Redundant Pneumatic Control Assembly for Online Turbine Trip Testing
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Solution Overview
Problem
Existing pneumatic control systems for combustion turbines have a single point of failure in trip valve actuation, leading to potential equipment damage and unnecessary shutdowns, as well as inefficiencies in testing without tripping the turbine.
Innovation Solution
A redundant pneumatic control assembly with multiple parallel supply and vent channels and logic valves, controlled by solenoid valves, allowing for online testing and continued operation even if one valve fails, eliminating the need for turbine shutdown during repairs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single pneumatic control channel is used, then the device complexity is reduced, but the reliability deteriorates due to single point of failure
Solution Approach 1:
The pneumatic control system is divided into multiple independent parallel channels (first, second, and third channels), each with its own supply line, vent line, and logic valves. This segmentation allows the system to maintain functionality even if one channel fails, directly resolving the contradiction between reliability and complexity by distributing control across independent segments.
Solution Approach 2:
The system incorporates redundant pneumatic channels and logic valves as a form of beforehand cushioning against potential failures. By pre-configuring alternative pathways for compressed air supply and venting, the system ensures continued operation even when a single channel or valve fails, addressing the reliability concern without requiring immediate complex intervention.
2Loss of time
If traditional testing methods are used, then the measurement precision is sufficient, but the loss of time increases due to turbine shutdown requirements
Solution Approach 1:
The system enables preliminary testing of the pneumatic control assembly while the turbine remains operational. By incorporating isolation valves and parallel channels that allow testing without affecting turbine operation, the system eliminates the need for shutdowns during maintenance and testing, directly reducing time loss while maintaining operational ease.
Solution Approach 2:
The pneumatic control assembly acts as an intermediary system that can be tested independently through its own supply and vent channels. The logic valves and solenoid valves serve as mediators that allow testing of control functions without directly impacting the turbine's operation, enabling maintenance activities without shutdowns.
3Reliability
If redundant pneumatic channels are implemented, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The redundant system is segmented into distinct parallel channels with independent control, allowing the complexity to be organized and managed separately. Each channel functions as an independent unit, making the overall complex system more manageable and maintainable while ensuring reliability through redundancy.
Solution Approach 2:
Multiple pneumatic channels and logic valves are merged into a unified control assembly that shares common components such as the compressed air supply connection and vent connection. This merging approach reduces the overall complexity by consolidating shared elements while maintaining the redundant parallel pathways for improved reliability.
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
The solution provides reliable and online testable control of combustion turbines, reducing downtime and preventing equipment damage by ensuring continued operation even if a valve fails, and allowing for testing without tripping the turbine.
Implementation Method 1
a first solenoid valve to control the first and second logic valves, a second solenoid valve to control the third and fourth logic valves, and a third solenoid valve to control the fifth and sixth logic valves
Implementation Method 2
first, second, third, fourth, fifth, and sixth logic valves... The first, second, third, fourth, fifth, and sixth logic valves are to control the flow of compressed air between the pneumatically actuated valve, the compressed air supply, and the vent
Data Source
AI summary
Testable, redundant pneumatic control assemblies and related systems and methods are described herein. An example pneumatic control assembly described herein includes first, second, and third parallel supply channels between a compressed air supply and valve header, first, second, and third parallel vent channels between a vent and the valve header, and first, second, third, fourth, fifth, and sixth logic valves. The first and sixth logic valves are disposed in the first parallel supply channel and the first parallel vent channel, the second and third logic valves are disposed in the second parallel supply channel and second parallel vent channel, and the fourth and fifth logic valves are disposed in the third parallel supply channel and third parallel vent channel. The pneumatic control assembly also includes a first, second, and third solenoid valves to control certain ones of the logic valves.