Variable Pump Control for Turbine Fogging Arrays
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Solution Overview
Problem
Combustion turbines face performance issues due to variations in air conditions, leading to undersupply or oversupply of liquid in fogging systems, which affect the moisture content of intake air and turbine efficiency.
Innovation Solution
A system that adjusts the output of a variable output pump supplying liquid to a fogging array based on weather sensor data, target humidity values, and flow rate sensors, using control valves to maintain optimal liquid flow and pressure, thereby minimizing undersupply and oversupply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed output pump is used to supply liquid to the fogging array, then the system structure is simple, but the liquid supply cannot be adapted to varying weather conditions and mass flow rates, causing undersupply or oversupply
Solution Approach 1:
The pump output is made variable through a variable frequency drive (VFD) that dynamically adjusts the pump speed based on real-time feedback from flow rate sensors and weather conditions. This transforms the fixed output pump into a dynamic system that adapts to changing mass flow rates and weather conditions, resolving the contradiction between simplicity and adaptability.
Solution Approach 2:
A feedback control system using flow rate sensors downstream of the pump and weather sensors upstream of the turbine provides real-time data to the controller. The controller adjusts the VFD output frequency based on this feedback, enabling the pump to automatically adapt to varying conditions while maintaining optimal liquid supply, thus achieving adaptability without excessive complexity.
2Productivity
If manual adjustment of liquid flow is used, then the control system is simple, but the response time to changing conditions is slow and imprecise
Solution Approach 1:
The automatic feedback control system continuously monitors flow rate and weather conditions, enabling rapid response to changing conditions without manual intervention. The controller automatically adjusts the VFD based on sensor feedback, achieving fast response times while maintaining reasonable automation levels through a centralized control algorithm.
Solution Approach 2:
The system performs self-adjustment through automatic control algorithms that process sensor data and modify pump output without human intervention. The controller autonomously responds to changing conditions by adjusting the VFD frequency, enabling the system to service itself and respond quickly to variations in mass flow rate and weather.
3Quantity of substance
If high liquid flow is supplied to the fogging array, then the moisture content of intake air increases, but this causes oversupply leading to wasted liquid and potential turbine issues
Solution Approach 1:
The feedback control system uses flow rate sensors to monitor actual liquid supply and weather sensors to determine required moisture content. The controller adjusts the pump output to match the precise amount needed based on real-time conditions, preventing both undersupply (insufficient moisture) and oversupply (liquid waste), thus resolving the contradiction between achieving target moisture content and avoiding waste.
Solution Approach 2:
The system dynamically changes the pump output parameter based on varying weather conditions and mass flow rates. By adjusting the VFD frequency, the pump delivers precisely the right amount of liquid needed for current conditions, preventing liquid waste while ensuring adequate moisture content in the intake air.
4Loss of substance
If low liquid flow is supplied to the fogging array, then liquid waste is reduced, but the moisture content of intake air becomes insufficient, affecting turbine performance
Solution Approach 1:
The feedback control system continuously monitors both flow rate and weather conditions to determine the optimal liquid supply level. By comparing actual supply with required supply based on weather data, the system ensures sufficient moisture content is delivered to maintain turbine performance reliability while avoiding liquid waste through precise control.
Solution Approach 2:
The system uses weather sensors to predict the required liquid supply based on forecasted conditions and mass flow rate. This preliminary determination allows the controller to pre-adjust the pump output to appropriate levels, ensuring sufficient moisture content is provided before turbine operation begins, thus maintaining performance reliability without excessive liquid supply.
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
The system effectively controls liquid flow to the fogging array, ensuring optimal moisture content of intake air, improving combustion turbine performance by adapting to varying conditions and preventing liquid supply imbalances.
Implementation Method 1
The fogging array introduces a spray of the water to thereby reduce inlet air temperature
Implementation Method 2
the output is adjusted based on feedback from a flow rate sensor located downstream of the pump
Implementation Method 3
the at least one control valve is actuated based on comparing an anticipated pressure value for liquid in a conduit between a pump and a fogging array to a measured actual pressure value in the conduit
Data Source
AI summary
Methods and apparatus for controlling liquid flow to a turbine fogging array. Some implementations are generally directed toward adjusting the output of a variable output pump that supplies water to the turbine fogging array. In some of those implementations, the output is adjusted based on a determined target pump output value that is indicative of a pump output required to change the moisture content of intake air of a combustion turbine to meet a target humidity value. Some implementations are generally directed toward actuating at least one control valve of a plurality of control valves that control liquid throughput to one or more fogging nozzles of a fogging array.