Economically efficient operation of a power generator

• US 10,205,322 B1
• Filed: 03/08/2016
• Issued: 02/12/2019
• Est. Priority Date: 03/09/2015
• Status: Active Grant

• Current Assignee: Cummins Power Generation IP, Inc. (Cummins Incorporated)
• Original Assignee: Cummins Power Generation IP, Inc. (Cummins Incorporated)
• Inventors: Keene, Kevin, Fuchs, Benjamin S., Hunt, Michelle
• Primary Examiner(s): Nguyen, Viet Q
• Application Number:
  US15/064,197
• Time in Patent Office: 1,071 Days
• Field of Search: 700287, 700286
• CPC Class Codes: G06Q 10/04 Forecasting or optimisation specially adapted for administrative or management purposes, e.g. linear programming or "cutting stock problem" market predictions or forecasting for commercial activities G06Q30/0202
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: G06Q 10/0637 Strategic management or analysis, e.g. setting a goal or target of an organisation; Planning actions based on goals; Analysis or evaluation of effectiveness of goals
• CPC Class Codes: H02J 2300/10 The dispersed energy generation being of fossil origin, e.g. diesel generators
• CPC Class Codes: H02J 3/381 Dispersed generators
• CPC Class Codes: Y02E 40/70 Smart grids as climate change mitigation technology in the energy generation sector
• CPC Class Codes: Y04S 10/50 Systems or methods supporting the power network operation or management, involving a certain degree of interaction with the load-side end user applications

Abstract

A method of operating a power generator comprises receiving, a fault code corresponding to an operating condition of the power generator being outside of an acceptable range. A generator controller determines a cost of increased maintenance or repairing damage associated with overriding the fault code and maintaining existing power output from the power generator through the operating condition. A cost of a utility fine or contractual penalty associated with shutting down the power generator is determined in response to the fault code. The generator controller compares the cost of the utility fine or contractual penalty associated with shutting down the power generator with the cost of increased maintenance or damage repair to the power generator associated with overriding the fault code and maintaining existing power output through the operating condition. In response to the comparing, the fault code is overridden continuing operation of the power generator.

Claims

1. A method of operating a power generator comprising a generator controller, the method comprising:

receiving, by the generator controller, a fault code corresponding to an operating condition of the power generator being outside of an acceptable range;

determining, by the generator controller, a cost of increased maintenance or repairing damage to the power generator associated with overriding the fault code and maintaining existing power output from the power generator through the operating condition;

determining, by the generator controller, a cost of a utility fine or contractual penalty associated with shutting down the power generator in response to the fault code;

comparing, by the generator controller, the cost of the utility fine or contractual penalty associated with shutting down the power generator with the cost of increased maintenance or damage repair to the power generator associated with overriding the fault code and maintaining existing power output through the operating condition; and

in response to the comparing, overriding the fault code and continuing operation of the power generator.

2. The method of claim 1, wherein the cost of increased maintenance or repairing damage further includes one of calculating a probability of damage from continued operation the power generator and a probability the need for increased or accelerated maintenance on the power generator.

3. The method of claim 2, wherein the cost of repairing damage, the probability of damage, or the cost of increased maintenance to the power generator increases as a function of time, and wherein the cost of repairing damage and the cost of increased maintenance each comprises an estimated cost or an actual cost.

4. The method of claim 1, wherein continuing operation of the power generator comprises causing a reduction in the power output of the power generator to a level that reduces the cost of the increased maintenance or damage repair to the generator and reduces the cost of the utility fine or contractual penalty.

5. The method of claim 4, wherein the reduced power output level is determined based upon the operating condition generating the fault code.

6. The method of claim 1, wherein comparing, by the generator controller, the cost of the utility fine or contractual penalty associated with shutting down the power generator with the cost of repairing damage to the power generator further comprises determining if the cost of the utility fine, contractual penalty, or other contractual obligation is greater than the cost of continuing operation, wherein continuing operation corresponds to a violation of at least one of a local noise ordinances, fuel use restrictions, or pollution limitations.

7. The method of claim 1, wherein the power generator is a combined heat and power generator or a combined heat and power and cooling generator.

8. The method of claim 1, wherein the cost of a utility fine or contractual penalty associated with shutting down the power generator decreases as a function of time.

9. The method of claim 1, further comprising:

determining that the power generator will shut down during a contractually pre-designated time period;

determining an aggregate shutdown cost from the cost of the utility fine associated with shutting down the power generator and the cost of increased maintenance or damage repair to the power generator associated with overriding the fault code and maintaining existing power output through the operating condition; and

shutting down the power generator when the aggregate shutdown cost reaches a predetermined threshold or minimum aggregate for the contractually pre-designated time period.

10. The method of claim 9, wherein the aggregate shutdown cost comprises the cost of increased maintenance or damage repair to the power generator associated with overriding the fault code and maintaining existing power output through the operating condition added to the cost of the utility fine or contractual penalty associated with shutting down the power generator.

11. The method of claim 9, wherein the predetermined threshold is the minimum aggregate shutdown cost for the contractually pre-designated time period.

