Sensor-based performance-seeking gas turbine engine control

• US 8,490,404 B1
• Filed: 02/28/2012
• Issued: 07/23/2013
• Est. Priority Date: 02/28/2012
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Adibhatla, Sridhar, Kamath, Deepak Manohar, Shinkle, William Randolph
• Primary Examiner(s): Wongwian, Phutthiwat
• Application Number:
  US13/407,004
• Time in Patent Office: 511 Days
• Field of Search: 607/72, 607/73, 607/93, 607/94, 607/95, 700/286, 700/287, 701/100, 701/102
• US Class Current: 60/772
• 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 9/54 by throttling the working fluid, by adjusting vanes
• CPC Class Codes: F05D 2270/05 to affect the output of the engine
• CPC Class Codes: F05D 2270/061 in particular the electrical frequency of driven generator
• CPC Class Codes: F05D 2270/20 to optimize the performance of a machine
• CPC Class Codes: F05D 2270/303 Temperature
• CPC Class Codes: F05D 2270/304 Spool rotational speed
• CPC Class Codes: F05D 2270/306 Mass flow
• CPC Class Codes: F05D 2270/335 Output power or torque
• CPC Class Codes: F05D 2270/44 active, predictive, or anticipative

Abstract

Sensor-based, performance-seeking control of gas turbine engines is disclosed. An example method of controlling a gas turbine engine may include varying an engine input parameter while operating the gas turbine engine to produce a desired output, including measuring a pre-adjustment value of an engine operating parameter with an engine input parameter at an initial value, adjusting the engine input parameter to a current adjusted value, and measuring a post-adjustment value of the engine operating parameter. The method may include determining a future adjusted value of the engine input parameter and iteratively repeating the varying the engine input parameter operation and the determining the future adjusted value of the engine input parameter operation. The method may be performed while operating the gas turbine engine to produce a desired output.

Claims

1. A method of controlling operation of a gas turbine engine, the method comprising:

varying an engine input parameter while operating a gas turbine engine to produce a desired output, varying the engine input parameter comprising

measuring a pre-adjustment value of an engine operating parameter while operating the gas turbine engine with the engine input parameter at an initial value while producing the desired output,

adjusting the engine input parameter to a current adjusted value, the current adjusted value differing from the initial value, and

measuring a post-adjustment value of the engine operating parameter while operating the gas turbine engine with the engine input parameter at the adjusted value and while producing the desired output;

determining a future adjusted value of the engine input parameter based at least in part upon the initial value of the engine input parameter, the pre-adjustment value of the engine operating parameter, the current adjusted value of the engine input parameter, and the post-adjustment value of the engine operating parameter, the future adjusted value being closer to an optimal value of the engine input parameter than the current adjusted value of the engine input parameter, with respect to the engine operating parameter; and

iteratively repeating the varying the engine input parameter operation and the determining the future adjusted value of the engine input parameter operation, using the current adjusted value of a prior iteration as the initial value for a subsequent iteration and the future adjusted value from the prior iteration as the current adjusted value for the subsequent iteration.

2. The method of claim 1, wherein operating the gas turbine engine to produce the desired output comprises controlling a fuel flow rate of fuel to the gas turbine engine to provide the desired output, the desired output comprising at least one of a desired fan speed and a desired engine pressure ratio;

wherein the engine operating parameter comprises the fuel flow rate;

wherein the engine input parameter comprises a position of a variable stator vane associated with a compressor of the gas turbine engine; and

wherein the optimal value of the engine input parameter comprises the position of the variable stator vane that corresponds to a minimum fuel flow rate that produces the desired output.

3. The method of claim 1, wherein the desired output comprises a desired electrical output of a generator operatively coupled to the gas turbine engine;

wherein the engine operating parameter comprises at least one of an electrical power output of the generator, an efficiency of the gas turbine engine, an exhaust emissions measurement associated with the gas turbine engine, a heat rate of the gas turbine engine, a fuel flow rate of fuel supplied to the gas turbine engine, and a power turbine inlet temperature associated with a power turbine of the gas turbine engine;

wherein the engine input parameter comprises at least one of a high-pressure compressor inlet temperature associated with a high-pressure compressor of the gas turbine engine, a position of a variable stator vane associated with the high-pressure compressor, a position of a variable inlet guide vane associated with a booster of the gas turbine engine, and an injection water flow rate of injection water supplied to a combustor of the gas turbine engine; and

wherein the optimal value of the engine input parameter corresponds to at least one of a maximum electrical power output, a maximum efficiency, a minimum exhaust emissions measurement, a minimum heat rate, a minimum fuel flow rate, and a minimum power turbine inlet temperature.

