Professional Documents
Culture Documents
Tim Healy
April, 2009
1
Thermal
Nuclear
Nuclear
Cleaner Coal
Renewables
Gas
Biomass
Wind
Solar
Hydro
3
Trillion Kilowatt-Hours
Coal
Natural Gas
Liquids
Renewables
Nuclear
20
15
10
5
0
2005
2010
2015
2020
2025
2030
6.4%
8.2%
6.5%
5.1%
4.7%
3.2%
1.7%
-0.5%
World
1.6%
-1.5%
1.7%
2.2%
1.4%
Russia Middle
East
-2.3%
China
India
-2.5%
USA Eurozone Japan
24
Outline
Industrial Gas Turbines Short-Course
Legacy Control Algorithms
Model-Based Control for Fuel Flexibility
The Road Ahead
A Sense of Power
x 10
Ford Shelby GT500
~500 SHP
GE Evolution Locomotive
~5000 SHP
GE 9H Industrial GT Engine
~500,000 SHP (combined-cycle)
x 10
x 10
GE-90 Aircraft GT Engine
~50,000 SHP
1
2
Gen
Comb
Comp
4
Turb
Heat Source
Stack
T
GT
TEMPERATURE
COMBUSTION
2
K
STAC
1
ENTROPY
S
8
HRSG
9
Gen
ST
10
Pump
6
Air
1
Gen
Cond
5
Fuel
2
Comb
Comp
4
GT
Heat Source
GT
GAS
UST
EXHA
2
HRSG
8
7
STACK
5, 6
4
9
ST
COMPRESSI
ON
TEMPERATURE
COMBUSTION
RANKINE
STEAM CYCLE
CONDENSER
10
Heat Sink
ENTROPY
S
9
Fuel
Flow
Combustor
Turbine
Exhaust
Flow
Compressor
Shaft
10
Chamber Arrangement
on Gas Turbine
Multiple Fuel
Nozzles
11
Fuel
System
Operability
Exhaust
Frame
Durability
Compressor
AeroMechanics
Combustor
Flashback
(Flameholding)
Compressor
Surge
Combustor
Emissions
(NOx, CO, UHC)
Power
Output
Combustion
Dynamics
Optimal
Efficiency
AutoIgnition
Combustor
Lean BlowOut (LBO)
12
Outline
Industrial Gas Turbines Short-Course
Legacy Control Algorithms
Model-Based Control for Fuel Flexibility
The Road Ahead
13
Ambient Pressure
Ambient
Temperature
Generator
Power
Generator
Losses
Inlet
Pressure
Drop
Effectors
Inlet Temperature
Inlet Humidity
Sensors
Fuel Splits
Compressor
Discharge
Pressure
Compressor
Discharge
Temperature
14
P3
Isentropic
Expansion
Temperature
e
ssur
t Pre on
n
a
t
i
s
Con at Addit
He
P 2=
Maximum Cycle
Temperature
Cycle =
P 1= P4
P2 T2
=
P1 T1
Entropy
Cycle
Comp
1
Turb
2 Comb 3
P T
= 3 = 3
P4 T4
T
= 1 3
T4
Problem:
Desire To Control T3,
But T3 is Not Measured
(1 ) ( 1)
Turbine Efficiency
Solution:
Correlate T3 to a
Measured Variable
turbine =
T3 =
T
T'
T4
1 - turbine 1
( )
P3 1
P4
T3 = f ( T4 , PRc )
T3 = f ( T4 , t , PRt )
15
Splits
X ~ Tx
PRc
T4_max
MINIMUM
T4
T4_req +
P+I
Wf / IGV
T4
Pre-Programmed
Control Schedules
Field-Tuned For
Performance &
Operability
PRc
Characteristics
Simple
(Easily Understood and Verified)
16
Outline
Industrial Gas Turbines Short-Course
Legacy Control Algorithms
Model-Based Control for Fuel Flexibility
The Road Ahead
17
94
Ethane
Content [%]
Methane
Content [%]
Abu
Dhabi
14
Trinidad
96
Norway
92
Nigeria
Algeria
90
88
Malaysia
Abu
Dhabi
86
Qatar
Oman
84
82
12
10
Algeria
8
Oman
6
4
Qatar
Malaysia
Nigeria
Norway
Trinidad
USA
80
US (Typical)
