Microprocessor-based control system for gas turbine electric powerplant

• US 6,941,217 B1
• Filed: 09/03/2004
• Issued: 09/06/2005
• Est. Priority Date: 04/16/2002
• Status: Expired due to Fees

• Current Assignee: Altek Power Corp.
• Original Assignee: Altek Power Corp.
• Inventors: Munson, Bill C. Jr.
• Primary Examiner(s): Chin, Gary
• Application Number:
  US10/934,803
• Time in Patent Office: 368 Days
• Field of Search: 701/700, 700/287, 700/288, 700/289, 700/290, 477/30, 477/31, 477/121, 361/51, 602/261, 602/37, 602/39
• US Class Current: 701/100
• CPC Class Codes: F01D 19/00 Starting of machines or engines; Regulating, controlling, or safety means in connection therewith warming-up before starting F01D25/10; turning or inching gear F01D25/34
• CPC Class Codes: F01D 21/00 Shutting-down of machines or engines, e.g. in emergency; Regulating, controlling, or safety means not otherwise provided for
• CPC Class Codes: F02C 9/00 Controlling gas-turbine plants; Controlling fuel supply in air- breathing jet-propulsion plants controlling air intakes F02C7/057; controlling turbines F01D; controlling compressors F04D27/00; controlling in general G05
• CPC Class Codes: F02C 9/28 Regulating systems responsive to plant or ambient parameters, e.g. temperature, pressure, rotor speed F02C9/30 - F02C9/38, F02C9/44 take precedence
• CPC Class Codes: F05D 2270/54 by electronic means, e.g. electronic tubes, transistors or IC's within an electronic circuit

Abstract

A microprocessor-based control system for a gas turbine electrical powerplant. the microprocessor-based control system controls the startup, operation, and shutdown of the gas turbine electric powerplant. The microprocessor-based control system of the present invention dispenses with the need to utilize relays, timers, or other control hardware. Rather, the microprocessor-based control system employs software that replaces the control hardware, and directly reads the inputs, calculates the control actions, and writes the outputs. The microprocessor-based control system is also in electrical communication with an overspeed control system, provided to ensure that a runaway condition of the gas turbine engine does not occur should the gas turbine engine become disconnected from the speed reducer (gearbox) or generator. Sensors are used to monitor multiple operating conditions of the powerplant. The microprocessor-based control system communicates with the sensors, and activates the overspeed control system if an overspeed condition is detected.

Claims

1. A method for controlling a gas turbine engine driven electric powerplant, said method comprising:

determining an initial turbine speed analog value from a synchronizer speed bias signal and one or more predetermined setpoint values, and inputting said analog value to a turbine speed setpoint subroutine;

using an output from said turbine speed setpoint subroutine and a measured power turbine shaft speed to calculate a fuel control valve analog value, and inputting said fuel control valve analog value to a fuel control valve subroutine;

using an output from said fuel control valve subroutine to energize a fuel control valve positioner that is adapted to set the position of a fuel control valve accordingly;

calculating a fuel control valve analog adjustment value using said power turbine shaft speed, a fuel control valve setpoint value and said output from said fuel control valve subroutine, inputting said fuel control valve analog adjustment value to a fuel control valve adjustment subroutine and using an output from said fuel control valve adjustment subroutine to continually fine tune said fuel control valve position;

inputting said fuel control valve adjustment subroutine output into a feedback loop to obtain fuel control valve gain and reset values, and feeding said fuel control valve gain and reset values into a PID controller so that said output of said fuel control valve adjustment subroutine is continually updated;

averaging a plurality of exhaust gas temperature measurement values and using the resulting average exhaust gas temperature value and a predetermined exhaust gas temperature setpoint value to produce a resulting analog value that is input to an exhaust gas temperature load bias subroutine;

using a compressor turbine shaft speed measurement value and a compressor turbine shaft speed setpoint value to produce a resulting analog value that is input to a compressor turbine shaft speed load bias subroutine;

using a load setpoint value and an output from each of said exhaust gas temperature load bias subroutine and said compressor turbine shaft speed load bias subroutine as inputs to a total load setpoint subroutine; and

using an output from each of said total load setpoint subroutine and said fuel control valve subroutine as inputs to said compressor turbine shaft speed load bias subroutine, thereby continually adjusting the output thereof;

whereby the rotational speed of said gas turbine engine is maintained within predetermined limits by adjusting the rate at which fuel is supplied to said engine so as to correspond to changes in a load on said engine.

