Real-time monitoring and automated intervention platform for long term operability of fuel cells

• US 10,461,347 B2
• Filed: 07/01/2016
• Issued: 10/29/2019
• Est. Priority Date: 07/06/2015
• Status: Active Grant

• Current Assignee: Bloom Energy Corporation
• Original Assignee: Bloom Energy Corporation
• Inventors: Venkat, Aswin, Miller, Brent, Raut, Prasad, Ramanan, Natarajan, Shukla, Deepak, Hall, Andrew, Vachhani, Pramod
• Primary Examiner(s): Ruddock, Ula C
• Assistant Examiner(s): Van Oudenaren, Matthew W
• Application Number:
  US15/200,599
• Publication Number:
  US 20170012309A1
• Time in Patent Office: 1,215 Days
• Field of Search: None
• CPC Class Codes: H01M 2008/1293 Fuel cells with solid oxide electrolytes
• CPC Class Codes: H01M 8/04201 Reactant storage and supply, e.g. means for feeding, pipes
• CPC Class Codes: H01M 8/0432 Temperature; Ambient temperature
• CPC Class Codes: H01M 8/04544 Voltage
• CPC Class Codes: H01M 8/04626 of auxiliary devices, e.g. batteries, capacitors
• CPC Class Codes: H01M 8/04664 Failure or abnormal function
• CPC Class Codes: H01M 8/04753 of fuel cell reactants
• CPC Class Codes: H01M 8/04992 characterised by the implementation of mathematical or computational algorithms, e.g. feedback control loops, fuzzy logic, neural networks or artificial intelligence
• CPC Class Codes: H01M 8/0618 Reforming processes, e.g. autothermal, partial oxidation or steam reforming
• CPC Class Codes: H01M 8/0675 Removal of sulfur
• CPC Class Codes: Y02E 60/50 Fuel cells

Abstract

Methods, apparatuses, and systems for real-time monitoring and automated intervention of a power generation. Embodiments may include receiving operating data from components of the power generation system. A potential failure condition for the components may be determined from real-time operating data of the received operating data before an occurrence of the potential failure condition. An alert may be issued in response to determining the real-time operating data indicates a potential failure condition, and instructions for remedying the potential failure condition may be transmitted to the power generation system. An algorithm for determining whether the real-time operating data indicates the potential failure condition may be updated by using preceding operating data in response to detecting the potential failure condition.

Claims

1. A method for monitoring a power generation system, comprising:

receiving operating data from at least one component of the power generation system;

determining whether real-time operating data of the received operating data indicates a potential failure condition for at least one of the components before an occurrence of a failure condition by;

determining whether any portion of the received operating data is in an accepted operating range;

in response to determining that the real-time operating data of the received operating data is not in an accepted operating range;

determining whether an algorithm for determining whether real-time operating data of the received operating data indicates a potential failure condition is available;

in response to determining the algorithm for determining whether the real-time operating data indicates the potential failure condition is unavailable;

correlating the real-time operating data with the potential failure condition; and

creating the algorithm for determining whether the real-time operating data indicates the potential failure condition; and

executing the algorithm for determining whether the real-time operating data indicates the potential failure condition;

issuing a first alert in response to determining the real-time operating data indicates the potential failure condition or transmitting instructions for remedying the potential failure condition to the power generation system; and

updating the algorithm for determining whether the real-time operating data indicates the potential failure condition using preceding operating data in response to determining the real-time operating data indicates the potential failure condition, wherein the preceding operating data is part of the received operating data that is received before the real-time operating data part of the received operating data.

2. The method of claim 1, further comprising:

determining whether the instructions for remedying the potential failure condition are available;

retrieving the instructions for remedying the potential failure condition from a storage device in response to determining the instructions for remedying the potential failure condition are available;

executing an algorithm for determining the remedy for the potential failure condition in response to determining the instructions for remedying the potential failure condition are unavailable; and

creating the instructions for remedying the potential failure condition.

3. The method of claim 2, further comprising:

determining whether third operating data of the received operating data received after transmitting the instructions for remedying the potential failure condition to the power generation system indicates improvement in the operating condition of the at least one of the components; and

updating the instructions for remedying the potential failure condition using the preceding operating data in response to determining the third operating data indicates improvement in the operating condition of the at least one of the components.