Abu Dhabi
Algeria
Malaysia
Nigeria
Norway
Oman
Qatar
Trinidad
Geographic Origin
US (Typical)
Abu Dhabi
Algeria
Malays ia
Nigeria
Norway
Oman
Qatar
Composition Variation
Will Increase As More
LNG Is Injected Into
Pipelines
Trinidad
Geographic Origin
4.5
1500
Propane
Content [%]
Oman
3.5
Nigeria
Qatar
2.5
Norway
Abu
Dhabi
1.5
Algeria
1
USA
Trinidad
0.5
0
Wobbe Index
Malaysia
1450
Abu Dhabi
Algeria
Malays ia
Nigeria
Norway
Oman
Qatar
Trinidad
MWI =
HHV
Sg
Wobbe Index
LHV
S g T
HHV, LHV
Sg
Qatar
Norway
1400
Trinidad
USA
1350
US (Typical)
Abu Dhabi
Geographic Origin
WI =
Nigeria
Algeria
1300
US (Typical)
Oman
Malaysia
Abu
Dhabi
Algeria
Malaysia
Nigeria
Norway
Oman
Qatar
Trinidad
Geographic Origin
18
What Is At Risk?
Gas turbine operability concerns due
to composition variation:
Addressed by gas
fuel specification
(given expected variation,
not an issue for most premixed combustion systems)
Auto-Ignition
Flashback
Emissions (NOx, CO)
Combustion Dynamics
Blow-out
Addressed today
by manual tuning
(given expected variation,
potentially a very serious issue)
19
NP
NG
NG
NP
NG
LNG
NP
LNG
LNG
Fictitious
region /
pipeline
20
Legacy Solution
Closed-Loop MWI With Fuel Temperature
IP Feedwater
Control
Dual GCs
Performance
Heater
Characteristics
Costly
(Dual Gas Chromatographs)
Low-Bandwidth
(GCs & Fuel Heat Exchangers)
Limited Authority
(Performance Heater Capability)
Sub-Optimal Efficiency
(Any Off-Nominal Fuel Temperature)
21
Limit Scheduling
Loop
Selection
+_
+_
+_
Loop
Selection
+_
+_
0 . 16
(6 . 394 * SH )
W
3 . 95 * e
T3
NOx@ 270
1 . 25
O2 =
15
%
P3 * e
Physics-Based
Boundary Models
NOxref * e
*e
9.5( SH SH ref )
IGV
Loop
Selection
+_
Wf
Fuel
Splits
Virtual
Sensors
ARES - Parameter
Estimation
*Q
Engine Model
Characteristics
Robust / Flexible / Expandable
(Additional Boundaries / Loops)
22
Filter
Extended Kalman Filter Formulation
On-Line Jacobian & KF Gain Calculation
Re-configurable for Fault Accommodation
Avoids Parallel Linear Model Process
Measured
Inputs
Measured
Outputs
x , y
Estimated
Outputs
ARES - Parameter
Estimation
u
x prt
+
_
State
Estimate
Extended
Outputs
P = a P aT + Q
s = J P JT + R
K = P J T s 1
x
+
+
Z-1
Partial
Deriv.
Calc.
y prt
Engine Model
y ext
Engine Model
ARES - Parameter
Estimation
P = P K J P
(Covariance of
Prediction Error)
(Covariance of
Residual)
(Gain Matrix)
a, J
Q, R
(Covariance of
Prediction Error)
Z-1
23
eNOx
min
eNOx
+_
Control
NOx
Fuel_
Fraction
+_
+_
+_
+_
+_
+_
+_
+_
+_
Loop-In-Control
Structure
Environment
Limit Scheduling
NOx
(target)
e1
e2
max
CDM
Physics-Based
Boundary Models
NOx @15%O2 =
f ( Tflame, Humidity,
Fuel_Fraction )
Virtual
Sensors
GT
Effectors
Sensors
ARES - Parameter
Estimation
Engine Model
Tflame, Tfire,
W2, etc.
