Micro Grid Controller Prevents Wet Stacking
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Solution Overview
Problem
In micro grid power systems, low load conditions lead to exhaust gas temperatures below the condensation temperature of oil and unburned fuel, causing wet stacking or slobber, which can damage exhaust systems, and operating engines at a fixed minimum power increases fuel consumption, especially when combined with photovoltaic systems.
Innovation Solution
A micro grid power system with a controller that monitors exhaust gas temperatures and adjusts the operation of generator sets and photovoltaic systems to maintain temperatures above a threshold, ensuring the condensation of oil and unburned fuel is prevented, while optimizing power distribution between generator sets and photovoltaic power sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the power output of engines is controlled based on the power needed to operate the connected loads, then the fuel consumption is reduced, but the temperature of exhaust gases decreases below the condensation temperature of oil and unburned fuel, causing wet stacking
Solution Approach 1:
The controller continuously monitors exhaust gas temperature and adjusts engine power output accordingly. When exhaust gas temperature approaches the condensation point of oil and unburned fuel, the controller increases engine power to maintain temperature above this threshold, preventing wet stacking while optimizing fuel consumption.
Solution Approach 2:
The system dynamically adjusts engine power output based on real-time exhaust gas temperature conditions rather than operating at a fixed minimum power. This dynamic control allows the engine to operate at lower power levels when conditions permit, reducing fuel consumption, while automatically increasing power when needed to prevent condensation.
2Reliability
If the engine operates at a fixed minimum power output, then the temperature of exhaust gases is maintained high enough to prevent wet stacking, but the fuel consumption increases
Solution Approach 1:
The system replaces fixed minimum power operation with dynamic power adjustment based on exhaust gas temperature monitoring. The engine operates at variable power levels, increasing only when necessary to prevent wet stacking, thereby reducing overall fuel consumption while maintaining reliability.
Solution Approach 2:
The controller changes the operating parameters of the engine dynamically by adjusting power output based on exhaust gas temperature measurements. This allows the system to maintain the critical temperature threshold for preventing condensation while minimizing fuel consumption by avoiding unnecessary operation at fixed minimum power.
3Reliability
If a load bank with heating elements is connected to increase engine exhaust temperature, then wet stacking is avoided, but the power output increases thereby increasing fuel consumption
Solution Approach 1:
The patent extracts the temperature control function from the mechanical engine operation and implements it through a separate electronic control system that monitors exhaust gas temperature and adjusts engine power accordingly. This separates the primary function of power generation from the secondary function of temperature maintenance, allowing more efficient control.
Solution Approach 2:
Instead of using passive heating elements that continuously consume energy, the system employs active feedback control where the controller monitors exhaust gas temperature and adjusts engine power output only when necessary to maintain temperature above the condensation point, significantly reducing energy waste compared to continuous heating.
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 solution effectively prevents wet stacking, reduces fuel consumption, and optimizes the operation of both generator sets and photovoltaic systems by maintaining exhaust gas temperatures above the condensation point, thereby enhancing system efficiency and reducing maintenance needs.
Implementation Method 1
the temperature of the exhaust gases in an exhaust conduit may go below the condensation temperature of oil and/or unburned fuel present in the exhaust gases. In such cases, the condensation of the oil or the unburned fuel inside the exhaust conduit may lead to accumulation of oil in the exhaust conduit.
Implementation Method 2
The photovoltaic system includes a plurality of photovoltaic panels for generating power
Data Source
AI summary
A micro grid power system includes a plurality of generator sets, a photovoltaic system, an external load, and a controller. Each generator set includes an engine and a sensor to determine a temperature of exhaust gases exiting the engine. The photovoltaic system includes a plurality of photovoltaic panels for generating power. The external load is powered by the plurality of generator sets and the photovoltaic system. The controller is configured to determine the external load, and control the plurality of generator sets to maintain the temperature above a threshold temperature. The controller is further configured to determine a remaining load which is the external load subtracted by a portion of the external load powered by the plurality of generator sets, and control the photovoltaic system to power the remaining load.