Steam Turbine Cooling Rate Control via Feedback
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Solution Overview
Problem
Current steam turbine cooling methods, particularly 'forced cooling,' are inefficient and time-consuming, often resulting in wasted fuel due to limited exploitation of cooling freedoms and lack of real-time temperature gradient feedback control during power operation.
Innovation Solution
A method that involves determining and regulating the steam turbine's cooling rate by comparing the actual and specified cooling rates, with an automation system ensuring the steam generator operates to maintain the cooling rate within predetermined limits, utilizing finite element methods, component temperature considerations, and feedback control to optimize cooling within design limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid ramps are used to reduce steam temperature during operation, then the steam turbine design limits are not exceeded, but the cooling process time is extended and fuel efficiency is reduced
Solution Approach 1:
The patent implements a feedback control system that continuously monitors the actual cooling rate of the steam turbine and compares it with the predetermined cooling rate. The steam generator is operated to adjust the steam temperature based on this comparison, ensuring the actual cooling rate substantially corresponds to the predetermined rate. This closed-loop feedback mechanism allows dynamic adjustment of cooling parameters to optimize both time and safety compliance.
Solution Approach 2:
The patent transitions from static rigid ramps to dynamic cooling rate control. The predetermined cooling rate can be adapted based on real-time conditions, allowing the system to optimize the cooling process dynamically. The automation system continuously adjusts operating parameters to maintain the desired cooling rate, enabling more flexible and efficient cooling compared to fixed ramp schedules.
2Reliability
If rigid ramps are used to reduce steam temperature during operation, then the steam turbine design limits are not exceeded, but fuel consumption increases due to limited exploitation of cooling freedoms
Solution Approach 1:
The feedback control system monitors the actual cooling rate and adjusts the steam generator operation accordingly. By comparing actual versus predetermined cooling rates in real-time, the system can optimize fuel consumption by only applying cooling when and where needed, rather than following fixed rigid ramps that may over-cool or waste fuel during periods when natural cooling suffices.
Solution Approach 2:
The patent changes the cooling parameters from fixed rigid ramps to dynamically adjusted predetermined cooling rates. The automation system can modify steam temperature, pressure, and flow parameters based on real-time cooling rate measurements, allowing optimal exploitation of cooling freedoms and minimizing fuel consumption while maintaining safety compliance.
3Productivity
If feedback control of temperature gradient is implemented during power operation, then cooling process is accelerated, but system complexity increases
Solution Approach 1:
The patent implements feedback control by continuously determining the actual cooling rate and comparing it with the predetermined cooling rate during power operation. The automation system uses this feedback to adjust the steam generator operation in real-time, accelerating the cooling process while maintaining control within acceptable complexity through automated algorithms.
Solution Approach 2:
The system performs self-monitoring and self-adjustment of cooling parameters. The automation system automatically determines cooling rates, compares them with targets, and adjusts operating parameters without requiring constant manual intervention, thereby accelerating cooling while managing complexity through autonomous operation.
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 accelerates the steam turbine cooling process while ensuring safe operation within design limits, optimizing fuel usage by dynamically adjusting cooling rates based on real-time conditions and component temperatures.
Implementation Method 1
For cooling, it is common practice to cool the steam turbine using so-called 'forced cooling.' Forced cooling essentially comprises three phases.
Implementation Method 2
the cooling rate takes into account the temperature of the components, such as the housing and the rotor of the steam turbine
Data Source
Figure 1
AI summary
The invention relates to an automation system that determines the theoretical maximum rate of cooling of a steam turbine (2) and operates a steam generator (6) in such a way that the thermal energy of the steam does not exceed nor drop below the predefined rate of cooling.