Turbine Control Parameters From Virtual Thermal Modeling
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Solution Overview
Problem
Wind turbines and gas turbines face challenges in monitoring temperature-sensitive components, leading to reduced annual energy production (AEP) due to the complexity and cost of instrumentation, particularly in harsh environments, which results in safety margins and increased costs.
Innovation Solution
A computer-implemented method using a validated physical turbine model to estimate virtual temperatures and parameters, such as noise, vibrations, and component stress, from a limited number of measurable values, allowing for the derivation of control parameters without the need for extensive sensor networks, thereby optimizing power production while ensuring safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If extensive sensor networks are used to monitor temperature-sensitive components, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent creates a virtual copy (digital twin) of the turbine system that replicates thermal behavior through simulation. Instead of physically instrumenting every component with sensors, the system uses a validated physical turbine model to generate virtual temperature measurements that mirror real component temperatures, thereby achieving accurate monitoring without extensive physical sensor networks
Solution Approach 2:
The patent replaces the mechanical/physical sensor instrumentation system with a computational simulation system. The validated physical turbine model computationally predicts temperatures of uninstrumented components by processing data from limited physical sensors, substituting complex physical measurement infrastructure with mathematical modeling and data processing
2Reliability
If safety margins are increased to protect temperature-sensitive components, then reliability is improved, but productivity decreases
Solution Approach 1:
The patent implements real-time feedback through the validated physical turbine model that continuously monitors virtual temperatures and provides actionable insights. This feedback mechanism enables operators to make informed decisions about pushing components closer to their thermal limits safely, rather than relying on conservative static safety margins, thereby optimizing the balance between reliability and productivity
Solution Approach 2:
The patent dynamically adjusts operational parameters based on real-time thermal state assessment from the simulation model. By changing operating parameters (such as power output, speed, or load) based on predicted thermal conditions, the system can safely operate closer to component thermal limits, increasing productivity while maintaining reliability through model-guided parameter optimization
3Reliability
If turbine components are over-engineered to withstand uncertainty, then reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent performs preliminary thermal assessment through the validated physical turbine model during the design and commissioning phases. By pre-characterizing thermal behaviors, heat transfer paths, and component thermal responses through simulation, the system establishes baseline thermal maps that inform optimized component specifications, avoiding unnecessary over-engineering while ensuring adequate thermal protection
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AI summary
Method for computer-implemented determination of control parameters of a turbine The invention describes a method for computer-implemented determination of control parameters (CP) of a turbine (T1,...,Tn) by consideration of component-relevant temperature limits. The turbine (T1,", Tn) is either a wind turbine having a generator or a gas turbine having a motor-drive. The method considers the impact of individual turbine manufacturing tolerances on the turbine performance in a turbine model in order to determine control parameters for the turbine without damaging it. The invention comprises the steps of: receiving, by an interface (IF), one or more measurement values of turbine sensors; determining, by a processing unit (PU), at components or turbine places being equipped or not with turbine sensors, one or more virtual parameters and/or temperatures by a simulation of the operation of the turbine (T1,...,Tn), the simulation being made with a given turbine model (TM) in which the one or more measurement values and one or more characteristic values (AG, MP, MDM, TC, CR) of the wind turbine (T1,...,Tn) are used as input parameters; and deriving, by the processing unit (PU), the control parameters (CP) for the wind turbine (T1,...,Tn) from the one or more virtual parameters and/or temperatures.