Catalyst module overheating detection and methods of response

• US 20070028625A1
• Filed: 09/01/2004
• Published: 02/08/2007
• Est. Priority Date: 09/05/2003
• Status: Active Grant

• Current Assignee: Kawasaki Jukogyo Kabushiki Kaisha
• Original Assignee: Kawasaki Jukogyo Kabushiki Kaisha
• Inventors: Joshi, Ajay, Yee, David
• Granted Patent: US 7,975,489 B2
• Time in Patent Office: Days
• US Class Current: 60/777
• CPC Class Codes: F23C 13/04 characterised by arrangements of two or more catalytic elements in series connection
• CPC Class Codes: F23C 13/06 in which non-catalytic combustion takes place in addition to catalytic combustion, e.g. downstream of a catalytic element
• CPC Class Codes: F23N 2225/16 burner temperature
• CPC Class Codes: F23N 2225/21 outlet temperature
• CPC Class Codes: F23N 2241/20 Gas turbines
• CPC Class Codes: F23N 5/082 using electronic means
• CPC Class Codes: F23N 5/102 using electronic means
• CPC Class Codes: F23N 5/242 using electronic means
• CPC Class Codes: F23R 3/34 Feeding into different combustion zones
• CPC Class Codes: F23R 3/40 characterised by the use of catalytic means

Abstract

According to one aspect, a method of detecting catalyst module overheating in a catalytic combustion system is provided. In one example, the method includes detecting one or more signals from at least one probe adapted to obtain values associated with at least one of the outlet gas temperature of a catalyst module and the outlet face temperature of the catalyst module included in a catalytic combustor. The one or more signals are compared with a preselected value associated with catalyst overheating. The detected temperature may be detected over time to determine a rate of change in the temperature. The temperature may be detected with a UV sensor directed to the catalyst outlet face.

Claims

1. A method for detecting catalyst module overheating in a catalytic combustion system comprising the acts of:

detecting one or more signals from at least one probe adapted to obtain values associated with at least one of an outlet gas temperature of a catalyst and an outlet face temperature of the catalyst included in a catalytic combustor; and

comparing the one or more signals with a value associated with catalyst overheating.

2. The method of claim 1, wherein detecting the one or more signals includes detecting at least one of an average temperature and maximum temperature.

3. The method of claim 1, wherein the one or more signals are detected over a period of time.

4. The method of claim 1, wherein detecting the one or more signals includes detecting a rate of change in the temperature.

5. The method of claim 1, wherein detecting the one or more signals includes determining at least one of an average temperature and maximum temperature associated with multiple temperature probes.

6. The method of claim 1, wherein the one or more signals are detected during a turbine speed approximately 95% or greater of full speed for a single shaft gas turbine.

7. The method of claim 1, wherein the one or more signals are detected during a turbine speed greater than or equal to idle speed for a two shaft gas turbine.

8. The method of claim 1, further including determining an inlet temperature of the catalyst, wherein the catalyst inlet temperature is substantially constant when determining the temperature associated with at least one of the outlet gas temperature of the catalyst and the outlet face temperature of the catalyst.

9. The method of claim 1, wherein the one or more signals are detected during a substantially stable control mode.

10. The method of claim 1, wherein detecting the one or more signals includes infrared thermal sensor with a field of view directed to an outlet face of the catalyst.

11. The method of claim 1, wherein detecting the one or more signals includes one or more temperature probes located downstream of the catalyst.

12. The method of claim 1, wherein detecting the one or more signals includes one or more temperature probes located upstream of the catalyst.

13. The method of claim 1, further including determining an interstage gas temperature between the catalyst and a second catalyst located serially in the catalytic combustor.

14. The method of claim 1, further including at least a second catalytic combustor arranged in a multi-combustor configuration.

15. A method for detecting catalyst module overheating in a catalytic combustion system comprising the acts of:

determining the position of a homogenous combustion wave relative to a catalyst included in a catalytic combustor; and

comparing the position with a value associated with the catalyst overheating.

16. The method of claim 15, wherein the position of the homogenous combustion wave is determined by an ultraviolet sensor.

17. The method of claim 16, wherein detecting the position of the homogenous combustion wave includes determining a magnitude of the ultraviolet sensor.

18. The method of claim 15, wherein the position of the homogenous combustion wave is measured over time.

19. The method of claim 15, wherein detecting the position of the homogenous combustion wave includes determining a rate of change in the homogeneous combustion wave position.

20. The method of claim 15, wherein determining the position of the homogenous combustion wave includes determining an average position associated with multiple ultraviolet sensors.

21. The method of claim 15, wherein the position of the homogenous combustion wave is determining during a turbine speed approximately 95% or greater of the full speed for a single shaft gas turbine.

22. The method of claim 15, wherein the position of the homogenous combustion wave is determined during a turbine speed greater than or equal to idle speed for a two shaft gas turbine.

23. The method of claim 15, further including detecting an inlet temperature of the catalyst, wherein the catalyst inlet temperature is substantially constant when determining the position of the homogenous combustion wave.

24. The method of claim 15, wherein the position of the homogenous combustion wave is determined during a substantially stable control mode.

