Turbine Liquid Fuel Simulator with Porting Valves

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Dual-fuel turbine engines face challenges in testing liquid fuel systems without powering down the turbine, as existing methods risk damage, emissions, and productivity loss, due to the need to burn liquid fuel and potential component degradation.

Innovation Solution

A turbine liquid fuel simulator system that includes fuel porting mechanisms with directional control valves to switch between directing liquid fuel to the nozzle and returning it to the tank, allowing for zero-emission testing without powering down the turbine, using a separate testing media tank and water-cooled components to manage high temperatures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the turbine is powered down and switched from gas to liquid fuel for testing, then the liquid fuel system can be tested, but productivity is lost and blade tip impact damage may occur

Engineering Contradiction:

Improveliquid fuel system functionalityVSAvoidturbine operation continuity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The fuel system is segmented into separate testable components. The liquid fuel system can be isolated and tested independently from the main turbine operation through dedicated test lines and valves, allowing validation without shutting down the turbine.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An intermediary test system is introduced that includes test valves, flow meters, and return lines. This intermediary infrastructure enables liquid fuel flow testing while the turbine continues operating on gas fuel, acting as a mediator between the two fuel systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If liquid fuel is burned during testing to validate the system, then complete system operation can be tested, but emissions are generated and fuel is consumed

Engineering Contradiction:

Improveliquid fuel system validationVSAvoidemissions

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The combustion step is extracted and removed from the testing process. The test system validates liquid fuel flow, pressure, and component operation by circulating fuel through test lines and back to the tank without introducing it to the combustion chamber, eliminating emissions entirely.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The potential harm of burning fuel during testing is converted into a benefit by using the fuel circulation system itself as the test medium. The fuel's physical properties (flow, pressure, temperature) are validated through measurement instruments without requiring combustion, turning a potentially harmful process into a harmless validation method.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If the turbine operates at full capacity during liquid fuel system operation, then the system is tested under real conditions, but damage may occur if components are compromised

Engineering Contradiction:

Improvesystem operational capabilityVSAvoidcomponent degradation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Instead of operating the full liquid fuel system at combustion capacity, only the necessary portions (pumps, valves, flow meters, return lines) are activated at reduced levels for testing. The fuel is circulated through the test infrastructure at controlled rates without reaching the combustor, providing sufficient validation without excessive stress on components.

Inventive Principle:

Principle #16Partial or excessive action

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

Enables zero-emission testing of liquid fuel systems, validating component operation and reducing the risk of damage and emissions, while maintaining turbine operation and productivity.

Implementation Method 1

Each fuel porting mechanism is configured to switch between a first position, wherein the fuel porting mechanism directs liquid fuel from the fuel tank to the nozzle, and a second position, wherein the fuel porting mechanism directs the liquid fuel from the fuel tank back to the fuel tank via the liquid fuel return line

Methodology Applied

Scientific EffectFluid flow control:

Implementation Method 2

using a separate testing media tank and water-cooled components to manage high temperatures

Methodology Applied

Scientific EffectWater cooling: Cooling

Data Source

PatentUS9354141B1Turbine liquid fuel simulator

Publication Date: 2016.05.31 JANSENS AIRCRAFT SYST CONTROLS

AI summary

A turbine liquid fuel simulator exposes the components of a liquid fuel system in a turbine engine to the same fuel flows and pressures that the liquid fuel system would endure in an actual startup and run sequence, without burning or otherwise emitting the liquid fuel from the system. A fuel porting mechanism, such as a direction control valve, is installed in each combustor of the turbine engine. The fuel porting mechanism is movable from a first position, wherein liquid fuel is delivered to the combustor nozzle to be burned in normal operation, to a second position, wherein the liquid fuel is diverted to return lines that deliver the liquid fuel back to the fuel tank. To simulate the actual pressures and flows, pressure differential orifices can be installed in the return fuel lines. The orifices includes structures that modify the liquid fuel flow to mimic delivery to the nozzle.