System and method for starting gas turbine engines

• US 10,641,179 B2
• Filed: 11/07/2016
• Issued: 05/05/2020
• Est. Priority Date: 11/07/2016
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Hayama, Mauro, Zhao, Xin, Tian, Ming, Hawkins, Mikhel, Asari, Koji, Swager, Thomas Charles, Clawson, Michael Allen
• Primary Examiner(s): Sutherland, Steven M
• Assistant Examiner(s): Chabreyrie, Rodolphe Andre
• Application Number:
  US15/344,778
• Publication Number:
  US 20180128182A1
• Time in Patent Office: 1,275 Days
• Field of Search: None
• CPC Class Codes: F02C 7/262 Restarting after flame-out
• CPC Class Codes: F05D 2220/32 in gas turbines
• CPC Class Codes: F05D 2220/323 for aircraft propulsion, e.g. jet engines
• CPC Class Codes: F05D 2260/85 Starting
• CPC Class Codes: F05D 2270/092 in particular blow-out and relight
• CPC Class Codes: F05D 2270/304 Spool rotational speed

Abstract

A method of starting a gas turbine engine includes determining an abnormal shutdown condition during operation of the gas turbine engine and determining a first set of lightoff parameters for the gas turbine engine. The method also includes restarting the gas turbine engine using the first set of lightoff parameters. The method further includes iteratively determining subsequent first sets of lightoff parameters and restarting the gas turbine engine using a respective subsequent first set of the determined subsequent first sets of lightoff parameters until the gas turbine maintains a first set of operational parameters, where the first set of operational parameters is representative of a robust lightoff of the gas turbine engine.

Claims

1. A system for starting a gas turbine engine, said system comprising:

a controller communicatively coupled to a starter, to an ignitor, and to at least one sensor, said controller comprising a processor programmed to;

determine an abnormal shutdown condition during operation of the gas turbine engine;

determine a first set of lightoff parameters for the gas turbine engine, wherein determining the first set of lightoff parameters comprises determining a flow rate of fuel into a combustor of the gas turbine engine and an operational status of the ignitor coupled to the combustor;

determine a temperature of a flow of exhaust gas exiting the gas turbine engine, wherein a first set of operational parameters includes at least one of the exhaust gas temperature being greater than a predetermined temperature value, a temperature rate of change value being greater than a predetermined temperature rate of change value, and a rate of change of a rotational velocity of a rotor of the gas turbine engine being greater than a predetermined rate of change value;

restart the gas turbine engine using the first set of lightoff parameters, wherein said controller is configured to restart the gas turbine engine using the first set of lightoff parameters comprises;

i) when a first condition is met, determining the rotational velocity of the rotor and increasing the rotational velocity, the first condition including the rotational velocity being at least one of;

substantially equal to a windmill speed value and less than a first predetermined rotational velocity value;

ii) when a second condition is met, injecting fuel into the combustor at a first flow rate and energizing the ignitor, the second condition including the rotational velocity being greater than a second predetermined rotational velocity value;

iii) when a third condition is met, turning off a starter, the third condition including;

the first set of operational parameters not being maintained for a first predetermined amount of time; and

the rotational velocity value being greater than a third predetermined velocity value for the first predetermined amount of time, the third predetermined rotational velocity value greater than the second predetermined rotational velocity value; and

iteratively, determine subsequent first sets of lightoff parameters and restarting the gas turbine engine using a respective subsequent first set of the determined subsequent first sets of lightoff parameters until the gas turbine engine maintains the first set of operational parameters, the first set of operational parameters representative of a robust lightoff of the gas turbine engine.

2. The system in accordance with claim 1, wherein the processor is further comprising programmed to:

determine a partial lightoff of the gas turbine engine;

iteratively, determine a second set of lightoff parameters; and

restart the gas turbine engine using the second set of lightoff parameters until the gas turbine engine maintains the first set of operational parameters.

3. The system in accordance with claim 1, wherein the processor is further programmed to:

determine a no lightoff condition of the gas turbine engine;

iteratively, determine a third set of lightoff parameters; and

restart the gas turbine engine using the third set of lightoff parameters until the gas turbine engine maintains the first set of operational parameters.

4. The system in accordance with claim 1, wherein the processor is further programmed to:

determine a second set of operational parameters, the second set of operational parameters representative of a partial lightoff of the gas turbine engine;

iteratively, determine a second set of lightoff parameters including a second flow rate;

adjust at least one of the first predetermined amount of time, the first predetermined rotational velocity value, the second predetermined rotational velocity value, and the third predetermined rotational velocity value; and

restart the gas turbine engine using the second set of lightoff parameters until the gas turbine engine maintains the first set of operational parameters.