25. A method for detecting catalyst module overheating in a catalytic combustion system comprising the acts of:

detecting a first temperature associated with a preburner inlet temperature,

detecting a second temperature associated with a preburner outlet temperature;

determining a difference between the second temperature and the first temperature; and

comparing the difference with a value, wherein the value is associated with a catalyst located downstream of the preburner overheating.

26. The method of claim 25, wherein the value is associated with the catalyst overheating.

27. The method of claim 25, wherein the temperature is detected during a turbine speed approximately 95% or greater of full speed for a single shaft gas turbine.

28. The method of claim 25, wherein the temperature is detected during a turbine speed greater than or equal to idle speed for a two shaft gas turbine.

29. The method of claim 25, wherein the temperature is detected during a substantially stable control mode.

30. A method for controlling a catalytic combustion system comprising the acts of:

determining one or more temperatures associated with a catalyst in a combustor exceeding a preselected temperature value, wherein the temperature value is associated with overheating of the catalyst; and

varying at least one of fuel flow and air flow to the catalyst to reduce the temperature.

31. The method of claim 30, wherein the one or more temperatures are associated with at least one of an outlet gas temperature of the catalyst and an outlet face temperature of the catalyst.

32. The method of claim 30, wherein the combustor includes at least two catalysts arranged serially and the one or more temperatures are associated with at least one of an outlet gas temperature of at least one of the catalysts, an outlet face temperature of at least one of the catalysts, and an interstage catalyst temperature located between two serially adjacent catalysts.

33. The method of claim 30, wherein varying includes decreasing at least one of an air-to-fuel ratio and a catalyst inlet temperature.

34. The method of claim 30, wherein the air flow is varied with one or more of a bypass valve, bleed valve, and inlet guide vane.

35. The method of claim 30, wherein at least one of the fuel flow and air flow is varied incrementally until the one or more temperatures are reduced.

36. The method of claim 30, further including incrementally reducing a demand value associated with one or more of the fuel flow and air flow to the system until the one or more temperatures are reduced below the threshold temperature.

37. The method of claim 30, wherein the one or more temperatures are reduced by reducing fuel flow to a preburner of the system.

38. The method of claim 30, wherein the one or more temperatures are reduced by reducing the fuel flow to the catalyst.

39. The method of claim 30, wherein the one or more temperatures are reduced by reducing catalyst inlet fuel-to-air ratio.

40. A catalytic combustion system, comprising:

a combustor housing with a catalyst disposed therein;

a first temperature probe with a field of view directed to an outlet face of the catalyst;

one or more second temperature probes upstream of the catalyst and positioned to measure a catalyst inlet temperature; and

one or more third temperature probes downstream of the catalyst and positioned to measure a catalyst outlet temperature.

41. The system of claim 40, further including at least a second combustor housing disposed in a multi-combustor configuration.

42. The system of claim 40, wherein the first temperature probe includes an ultra-violet sensor.

43. The system of claim 40, wherein the one or more second temperature probes are disposed within 4 inches of the catalyst inlet face.

44. The system of claim 40, wherein the one or more second temperature probes are disposed within 2 inches of the catalyst inlet face.

45. The system of claim 40, wherein the one or more third temperature probes are disposed within 4 inches of the catalyst outlet face.

46. The system of claim 40, wherein the one or more third temperature probes are disposed within 2 inches of the catalyst outlet face.

47. The system of claim 40, further including one or more of a bypass valve, bleed valve, and inlet guide vane.

48. A method for operating a catalytic combustion system comprising:

ramping a catalytic combustion system having a catalyst at a first rate to a preselected load level; and

ramping at a second rate after the preselected load level has been reached, wherein the second rate is less than the first rate.

49. The method of claim 48, wherein the preselected load level is associated with a catalyst outlet gas temperature threshold.

50. The method of claim 48, wherein the preselected load level is associated with a catalyst outlet face temperature threshold.

51. The method of claim 48, further including pausing for a time between ramping at the first rate and the second rate.

52. The method of claim 48, further including reducing operating schedules between the first rate and the second rate.

53. The method of claim 48, further including reducing at least one of a catalyst outlet gas temperature and catalyst outlet face temperature prior to ramping at the second rate.

54. The method of claim 48, further including reducing at least one of a catalyst outlet gas temperature and catalyst outlet face temperature between ramping at the first rate and the second rate.

55. A method for operating a catalytic combustion system comprising:

ramping a catalytic combustion system having a catalyst at a first rate until a temperature associated with the catalyst reaches a preselected upper value;

pausing for a period of time where the system is not ramped; and

ramping the catalyst combustion system at a second rate subsequent to the pause.

56. The method of claim 55, wherein the period of time is such that the temperature reduces to a preselected lower value.

57. The method of claim 55, wherein the preselected upper value is associated with the catalyst overheating.

58. The method of claim 55, wherein the temperature includes at least one of a catalyst outlet gas temperature and a catalyst outlet face temperature

59. The method of claim 55, wherein the first rate and second rate are equal.

60. The method of claim 55, wherein the first rate is greater than the second rate.