Turbine Safety Controller Segmentation for Retrofit
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Solution Overview
Problem
Current control systems for gas turbine engines are limited in cost and configurability, making it difficult to implement comprehensive monitoring and safety functions that conform to industrial standards without modifying or replacing existing turbine-generator controllers.
Innovation Solution
A separate and functionally independent Safety-Instrumented System (SIS) controller is introduced, which uses the same inputs as the turbine-generator controller to implement additional safety and monitoring functions, including system initialization, startup, operation monitoring, and shutdown, while conforming to standards like IEC 61508 and AS 3814 without modifying the existing controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate Safety-Instrumented System (SIS) controller is introduced, then safety and reliability are improved, but device complexity increases
Solution Approach 1:
The control system is divided into two separate functional controllers: the existing turbine-generator controller for normal operation and a new Safety-Instrumented System controller for safety functions. This segmentation allows each controller to be optimized for its specific purpose while maintaining overall system reliability without requiring the original controller to handle both functions.
Solution Approach 2:
The SIS controller acts as an intermediary between the existing controller and the safety-critical functions. It receives inputs from the same sensors as the original controller but processes only safety-related logic, providing a dedicated safety layer that isolates safety functions from the main control logic.
2Reliability
If comprehensive safety monitoring functions are implemented, then reliability is improved, but cost increases
Solution Approach 1:
The SIS controller is designed to be universally applicable to existing turbine-generator systems by using the same input signals and control architecture as the original controller. This multi-functionality approach allows comprehensive safety monitoring to be added without requiring expensive hardware modifications or system replacements.
Solution Approach 2:
The SIS controller creates a functional copy of the original controller's input interface and control architecture, but dedicated solely to safety functions. This copying approach allows safety monitoring to be implemented using the same technological foundation, reducing the need for expensive specialized hardware while maintaining comprehensive safety coverage.
3Ease of manufacture
If existing turbine-generator controllers are used without modification, then ease of manufacture is improved, but adaptability worsens
Solution Approach 1:
The system is segmented into two independent controllers with separate functional responsibilities. The original controller continues to handle normal operation functions unchanged, while the new SIS controller handles safety functions. This segmentation preserves the existing controller's simplicity and cost-effectiveness while adding the needed safety functionality through a separate, purpose-built controller.
Solution Approach 2:
The SIS controller serves as an intermediary layer that adapts safety functions to work with the existing controller's input interface without modifying the original controller itself. This intermediary approach maintains compatibility with existing hardware while providing the adaptability needed for comprehensive safety monitoring.
Data Source
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Figure 2A
Figure 2B
AI summary
A retrofit kit (20) for a turbine system (10) is provided that includes a safety instrumented system (SIS) controller (18) having a first plurality of functions (108, 110) and the SIS controller (18) is configured to be coupled to a turbine-generator controller (16), wherein the SIS controller (18) permits a startup function of the turbine-generator controller (16) based on a plurality of inputs (76) from a turbine (12).