5. The system in accordance with claim 1, wherein the processor is further programmed to:

determine a third set of operational parameters, the third set of operational parameters representative of a no lightoff condition of the gas turbine engine;

iteratively, determine a third set of lightoff parameters including a third flow rate;

adjust at least one of the first predetermined amount of time, the first predetermined rotational velocity value, the second predetermined rotational velocity value, and the third predetermined rotational velocity value; and

restart the gas turbine engine using the third set of lightoff parameters until the gas turbine engine maintains the first set of operational parameters.

6. The system in accordance with claim 1, wherein the processor is further programmed to:

further increase the rotational velocity when the third condition is not met and a fourth condition is met, the fourth condition including the first set of operational parameters being maintained for a second predetermined amount of time after the first predetermined amount of time;

turn off the starter when a fifth condition is met, the fifth condition representative of a successful starting of the gas turbine engine and including the rotational velocity being greater than a fourth predetermined rotational velocity value, the fourth predetermined rotational velocity value greater than the third predetermined rotational velocity value; and

de-energizing the ignitor.

7. A system for starting a gas turbine engine, the gas turbine engine including a rotor and a combustor having an ignitor configured to ignite a fuel in the combustor, said system comprising:

a starter in torque communication with the rotor;

a fuel flow valve in serial flow communication with the combustor and configured to inject the fuel into the combustor;

at least one sensor coupled to the gas turbine engine, wherein said at least one sensor comprises a speed sensor configured to measure a rotational velocity of the rotor and a plurality of sensors comprising a temperature sensor configured to measure a temperature of a flow of exhaust gas exiting the gas turbine engine; and

a controller communicatively coupled to said starter, to said ignitor, and to said at least one sensor, said controller comprising a processor programmed to;

determine an abnormal shutdown condition of the gas turbine engine;

determine a first set of lightoff parameters for the gas turbine engine, wherein a first set of operational parameters includes at least one of the exhaust gas temperature being greater than a predetermined temperature value, a temperature rate of change value being greater than a predetermined temperature rate of change value, and a rate of change of the rotational velocity being greater than a predetermined rate of change value, and wherein the first set of lightoff parameters further includes a flow rate of the fuel through said fuel flow valve into the combustor and an operational status of the ignitor;

restart the gas turbine engine using the first set of lightoff parameters, wherein in restarting the gas turbine engine using the first set of lightoff parameters, the processor is programmed to;

i) transmit, when a first condition is met, a starter signal having a first value to said starter to facilitate increasing, using said starter, the rotational velocity, the first condition including the rotational velocity being at least one of;

substantially equal to a windmill speed value and less than a first predetermined rotational velocity value;

ii) transmit, when a second condition is met, a valve signal having a first value to said fuel flow valve to facilitate injecting the fuel at a first flow rate and an ignitor signal having a first value to the ignitor to facilitate energizing the ignitor, the second condition including the rotational velocity being greater than a second predetermined rotational velocity value;

iii) transmit, when a third condition is met, the starter signal having a second value, the second value different from the first value, to said starter to facilitate turning off said starter, the third condition including;

the first set of operational parameters not being maintained for a first predetermined amount of time and the rotational velocity value being greater than a third predetermined rotational velocity value for the first predetermined amount of time, the third predetermined rotational velocity value greater than the second predetermined rotational velocity value; and

iteratively, determine subsequent first sets of lightoff parameters and restart the gas turbine engine using a respective subsequent first set of the determined subsequent first sets of lightoff parameters until the gas turbine engine maintains the first set of operational parameters, the first set of operational parameters representative of a robust lightoff of the gas turbine engine.

8. The system in accordance with claim 7, wherein said processor is further programmed to:

determine a partial lightoff of the gas turbine engine;

iteratively, determine a second set of lightoff parameters; and

restart the gas turbine engine using the second set of lightoff parameters until the gas turbine engine maintains the first set of operational parameters.

9. The system in accordance with claim 7, wherein said processor is further programmed to:

determine a no lightoff condition of the gas turbine engine;

iteratively, determine a third set of lightoff parameters; and

restart the gas turbine engine using the third set of lightoff parameters until the gas turbine engine maintains the first set of operational parameters.

10. The system in accordance with claim 7, wherein said at least one sensor further comprises a plurality of sensors comprising a temperature sensor configured to measure a temperature of a flow of exhaust gas exiting the gas turbine engine, and wherein the first set of operational parameters further includes at least one of the exhaust gas temperature being greater than a predetermined temperature value and a temperature rate of change value being greater than a predetermined temperature rate of change value.

11. The system in accordance with claim 7, wherein said processor is further programmed to:

determine a second set of operational parameters, the second set of operational parameters representative of a partial lightoff of the gas turbine engine;

iteratively, determine a second set of lightoff parameters including a second flow rate;

adjust at least one of the first predetermined amount of time, the first predetermined rotational velocity value, the second predetermined rotational velocity value, and the third predetermined rotational velocity value; and

restart the gas turbine engine using the second set of lightoff parameters until the gas turbine engine maintains the first set of operational parameters.