4. The method of claim 3, wherein the desired electrical output comprises at least one of a desired alternating current frequency and a desired electrical power output.

5. The method of claim 1, further comprising, prior to varying the engine input parameter while operating the gas turbine engine, determining that the gas turbine engine is operating in a pseudo-steady-state condition.

6. The method of claim 5, wherein the gas turbine engine is mounted to an aircraft;

and

wherein the pseudo-steady-state condition comprises one of cruise, climb, or descent.

7. The method of claim 5, wherein the gas turbine engine is operatively coupled to a generator;

and

wherein the pseudo-steady-state condition comprises a substantially constant electrical power output of the generator.

8. The method of claim 1,

wherein the engine input parameter consists of a single parameter;

and

wherein determining the future adjusted value of the engine input parameter comprises univariate optimization.

9. The method of claim 1,

wherein the engine input parameter comprises a plurality of parameters;

and

wherein determining the future adjusted value of the engine input parameter comprises multivariate optimization.

10. The method of claim 1, further comprising

storing the current adjusted value of the engine input parameter during a first period of pseudo-steady state operation of the gas turbine engine;

and

using the stored current adjusted value as the initial value of the engine input parameter in a second period of pseudo-steady state operation;

wherein the first period of pseudo-steady state operation and the second period of pseudo-steady state operation are separated by an intervening period of non-steady-state operation.

11. A control system for a gas turbine engine, the control system comprising:

an operating parameter sensor operable to measure an engine operating parameter associated with a gas turbine engine;

an output sensor operable to measure an output of the gas turbine engine;

an actuator operable to modulate an engine input parameter associated with the gas turbine engine;

a processor operatively coupled to the operating parameter sensor, the output sensor, and the actuator; and

a storage medium operatively coupled to the processor, the storage medium comprising machine-readable instructions operatively enabling the processor to;

receive a pre-adjustment value of the engine operating parameter measured by the operating parameter sensor,

cause the actuator to adjust the engine input parameter from an initial value to a current adjusted value while operating the gas turbine engine to substantially maintain the output of the gas turbine engine sensor at a desired output as measured by the output sensor,

receive a post-adjustment value of the engine operating parameter measured by the operating parameter sensor,

determine a future adjusted value of the engine input parameter based at least in part upon the initial value of the engine input parameter, the pre-adjustment value of the engine operating parameter, the current adjusted value of the engine input parameter, and the post-adjustment value of the engine operating parameter, the future adjusted value being closer to an optimal value of the engine input parameter than the current adjusted value of the engine input parameter, with respect to the engine operating parameter, and

iteratively adjust the engine input parameter and determine the future adjusted value of the engine input parameter, using the current adjusted value of a prior iteration as the initial value for a subsequent iteration and the future adjusted value from the prior iteration as the current adjusted value for the subsequent iteration, while operating the gas turbine engine to substantially maintain the output of the gas turbine engine at the desired output.

12. The control system of claim 11, wherein operating the gas turbine engine to substantially maintain the output of the gas turbine engine at the desired output comprises controlling a fuel flow rate of fuel to the gas turbine engine to provide the desired output, the desired output comprising at least one of a desired fan speed and a desired engine pressure ratio;

wherein the engine operating parameter comprises the fuel flow rate;

wherein the engine input parameter comprises a position of a variable stator vane associated with a compressor of the gas turbine engine; and

wherein the optimal value of the engine input parameter comprises the position of the variable stator vane that corresponds to a minimum fuel flow rate that substantially maintains the desired output.