24
Adaptive-Model Approach
15
Site
Site
Site
Site
Site
14
13
12
A
B
C
D
E (10% C2)
XR
1.0
11
Closed-Loop
Control
+_
10
9
8
7
Boundary
Sensor
0.5
Predicted
Dynamics
[psi]
Predicted
NOx
[ppm@15%O2]
0.5
5
1.0
1.5
10 11 12 13 14 15
Measured
[psi]
Measured Dynamics
NOx [ppm@15%O2]
Design
Center
( Small
Performance
Impact )
( No Performance
Impact )
( Performance
Impact )
Load
Runback
Fuel
Temp.
Fuel
Fraction
Expected
LNG Range
Boundary
Model
Performance optimization
through hierarchical
application of effectors
Wobbe
25
200
400
2%
0%
9
8
7
6
400
-20
~260F fuel
temperature
excursion imposed
(~20% MWI) over
five minutes (max
capability of fuel
heat exchanger)
20
40
60
10
80
80
60
40
20
0
Time [sec]
100
120
NOx
Load
110
100
90
6
-20
600
OpFlex Wide
Wobbe system
maintains
emissions &
dynamics levels
using fuel
distribution only
Combustion Dynamics
Amplitude [% Of Target]
Combustion Dynamics
Amplitude [% Of Target]
Frequency 1
Frequency 2
400
~10% WI change
imposed over ~30
seconds (rate
>18%/minute)
-6%
20
40
60
80
80
100
Time [sec]
200
-4%
600
120
Closed-loop
simulation of modelbased control
algorithm (7FA+e
DLN2.6, base-load,
ISO Day)
-2%
Time [sec]
100
Time [sec]
10
200
4%
600
Time [sec]
6%
MWI
Fuel Temp.
400
350
300
250
200
150
100
50
0
Closed-Loop Simulation
NOx [ppm@15%O2]
56
54
52
50
48
46
44
42
40
Field Test
120
100
Frequency 1
Frequency 2
80
60
40
20
0
-20
20
40
60
80
100
Time [sec]
26
Assessment
The Model-Based Control system provides many
advantages over competing technologies with similar
objectives:
Cost
No additional auxiliary equipment required beyond control system sensor
redundancy. No gas analyzer required
Operability
Negligible change in output or efficiency as a result of changing fuel
properties
Lower combustion dynamics across the operational envelope
Improved output & efficiency at off-design conditions
Reliability
Increased system availability due to sensor fault detection and
accommodation
Emissions
Tighter NOx control over a wider operational envelope
27
28
Liquid fuels
Light crude
Heavy crude
vanadium & sulfur
Synthetic fuels
29
HRSG
Pump
Cooling
O2
Gasifier
Gen
ST
CleanUp
Cond
Syngas
Air
Comb
Feed
Prep.
Gen
Comp
GT
Fuel + H2O
Electricity /
Steam
as
Syn g
Gasifier
Sulfur
Removal
Sulfur
Combined Cycle
Power Block
30
Plant-Level Optimization
Model Predictive Controls for
Combined-Cycle Plant Start-Up
Optimized
Load Profile
Time
Stress
constraints
HP & IP maximum rotor stresses
Final CC load
Time
MPC Controller
GT, HRSG, ST models
HP & IP rotor stresses
Optimize
GT loading
over Time
Horizon
GT load
reference
Control
System
State estimation
Measurements
Steam & metal Temperatures, Steam Pressures
Measurements
31
Back-Up
32
2007
2030
Cold Tone
Hot Tone
Dynamics
Dynamics
Window
NOx
Dynamics
Combustion Operability
Limit
Dynamics
Window NOx
Guarantee
NOx
Fuel-Air Ratio
Lean
Blow Out
Lean
Blow
Out
Operability
Window
CO
CO
Window
Fuel-Air Ratio
CO
Tfire (Power)
Fuel-Air Ratio
Window
Guarantee
Fuel-Air Ratio
35