12. The system in accordance with claim 7, wherein said processor is further programmed to:

determine a third set of operational parameters, the third set of operational parameters representative of a no lightoff condition of the gas turbine engine;

iteratively, determine a third set of lightoff parameters including a third flow rate;

adjust at least one of the first predetermined amount of time, the first predetermined rotational velocity value, the second predetermined rotational velocity value, and the third predetermined rotational velocity value; and

restart the gas turbine engine using the third set of lightoff parameters until the gas turbine engine maintains the first set of operational parameters.

13. The system in accordance with claim 7, wherein said processor is further programmed to:

transmit the starter signal having the first value to said starter to facilitate further increasing, using said starter, the rotational velocity when the third condition is not met and a fourth condition is met, the fourth condition including the first set of operational parameters being maintained for a second predetermined amount of time after the first predetermined amount of time;

transmit the starter signal having the second value to said starter to facilitate turning off said starter when a fifth condition is met, the fifth condition representative of a successful starting of the gas turbine engine and including the rotational velocity being greater than a fourth predetermined rotational velocity value, the fourth predetermined rotational velocity value greater than the third predetermined rotational velocity value; and

transmitting the ignitor signal having a second value, the second value different from the first value, to the ignitor to facilitate de-energizing the ignitor.

14. A non-transitory computer-readable memory having computer-executable instructions embodied thereon, wherein when executed by a computing device, the computer-executable instructions cause the computing device to:

determine an abnormal shutdown condition during operation of a gas turbine engine;

determine a first set of lightoff parameters for the gas turbine engine;

determine a temperature of a flow of exhaust gas exiting the gas turbine engine, wherein a first set of operational parameters includes at least one of the exhaust gas temperature being greater than a predetermined temperature value, a temperature rate of change value being greater than a predetermined temperature rate of change value, and a rate of change of a rotational velocity of a rotor of the gas turbine engine being greater than a predetermined rate of change value;

restart the gas turbine engine using the first set of lightoff parameters, wherein restarting the gas turbine engine using the first set of lightoff parameters comprises;

i) when a first condition is met, determining the rotational velocity of the rotor and increasing the rotational velocity, the first condition including the rotational velocity being at least one of;

substantially equal to a windmill speed value and less than a first predetermined rotational velocity value;

ii) when a second condition is met, injecting fuel into the combustor at a first flow rate and energizing the ignitor, the second condition including the rotational velocity being greater than a second predetermined rotational velocity value;

iii) when a third condition is met, turning off a starter, the third condition including;

the first set of operational parameters not being maintained for a first predetermined amount of time; and

the rotational velocity value being greater than a third predetermined velocity value for the first predetermined amount of time, the third predetermined rotational velocity value greater than the second predetermined rotational velocity value; and

iteratively, determine subsequent first sets of lightoff parameters and restart the gas turbine engine using a respective subsequent first set of the determined subsequent first sets of lightoff parameters until the gas turbine engine maintains the first set of operational parameters, the first set of operational parameters representative of a robust lightoff of the gas turbine engine.

15. The non-transitory computer-readable memory of claim 14, wherein when executed by the computing device, the computer-executable instructions further cause the computing device to:

determine a second set of operational parameters, the second set of operational parameters representative of a partial lightoff of the gas turbine engine;

iteratively, determine a second set of lightoff parameters including a second flow rate;

adjust at least one of the first predetermined amount of time, the first predetermined rotational velocity value, the second predetermined rotational velocity value, and the third predetermined rotational velocity value; and

restart the gas turbine engine using the second set of lightoff parameters until the gas turbine engine maintains the first set of operational parameters.

16. The non-transitory computer-readable memory of claim 14, wherein when executed by the computing device, the computer-executable instructions further cause the computing device to:

determine a third set of operational parameters, the third set of operational parameters representative of a no lightoff condition of the gas turbine engine;

iteratively, determine a third set of lightoff parameters including a third flow rate;

adjust at least one of the first predetermined amount of time, the first predetermined rotational velocity value, the second predetermined rotational velocity value, and the third predetermined rotational velocity value; and

restart the gas turbine engine using the third set of lightoff parameters until the gas turbine engine maintains the first set of operational parameters.

17. The non-transitory computer-readable memory of claim 14, wherein when executed by the computing device, the computer-executable instructions further cause the computing device to:

cause the rotational velocity to further increase when the third condition is not met and a fourth condition is met, the fourth condition including the first set of operational parameters being maintained for a second predetermined amount of time after the first predetermined amount of time;

cause the starter to turn off when a fifth condition is met, the fifth condition representative of a successful starting of the gas turbine engine and including the rotational velocity being greater than a fourth predetermined rotational velocity value, the fourth predetermined rotational velocity value greater than the third predetermined rotational velocity value; and

cause the ignitor to de-energize.