On-site Power Plant Controller Adaptive Transient Load Response
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Solution Overview
Problem
On-site power plants face challenges in controlling operation to avoid excess power generation, inefficient fuel usage, and inadequate temperature control, leading to shutdowns and increased utility costs, particularly due to malfunctions in fuel boosters and transient power demands.
Innovation Solution
A controller system that adjusts the operation of prime movers based on load requirements, fuel availability, and temperature control needs, allowing for continued operation during power transients and optimizing fuel consumption by selecting the appropriate number of prime movers and prioritizing their operation to match power output with demand and fuel capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the on-site power plant operates at a desired power level, then power generation meets the load requirement, but excess power is exported to the grid causing relay shutdown
Solution Approach 1:
The control system dynamically adjusts the operation of prime movers based on real-time load conditions. When a down transient occurs, the system selectively reduces or shuts down specific prime movers while maintaining others in operation, rather than shutting down the entire power plant. This dynamic adjustment allows the system to adapt power output to match load requirements and avoid excess power export that would trigger relay shutdown.
Solution Approach 2:
The power plant is divided into multiple independent prime movers (e.g., first plurality and second plurality of microturbines). The control system can selectively adjust the operation of individual prime movers or groups based on load conditions. This segmentation allows partial operation continuation during transients, maintaining reliability while preventing excess power generation.
2Reliability
If the entire on-site power plant is shut down to avoid power export, then relay shutdown is prevented, but the facility loses heating or cooling and incurs increased utility demand charges
Solution Approach 1:
By dividing the power plant into multiple independent prime mover groups, the system can selectively shut down only the necessary portions to prevent excess power export while keeping other prime movers operational. This selective segmentation ensures that sufficient power generation capacity remains online to maintain heating or cooling functions, avoiding complete energy loss.
Solution Approach 2:
The control system dynamically determines the optimal combination of prime movers to operate based on real-time conditions including load requirements, heating/cooling needs, and power export risks. This dynamic optimization allows the system to maintain the minimum necessary operation to provide thermal energy while avoiding relay shutdown conditions.
3Ease of operation
If excess exhaust gas from prime movers is vented to atmosphere, then cogeneration unit operation is simplified, but efficiency losses occur
Solution Approach 1:
The control system uses feedback from the building management system regarding heating or cooling requirements to dynamically adjust prime mover operation. This feedback loop allows the system to optimize exhaust gas utilization by matching prime mover output to actual thermal demand, reducing or eliminating the need to vent excess exhaust gas while maintaining efficient cogeneration operation.
Solution Approach 2:
The system integrates temperature control functions directly with prime mover operation, allowing the power plant to self-regulate its exhaust gas utilization based on facility thermal needs. The prime movers serve dual purposes of power generation and thermal provision, with the control system automatically balancing these functions to maximize efficiency.
4Reliability
If fuel boosters are provided with excess capacity for starting prime movers, then startup fuel consumption is adequate, but system cost increases
Solution Approach 1:
The control system dynamically manages fuel distribution to prime movers based on operational state. During startup, fuel is preferentially directed to the prime mover requiring startup. During normal operation, fuel distribution is optimized for running prime movers. This dynamic fuel management allows the system to achieve reliable startup capability with smaller, less expensive fuel booster capacity than would be required if excess capacity were provisioned for simultaneous startup of all prime movers.
Solution Approach 2:
The control system prepares fuel distribution in advance of startup requirements by pre-positioning fuel flow paths and adjusting booster operation before prime mover startup is needed. This preliminary action ensures that adequate fuel capacity is available for startup without requiring the fuel boosters to be continuously sized for maximum simultaneous startup demand.
Data Source
AI summary
An on-site power plant (24) has a controller (40) that selectively controls operation of prime movers (26, 28, 30). In one example, the controller (40) changes the number of operating prime movers responsive to a transient in a load (22) requirement while continuing to operate at least one of the prime movers. One example includes prioritizing the prime movers (26, 28, 30) for operation based upon the needs of a cogeneration unit (32, 34, 36) associated with the prime movers for providing a temperature control function within a facility. Another example includes controlling operation of the prime movers based upon a capacity for fueling the prime movers.