12. The method of claim 1, wherein the power generator comprises a plurality of power generators.

13. The method of claim 1, further comprising:

receiving an indication of at least one of an energy cost and value;

determining a profit from operating the power generator based upon a difference between energy price and at least one of a maintenance cost, a fuel price, or a replacement cost amortization; and

if the profit is greater than a predetermined threshold, maintaining existing power output of the power generator.

14. The method of claim 13, wherein the at least one of the energy cost and value comprises at least one of a fuel price and an electricity price.

15. The method of claim 13, wherein the energy price is received in real-time via remote monitoring.

16. A controller for operating a power generator comprising:

a memory device; and

a processor communicatively coupled to the memory device and configured to;

receive a fault code corresponding to an operating condition of the power generator being outside of an acceptable range;

determine a cost of repairing damage to the power generator associated with overriding the fault code and maintaining existing power output of the power generator through the operating condition;

determine a cost of a utility fine or contractual penalty associated with shutting down the power generator in response to the fault code;

compare the cost of the utility fine or contractual penalty associated with shutting down the power generator with the cost of repairing damage to the power generator associated with overriding the fault code and maintaining existing power output through the operating condition; and

in response to the comparing, override the fault code and maintain existing power output through the operating condition, so as to continue operation of the power generator.

17. The controller of claim 16, wherein the processor is configured to cause a reduction in the power output of the power generator to a level that reduces the cost of repairing damage to the generator and reduces the cost of the utility fine or contractual penalty to an aggregate minimum.

18. The controller of claim 16, wherein the cost of repairing damage further comprises a cost of increased maintenance and the cost of damage repair to the power generator.

19. The controller of claim 17, wherein the reduced power output level is determined based upon the operating condition generating the fault code.

20. The controller of claim 16, wherein the processor is configured to:

determine that the power generator will shut down during a contractually pre-designated time period;

determine an aggregate shutdown cost from the cost of the utility fine associated with shutting down the power generator and the cost of repairing damage to the power generator associated with overriding the fault code and maintaining existing power output through the operating condition; and

shut down the power generator when the aggregate shutdown cost reaches a minimum aggregate for the contractually pre-designated time period.

21. A non-transitory computer-readable storage medium having machine instructions stored therein, the instructions being executable by a processor of a power generator controller to cause the processor to:

receive a fault code corresponding to an operating condition of apower generator being outside of an acceptable range;

determine a cost of repairing damage to the power generator associated with overriding the fault code and maintaining existing power output of the generator through the operating condition;

determine a cost of a utility fine or a contractual penalty associated with shutting down the power generator in response to the one or more fault codes;

compare the cost of the utility fine or the contractual penalty associated with shutting down the power generator with the cost of repairing damage to the power generator associated with overriding the fault code and maintaining existing power output through the operating condition; and

in response to the comparing, override the fault code and maintain existing power output through the operating condition so as to continue operation of the power generator.

22. The non-transitory computer-readable storage medium of claim 21, wherein the instructions are executable by the processor to cause the processor to reduce the power output of the power generator to a level that reduces the cost of repairing damage to the generator and reduces the cost of the contractual penalty.

23. The non-transitory computer-readable storage medium of claim 22, wherein the instructions are executable by the processor to cause the processor to determine the reduced power level based upon the one or more operating conditions generating the fault code.

24. The non-transitory computer-readable storage medium of claim 21, wherein the instructions are further executable by the processor to cause the processor to:

determine that the power generator will shut down during a contractually pre-designated time period;

determine an aggregate shutdown cost from the cost of the contractual penalty associated with shutting down the power generator and the cost of repairing damage to the power generator associated with overriding the fault code and maintaining existing power output through the operating condition; and

shut down the power generator when the aggregate shutdown cost reaches a minimum aggregate for the contractually pre-designated time period.

25. A power generation system, comprising:

a power generator comprising an engine and an alternator; and

a generator controller operatively coupled to the power generator, the generator controller configured to;

receive a fault code corresponding to an operating condition of the power generator being outside of an acceptable range;

determine a cost of increased maintenance or repairing damage to the power generator associated with overriding the fault code and maintaining existing power output from the power generator through the operating condition;

determine a cost of a utility fine or contractual penalty associated with shutting down the power generator in response to the fault code;

compare the cost of the utility fine or contractual penalty associated with shutting down the power generator with the cost of increased maintenance or damage repair to the power generator associated with overriding the fault code and maintaining existing power output through the operating condition; and

in response to the comparing, override the fault code and maintain existing power output through the operating condition so as to continue operation of the power generator.

26. The power generation system of claim 25, wherein the generator controller is further configured to:

determine if the cost of the utility fine or contractual penalty associated with shutting down the power generator is greater than the cost of increased maintenance or damage repair to the power generator associated with overriding the fault code and maintaining existing power output through the operating condition, and

in response to the determination that the cost of the utility fine or contractual penalty is greater than the cost of increased maintenance or damage repair to the power generator, overriding the fault code and continuing operation of the power generator.

27. The power generation system of claim 25, wherein the generator controller is further configured to:

determine that the power generator will shut down during a contractually pre-designated time period;

determine an aggregate shutdown cost from the cost of the contractual penalty associated with shutting down the power generator and the cost of repairing damage to the power generator associated with overriding the fault code and maintaining existing power output through the operating condition; and

shut down the power generator when the aggregate shutdown cost reaches a minimum aggregate for the contractually pre-designated time period.