4. The method of claim 3, wherein updating the algorithm for determining whether the real-time operating data indicates the potential failure condition using preceding operating data and updating the instructions for remedying the potential failure condition using the preceding operating data comprise executing at least one learning model using the preceding operating data to produce augmented parameters for the algorithm for determining whether the real-time operating data indicates the potential failure condition and the instructions for remedying the potential failure condition.

5. The method of claim 1, further comprising:

determining whether third operating data of the received operating data received after transmitting the instructions for remedying the potential failure condition to the power generation system data indicates a second potential failure condition;

determining whether the potential failure condition indicated by the real-time operating data has ceased in response to determining the third operating data does indicate the second potential failure;

cancelling the first alert in response to determining the third operating data does not indicate the second potential failure condition or in response to determining the potential failure condition indicated by the real-time operating data has ceased;

determining whether the third operating data indicates the same potential failure condition as indicated by the real-time operating data in response to determining the third operating data indicates the second potential failure condition;

issuing a second alert in response to determining the second potential failure condition indicated by the third operating data is different from the potential failure condition as indicated by the real-time operating data.

6. The method of claim 5, further comprising suppressing one of the first alert and the second alert having a lower priority than the other of the first alert and second alert.

7. The method of claim 1, wherein the power generation system comprises at least one fuel cell system, wherein the at least one fuel cell system comprises:

a blower which provides an air inlet stream into the fuel cell system;

a catalytic partial pressure oxidation (CPOx) reactor which partially oxidizes a fuel inlet stream during a start up mode;

a plurality of fuel cell modules, wherein each fuel cell module comprises;

a plurality of fuel cell stacks which generate electricity by oxidizing the fuel inlet stream; and

an anode tailgas oxidizer which oxidizes an anode exhaust stream using a cathode exhaust stream from the fuel cell stacks;

a mass flow controller which controls the fuel inlet stream flow rate to the each of the plurality of fuel cell modules;

a controller configured to control operating conditions of fuel cell system components including the blower, the CPOx reactor, the fuel cell stacks, the anode tailgas oxidizer, and/or the mass flow controller; and

a gateway configured to provide a bi-directional link with a remote server, transmit real-time operational data of the fuel cell system components, and receive the instructions for remedying the potential failure condition.

8. The method of claim 7, wherein:

receiving operating data from at least one component of the power generation system comprises receiving a voltage output of a plurality of fuel cell modules of the fuel cell system sharing one desulfurizer;

determining whether real-time operating data of the received operating data indicates a potential failure condition for at least one of the components before an occurrence of a failure condition comprises determining whether a rate of change in a calculated area specific resistance based on the voltage output of the plurality of fuel cell modules exceeds an accepted rate of change of area specific resistance indicating a potential sulfur breakthrough failure condition in the desulfurizer; and

issuing a first alert in response to determining the real-time operating data indicates the potential failure condition or transmitting instructions for remedying the potential failure condition to the power generation system comprises issuing the first alert indicating a potential sulfur breakthrough failure condition or transmitting instructions to activate a redundant sulfur absorbing bed.

9. The method of claim 7, wherein:

receiving operating data from at least one component of the power generation system comprises receiving a voltage output of a plurality of fuel cell systems or fleets which share the same fuel source;

determining whether real-time operating data of the received operating data indicates a potential failure condition for at least one of the components before an occurrence of a failure condition comprises determining whether a rate of change in a calculated area specific resistance based on the voltage output of the plurality of fuel cell systems or fleets exceeds an accepted rate of change of area specific resistance indicating potential fuel contamination; and

issuing a first alert in response to determining the real-time operating data indicates the potential failure condition or transmitting instructions for remedying the potential failure condition to the power generation system comprises issuing the first alert indicating a potential fuel contamination prompting reporting to a fuel utility provider or transmitting instructions to reduce or eliminate fuel input to the plurality of fuel cell systems or fleets.

10. The method of claim 7, wherein:

receiving operating data from at least one component of the power generation system comprises receiving a voltage output and ATO temperature of a fuel cell module;

determining whether real-time operating data of the received operating data indicates a potential failure condition for at least one of the components before an occurrence of a failure condition comprises determining whether the ATO temperature exceeds an accepted temperature and whether the voltage output exceeds an accepted voltage output indicating a potential mass flow controller drift in fuel supply to the fuel cell module; and

issuing a first alert in response to determining the real-time operating data indicates the potential failure condition or transmitting instructions for remedying the potential failure condition to the power generation system comprises issuing the first alert indicating the a potential mass flow controller drift or transmitting instructions to reduce the flow of fuel to the fuel cell module.