13. The control system of claim 11, wherein the desired output comprises a desired electrical output of a generator operatively coupled to the gas turbine engine;

wherein the engine operating parameter comprises at least one of an electrical power output of the generator, an efficiency of the gas turbine engine, an exhaust emissions measurement associated with the gas turbine engine, a heat rate of the gas turbine engine, a fuel flow rate of fuel supplied to the gas turbine engine, and a power turbine inlet temperature associated with a power turbine of the gas turbine engine;

wherein the engine input parameter comprises at least one of a high-pressure compressor inlet temperature associated with a high-pressure compressor of the gas turbine engine, a position of a variable stator vane associated with the high-pressure compressor, a position of a variable inlet guide vane associated with a booster of the gas turbine engine, and an injection water flow rate of injection water supplied to a combustor of the gas turbine engine; and

wherein the optimal value of the engine input parameter corresponds to at least one of a maximum electrical power output, a maximum efficiency, a minimum exhaust emissions measurement, a minimum heat rate, a minimum fuel flow rate, and a minimum power turbine inlet temperature.

14. The control system of claim 11, wherein the desired electrical output comprises at least one of a desired alternating current frequency and a desired electrical power output.

15. The control system of claim 11, wherein the machine-readable instructions operatively enable the gas turbine engine control system to determine that the gas turbine engine is operating in a pseudo-steady-state condition prior to varying the engine input parameter.

16. A storage medium comprising non-transitory, machine-readable instructions stored thereon, which, if executed by one or more processors, operatively enable a gas turbine engine control system to:

vary an engine input parameter while operating a gas turbine engine associated with the gas turbine engine control system to produce a desired output, including

measure a pre-adjustment value of an engine operating parameter while operating the gas turbine engine with the engine input parameter at an initial value while producing the desired output,

adjust the engine input parameter to a current adjusted value, the current adjusted value differing from the initial value, and

measure a post-adjustment value of the engine operating parameter while operating the gas turbine engine with the engine input parameter at the adjusted value and while producing the desired output;

determine a future adjusted value of the engine input parameter based at least in part upon the initial value of the engine input parameter, the pre-adjustment value of the engine operating parameter, the current adjusted value of the engine input parameter, and the post-adjustment value of the engine operating parameter, the future adjusted value being closer to an optimal value of the engine input parameter than the current adjusted value of the engine input parameter, with respect to the engine operating parameter; and

iteratively vary the engine input parameter and determine the future adjusted value of the engine input parameter, using the current adjusted value of a prior iteration as the initial value for a subsequent iteration and the future adjusted value from the prior iteration as the current adjusted value for the subsequent iteration.

17. The storage medium of claim 16, wherein operating the gas turbine engine to produce the desired output comprises controlling a fuel flow rate of fuel to the gas turbine engine to provide the desired output, the desired output comprising a desired value of a parameter associated with thrust produced by the gas turbine engine;

wherein the engine operating parameter comprises the fuel flow rate;

wherein the engine input parameter comprises a position of a variable stator vane associated with a compressor of the gas turbine engine; and

wherein the optimal value of the engine input parameter comprises the position of the variable stator vane that corresponds to a minimum fuel flow rate that produces the desired output.

18. The storage medium of claim 16,

wherein the desired output comprises at least one of a desired alternating current frequency and a desired electrical power output of a generator operatively coupled to the gas turbine engine;

wherein the engine operating parameter comprises at least one of the electrical power output of the generator, an efficiency of the gas turbine engine, an exhaust emissions measurement associated with the gas turbine engine, a heat rate of the gas turbine engine, a fuel flow rate of fuel supplied to the gas turbine engine, and a power turbine inlet temperature associated with a power turbine of the gas turbine engine;

wherein the engine input parameter comprises at least one of a high-pressure compressor inlet temperature associated with a high-pressure compressor of the gas turbine engine, a position of a variable stator vane associated with the high-pressure compressor, a position of a variable inlet guide vane associated with a booster of the gas turbine engine, and an injection water flow rate of injection water supplied to a combustor of the gas turbine engine; and

wherein the optimal value of the engine input parameter corresponds to at least one of a maximum electrical power output, a maximum efficiency, a minimum exhaust emissions measurement, a minimum heat rate, a minimum fuel flow rate, and a minimum power turbine inlet temperature.

19. The storage medium of claim 16, wherein the machine-readable instructions operatively enable the gas turbine engine control system to determine that the gas turbine engine is operating in a pseudo-steady-state condition prior to varying the engine input parameter.