Variable Extraction Orifice Control for Gas Turbine Efficiency
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Solution Overview
Problem
Conventional gas turbine engine designs face inefficiencies due to a one-size-fits-all approach to compressor air extraction, leading to excessive cooling air usage, which decreases engine performance and efficiency, especially during varying operational conditions such as peak power generation or base load operations.
Innovation Solution
A method involving variable compressor extraction flow control using a control unit that measures and monitors engine parameters to adjust the settings of variable extraction orifices, allowing for optimized airflow extraction based on temperature, pressure, and flow levels, thereby minimizing unnecessary cooling air usage and enhancing engine performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a one-size-fits-all approach is used for compressor air extraction, then the extraction capacity is fixed and simple to control, but excessive cooling air is used which decreases engine efficiency and performance
Solution Approach 1:
The patent implements variable extraction orifices that can dynamically adjust their opening degree based on operating conditions. The control system continuously monitors engine parameters and modulates the extraction flow area, transforming the static extraction system into a dynamic one that adapts to changing thermal and power demands, thereby reducing excess cooling air usage and improving efficiency
Solution Approach 2:
The patent changes the extraction flow area parameter dynamically by adjusting the opening degree of variable extraction orifices. This parameter change allows the system to optimize the balance between cooling requirements and efficiency losses under different operating conditions, directly addressing the energy loss problem without requiring complete system redesign
2Productivity
If variable extraction is implemented to optimize cooling air usage, then engine efficiency and output can be improved, but the control system complexity increases
Solution Approach 1:
The patent employs a control system that continuously monitors engine operating parameters such as thermal demand, power output, and extraction flow, and uses this feedback to dynamically adjust the opening degree of variable extraction orifices. This closed-loop feedback mechanism enables the system to automatically optimize engine output and efficiency while managing the complexity through automated control rather than manual intervention
Solution Approach 2:
The variable extraction system serves multiple functions: it optimizes cooling air distribution, maximizes engine output, improves efficiency, and adapts to different operating modes (base load, peak power, hot ambient conditions). This multi-functionality justifies the increased control system complexity by delivering comprehensive performance benefits across diverse operational scenarios
3Reliability
If excess cooling air is extracted from the compressor, then turbine blade cooling is ensured under all conditions, but the performance penalty increases due to reduced compressor efficiency
Solution Approach 1:
The patent applies different extraction flow rates to different turbine sections based on their specific cooling requirements. By distributing cooling air locally where needed rather than using a uniform extraction approach, the system ensures reliable turbine blade cooling in critical areas while minimizing excess extraction that would penalize compressor efficiency, thus resolving the contradiction between cooling reliability and energy loss
Data Source
AI summary
A method of controlling variable extraction flow in a combustion turbine engine, wherein extraction flow comprises a supply of compressed air extracted from the compressor and supplied to the turbine through extraction conduits, and wherein the extraction conduits includes a variable extraction orifice, the method comprising the steps of: measuring a plurality of turbine engine operating parameters; monitoring, by a control unit, the measured operating parameters of the combustion turbine engine; setting the variable extraction orifices to a setting that allows an approximate maximum level of extraction flow; calculating, by the control unit, at least one calculated operating parameter based upon model-based control and the measured operating parameters, including at least a current turbine inlet temperature and a maximum turbine inlet temperature; and manipulating the setting for the supply of fuel to the combustor such that an increased and/or maximum level of engine output is determined by comparing the values for the current turbine inlet temperature and the maximum turbine inlet temperature.