11. The method of claim 7, wherein:

receiving operating data from at least one component of the power generation system comprises receiving at least one of a temperature or power draw of the blower;

determining whether real-time operating data of the received operating data indicates a potential failure condition for at least one of the components before an occurrence of a failure condition comprises determining whether the at least one of a temperature or power draw of the blower exceeds an accepted at least one of a temperature or power draw indicating a potential blower malfunction;

issuing a first alert in response to determining the real-time operating data indicates the potential failure condition or transmitting instructions for remedying the potential failure condition to the power generation system comprises issuing the first alert indicating a potential blower malfunction or transmitting instructions to reduce power provided to the blower.

12. The method of claim 7, wherein:

receiving operating data from at least one component of the power generation system comprises receiving a voltage output of a fuel cell module;

determining whether real-time operating data of the received operating data indicates a potential failure condition for at least one of the components before an occurrence of a failure condition comprises determining whether a variation of the voltage output over time exceeds an accepted rate of change in voltage output of a first module or segment but not of other modules or segments of the same fuel cell system indicating a potential crack in a fuel cell or seal failure in the first fuel cell module or segment; and

issuing a first alert in response to determining the real-time operating data indicates the potential failure condition or transmitting instructions for remedying the potential failure condition to the power generation system comprises issuing the first alert indicating a potential crack in the fuel cell or seal failure in the first fuel cell module or segment or transmitting instructions to reduce or eliminate the flow of fuel to the fuel cell module.

13. A method for monitoring a power generation system, comprising:

receiving operating data from at least one component of the power generation system;

determining whether real-time operating data of the received operating data indicates a potential failure condition for at least one of the components before an occurrence of a failure condition;

issuing a first alert in response to determining the real-time operating data indicates the potential failure condition or transmitting instructions for remedying the potential failure condition to the power generation system; and

updating an algorithm for determining whether the real-time operating data indicates the potential failure condition using preceding operating data in response to determining the real-time operating data indicates the potential failure condition, wherein the preceding operating data is part of the received operating data that is received before the real-time operating data part of the received operating data;

wherein;

the power generation system comprises at least one fuel cell system, wherein the at least one fuel cell system comprises;

a blower which provides an air inlet stream into the fuel cell system;

a catalytic partial pressure oxidation (CPOx) reactor which partially oxidizes a fuel inlet stream during a start up mode;

a plurality of fuel cell modules, wherein each fuel cell module comprises;

a plurality of fuel cell stacks which generate electricity by oxidizing the fuel inlet stream; and

an anode tailgas oxidizer which oxidizes an anode exhaust stream using a cathode exhaust stream from the fuel cell stacks;

a mass flow controller which controls the fuel inlet stream flow rate to the each of the plurality of fuel cell modules;

a controller configured to control operating conditions of fuel cell system components including the blower, the CPOx reactor, the fuel cell stacks, the anode tailgas oxidizer, and/or the mass flow controller; and

a gateway configured to provide a bi-directional link with a remote server, transmit real-time operational data of the fuel cell system components, and receive the instructions for remedying the potential failure condition;

receiving operating data from at least one component of the power generation system comprises receiving a voltage output of a plurality of fuel cell modules of the fuel cell system sharing one desulfurizer;

determining whether real-time operating data of the received operating data indicates a potential failure condition for at least one of the components before an occurrence of a failure condition comprises determining whether a rate of change in a calculated area specific resistance based on the voltage output of the plurality of fuel cell modules exceeds an accepted rate of change of area specific resistance indicating a potential sulfur breakthrough failure condition in the desulfurizer; and

issuing a first alert in response to determining the real-time operating data indicates the potential failure condition or transmitting instructions for remedying the potential failure condition to the power generation system comprises issuing the first alert indicating a potential sulfur breakthrough failure condition or transmitting instructions to activate a redundant sulfur absorbing bed.