2. The method of claim 1, further comprising:

initially analyzing sensor inputs to determine whether static powerplant conditions are within predetermined limits; and

initiating a starter subroutine if said conditions are determined to be within acceptable limits, said starter subroutine consisting essentially of;

initiating a first fuel control valve control subroutine,

energizing an igniter output, and

energizing a gas turbine engine starter motor output.

3. The method of claim 1, further comprising initiating an emergency shutdown of said gas turbine engine by:

monitoring the status of an emergency stop pushbutton;

monitoring the status of powerplant conditions selected from the group consisting of exhaust gas temperature, engine oil tank temperature, compressor turbine shaft speed, power turbine shaft speed, gearbox oil tank temperature, turbine engine oil pressure, and gearbox oil pressure; and

initiating a primary stop subroutine and/or a fuel control valve lock subroutine whenever said emergency stop pushbutton is depressed and/or one or more of said monitored powerplant conditions has a value that exceeds a corresponding high or low limit;

whereby, as a result of outputs from said primary stop subroutine and said fuel control valve lock subroutine, the output of all cooling and lubrication devices driven by said gas turbine engine is halted and a flow of fuel supplied to said gas turbine engine is stopped.

4. The method of claim 1, further comprising reducing the load on said gas turbine engine if either of an output from said compressor turbine shaft speed load bias subroutine or said exhaust gas temperature load bias subroutine exceeds a predetermined limit.

5. The method of claim 1, further comprising automatically adjusting the position of a set of inlet guide vanes provided to direct the angle at which incoming air impinges blades of said compressor turbine by:

arithmetically manipulating a measured inlet air temperature value and a plurality of setpoint values to supply separate analog values to an operational inlet guide vane positioning subroutine and a start-up inlet guide vane positioning subroutine;

creating a first feedback loop by calculating the difference between outputs from said operational inlet guide vane positioning subroutine and said start-up inlet guide vane positioning subroutine, and arithmetically manipulating said difference and a setpoint value to supply an analog value to an inlet guide vane slope determining subroutine;

creating a second feedback loop by calculating the difference between an output from said inlet guide vane slope determining subroutine and a measured compressor turbine shaft speed value and arithmetically combining said difference with said output from said inlet guide vane slope determining subroutine;

using said output from said inlet guide vane slope determining subroutine and a setpoint value to produce an analog value that is input to an inlet guide vane setpoint subroutine; and

using an output from said inlet guide vane setpoint subroutine to energize an inlet guide vane positioner adapted to set the position of said inlet guide vanes accordingly.

6. The method of claim 1, further comprising using said fuel control valve adjustment subroutine output in a feedback loop that provides both said fuel control valve gain and reset values to said PID controller, the output of said PID controller used to continually update said analog value input to said fuel control valve adjustment subroutine.

7. The method of claim 1, further comprising using said compressor turbine shaft speed measurement value and said fuel control valve adjustment subroutine output as inputs to a maximum fuel control valve setting subroutine, the output of which is used to help fine tune the position of said fuel control valve.

8. The method of claim 1, further comprising causing the rapid removal of air from a combustion portion of said gas turbine engine in the event of an overspeed condition by:

arithmetically manipulating said measured power turbine shaft speed value and a plurality of setpoint values and inputting the result thereof to a generator speed subroutine;

inputting said setpoint values into each of a total generator current output subroutine and a generator power output delay subroutine;

calculating the difference in values between the outputs from said total generator current output subroutine and said generator power output delay subroutine and inputting said difference to a generator power output subroutine;

comparing an output from each of said generator speed subroutine and said generator power output delay subroutine to a respective low limit setpoint value;

if either, or both, of said outputs from said generator speed subroutine and said generator power output delay subroutine exceed said respective low limit setpoint values, triggering an input of an overspeed control subroutine;

using the output of said overspeed control subroutine to initiate a compressor bleed subroutine; and

using the output of said compressor bleed subroutine to energize a compressor air dump solenoid valve.