nozzle ring to enhance turbocharger performance, thereby reducing cold start time and power ramp time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the genset is cold started after being shut down for an extended period, then the genset can be quickly brought online to provide power, but the cold exhaust and low thermal energy cause significant time delays and power output limitations
Solution Approach 1:
The system performs preliminary actions before cold start by pre-heating the lubricant and coolant through external heating systems, and by storing thermal energy in the exhaust system during previous operation. This preliminary thermal preparation reduces the time penalty during subsequent cold starts by eliminating the need to warm up critical components from ambient temperature.
Solution Approach 2:
The system changes operational parameters during cold start by implementing continuous speed ramping without idle pauses, adjusting fueling rates dynamically, and modifying spark timing to optimize combustion efficiency at varying temperatures. These parameter changes enable faster power delivery while compensating for cold thermal conditions.
2Productivity
If the genset rapidly ramps up power output during cold start, then power delivery speed improves, but thermal energy limitations and low turbo pressure boost cause control difficulties and power overshoot
Solution Approach 1:
The control system continuously monitors power output, turbo pressure boost, and thermal energy levels during cold start, and dynamically adjusts fueling rates and speed ramping accordingly. This feedback mechanism prevents power overshoot by reducing fuel delivery when thermal conditions cannot support the requested power level, ensuring stable and reliable control throughout the cold start transient.
Solution Approach 2:
The system implements dynamic control strategies that adapt to changing thermal conditions during cold start. The fueling rate and spark timing are continuously adjusted based on real-time measurements of exhaust temperature, turbo pressure, and power output, allowing the genset to rapidly ramp power while maintaining control stability through moment-to-moment optimization.
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 genset cold start time to less than 75 seconds, maintains high efficiency, and prevents power overshoot by ensuring rapid and stable power delivery to meet load demands, even for single turbocharger gensets.
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
Figure 1
Figure 2
Figure 3
AI summary
A method of reducing cold startup time of a genset which includes an engine and a generator for providing a requested power to a utility grid or load comprises determining if the generator is electrically coupled to a utility grid or load. In response to determining the generator is electrically coupled to the utility grid or load, a speed bias value is controlled in response to the power being produced by the genset. The speed bias signal represents a difference between a target power output and a current power output of the genset. The power of the engine is controlled using the speed bias value.