14. A method for monitoring a power generation system, comprising:

receiving operating data from at least one component of the power generation system;

determining whether real-time operating data of the received operating data indicates a potential failure condition for at least one of the components before an occurrence of a failure condition;

issuing a first alert in response to determining the real-time operating data indicates the potential failure condition or transmitting instructions for remedying the potential failure condition to the power generation system; and

updating an algorithm for determining whether the real-time operating data indicates the potential failure condition using preceding operating data in response to determining the real-time operating data indicates the potential failure condition, wherein the preceding operating data is part of the received operating data that is received before the real-time operating data part of the received operating data;

wherein;

the power generation system comprises at least one fuel cell system, wherein the at least one fuel cell system comprises;

a blower which provides an air inlet stream into the fuel cell system;

a catalytic partial pressure oxidation (CPOx) reactor which partially oxidizes a fuel inlet stream during a start up mode;

a plurality of fuel cell modules, wherein each fuel cell module comprises;

a plurality of fuel cell stacks which generate electricity by oxidizing the fuel inlet stream; and

an anode tailgas oxidizer which oxidizes an anode exhaust stream using a cathode exhaust stream from the fuel cell stacks;

a mass flow controller which controls the fuel inlet stream flow rate to the each of the plurality of fuel cell modules;

a controller configured to control operating conditions of fuel cell system components including the blower, the CPOx reactor, the fuel cell stacks, the anode tailgas oxidizer, and/or the mass flow controller; and

a gateway configured to provide a bi-directional link with a remote server, transmit real-time operational data of the fuel cell system components, and receive the instructions for remedying the potential failure condition;

receiving operating data from at least one component of the power generation system comprises receiving a voltage output of a plurality of fuel cell systems or fleets which share the same fuel source;

determining whether real-time operating data of the received operating data indicates a potential failure condition for at least one of the components before an occurrence of a failure condition comprises determining whether a rate of change in a calculated area specific resistance based on the voltage output of the plurality of fuel cell systems or fleets exceeds an accepted rate of change of area specific resistance indicating potential fuel contamination; and

issuing a first alert in response to determining the real-time operating data indicates the potential failure condition or transmitting instructions for remedying the potential failure condition to the power generation system comprises issuing the first alert indicating a potential fuel contamination prompting reporting to a fuel utility provider or transmitting instructions to reduce or eliminate fuel input to the plurality of fuel cell systems or fleets.

15. A method for monitoring a power generation system, comprising:

receiving operating data from at least one component of the power generation system;

determining whether real-time operating data of the received operating data indicates a potential failure condition for at least one of the components before an occurrence of a failure condition;

issuing a first alert in response to determining the real-time operating data indicates the potential failure condition or transmitting instructions for remedying the potential failure condition to the power generation system; and

updating an algorithm for determining whether the real-time operating data indicates the potential failure condition using preceding operating data in response to determining the real-time operating data indicates the potential failure condition, wherein the preceding operating data is part of the received operating data that is received before the real-time operating data part of the received operating data;

wherein;

the power generation system comprises at least one fuel cell system, wherein the at least one fuel cell system comprises;

a blower which provides an air inlet stream into the fuel cell system;

a catalytic partial pressure oxidation (CPOx) reactor which partially oxidizes a fuel inlet stream during a start up mode;

a plurality of fuel cell modules, wherein each fuel cell module comprises;

a plurality of fuel cell stacks which generate electricity by oxidizing the fuel inlet stream; and

an anode tailgas oxidizer which oxidizes an anode exhaust stream using a cathode exhaust stream from the fuel cell stacks;

a mass flow controller which controls the fuel inlet stream flow rate to the each of the plurality of fuel cell modules;

a controller configured to control operating conditions of fuel cell system components including the blower, the CPOx reactor, the fuel cell stacks, the anode tailgas oxidizer, and/or the mass flow controller; and

a gateway configured to provide a bi-directional link with a remote server, transmit real-time operational data of the fuel cell system components, and receive the instructions for remedying the potential failure condition;

receiving operating data from at least one component of the power generation system comprises receiving a voltage output and ATO temperature of a fuel cell module;

determining whether real-time operating data of the received operating data indicates a potential failure condition for at least one of the components before an occurrence of a failure condition comprises determining whether the ATO temperature exceeds an accepted temperature and whether the voltage output exceeds an accepted voltage output indicating a potential mass flow controller drift in fuel supply to the fuel cell module; and

issuing a first alert in response to determining the real-time operating data indicates the potential failure condition or transmitting instructions for remedying the potential failure condition to the power generation system comprises issuing the first alert indicating the a potential mass flow controller drift or transmitting instructions to reduce the flow of fuel to the fuel cell module.

16. A method for monitoring a power generation system, comprising:

receiving operating data from at least one component of the power generation system;

determining whether real-time operating data of the received operating data indicates a potential failure condition for at least one of the components before an occurrence of a failure condition;

issuing a first alert in response to determining the real-time operating data indicates the potential failure condition or transmitting instructions for remedying the potential failure condition to the power generation system; and

updating an algorithm for determining whether the real-time operating data indicates the potential failure condition using preceding operating data in response to determining the real-time operating data indicates the potential failure condition, wherein the preceding operating data is part of the received operating data that is received before the real-time operating data part of the received operating data;

wherein;

the power generation system comprises at least one fuel cell system, wherein the at least one fuel cell system comprises;

a blower which provides an air inlet stream into the fuel cell system;

a catalytic partial pressure oxidation (CPOx) reactor which partially oxidizes a fuel inlet stream during a start up mode;

a plurality of fuel cell modules, wherein each fuel cell module comprises;

a plurality of fuel cell stacks which generate electricity by oxidizing the fuel inlet stream; and

an anode tailgas oxidizer which oxidizes an anode exhaust stream using a cathode exhaust stream from the fuel cell stacks;

a mass flow controller which controls the fuel inlet stream flow rate to the each of the plurality of fuel cell modules;

a controller configured to control operating conditions of fuel cell system components including the blower, the CPOx reactor, the fuel cell stacks, the anode tailgas oxidizer, and/or the mass flow controller; and

a gateway configured to provide a bi-directional link with a remote server, transmit real-time operational data of the fuel cell system components, and receive the instructions for remedying the potential failure condition;

receiving operating data from at least one component of the power generation system comprises receiving at least one of a temperature or power draw of the blower;

determining whether real-time operating data of the received operating data indicates a potential failure condition for at least one of the components before an occurrence of a failure condition comprises determining whether the at least one of a temperature or power draw of the blower exceeds an accepted at least one of a temperature or power draw indicating a potential blower malfunction;

issuing a first alert in response to determining the real-time operating data indicates the potential failure condition or transmitting instructions for remedying the potential failure condition to the power generation system comprises issuing the first alert indicating a potential blower malfunction or transmitting instructions to reduce power provided to the blower.

17. A method for monitoring a power generation system, comprising:

receiving operating data from at least one component of the power generation system;

determining whether real-time operating data of the received operating data indicates a potential failure condition for at least one of the components before an occurrence of a failure condition;

issuing a first alert in response to determining the real-time operating data indicates the potential failure condition or transmitting instructions for remedying the potential failure condition to the power generation system; and

updating an algorithm for determining whether the real-time operating data indicates the potential failure condition using preceding operating data in response to determining the real-time operating data indicates the potential failure condition, wherein the preceding operating data is part of the received operating data that is received before the real-time operating data part of the received operating data;

wherein;

the power generation system comprises at least one fuel cell system, wherein the at least one fuel cell system comprises;

a blower which provides an air inlet stream into the fuel cell system;

a catalytic partial pressure oxidation (CPOx) reactor which partially oxidizes a fuel inlet stream during a start up mode;

a plurality of fuel cell modules, wherein each fuel cell module comprises;

a plurality of fuel cell stacks which generate electricity by oxidizing the fuel inlet stream; and

an anode tailgas oxidizer which oxidizes an anode exhaust stream using a cathode exhaust stream from the fuel cell stacks;

a mass flow controller which controls the fuel inlet stream flow rate to the each of the plurality of fuel cell modules;

a controller configured to control operating conditions of fuel cell system components including the blower, the CPOx reactor, the fuel cell stacks, the anode tailgas oxidizer, and/or the mass flow controller; and

a gateway configured to provide a bi-directional link with a remote server, transmit real-time operational data of the fuel cell system components, and receive the instructions for remedying the potential failure condition;

receiving operating data from at least one component of the power generation system comprises receiving a voltage output of a fuel cell module;

determining whether real-time operating data of the received operating data indicates a potential failure condition for at least one of the components before an occurrence of a failure condition comprises determining whether a variation of the voltage output over time exceeds an accepted rate of change in voltage output of a first module or segment but not of other modules or segments of the same fuel cell system indicating a potential crack in a fuel cell or seal failure in the first fuel cell module or segment; and

issuing a first alert in response to determining the real-time operating data indicates the potential failure condition or transmitting instructions for remedying the potential failure condition to the power generation system comprises issuing the first alert indicating a potential crack in the fuel cell or seal failure in the first fuel cell module or segment or transmitting instructions to reduce or eliminate the flow of fuel to the fuel cell module.