METHOD AND SYSTEM FOR REAL TIME DRY LOW NITROGEN OXIDE (DLN) AND DIFFUSION COMBUSTION MONITORING

Abstract

A system and method for monitoring and diagnosing anomalies in a diffusion or dry low NOX combustion system of a gas turbine, the method including storing a plurality rule sets specific to a temperature spread of the gas turbine exhaust. The method further including determining an anomaly in the performance of the gas turbine using at least one of a swirl angle of the exhaust flow, a health of a plurality of flame detectors of the gas turbine, and a transfer of the gas turbine from a first mode of operation to a second lower NOX mode of operation, and recommending to an operator of the gas turbine a set of corrective actions to correct the anomaly.

Description

FIELD OF THE INVENTION

This description relates to generally to mechanical/electrical equipment operations, monitoring and diagnostics, and more specifically, to systems and methods for automatically advising operators of anomalous behavior of machinery.

BACKGROUND OF THE INVENTION

The combustion system is an important item to be monitored in a gas turbine. Traditional combustion monitoring systems use static thresholds that do not consider the machine operating conditions, such as combustion mode and load. As a result, they are inefficient and produce false or too-late alarms. For example, many hours are currently spent locating a source of a fault in the case of a real exhaust temperature spread issue. On the flame detector side, monitoring the digital signal only or analog output without a correct statistical approach is problematic and results in false warning.

Traditional monitoring systems suffer from technical deficiencies. Inaccuracy is the most evident, as seen by either too many false alarms or too late alarms are generally reported, without taking into account machine operating conditions; thus, no troubleshooting or little information is provided.

SUMMARY OF THE INVENTION

In one embodiment, a computer-implemented method for monitoring and diagnosing anomalies in an operation of a gas turbine, the method implemented using a computer device coupled to a user interface and a memory device, the method comprising storing a plurality rule sets in the memory device, the rule sets relative to the operation of the gas turbine, the rule sets including at least one rule expressed as a relational expression of a real-time data output relative to a real-time data input, the relational expression being specific to at least one of a temperature spread of an exhaust flow of the gas turbine, a swirl angle of the exhaust flow, a health of a plurality of flame detectors of the gas turbine, and a transfer of the gas turbine from a first mode of operation to a second lower NO_X mode of operation, receiving real-time and historical data inputs from a condition monitoring system associated with the gas turbine, the data inputs relating to parameters affecting at least one of the temperature spread of the exhaust flow of the gas turbine, the swirl angle of the exhaust flow, the health of the plurality of flame detectors of the gas turbine, and the transfer of the gas turbine from the first mode of operation to the second lower NO_X mode of operation, determining a fuel gas line pressure drop using the received data, comparing the determined pressure drop to a predetermined threshold range, and recommending to an operator of the gas turbine to transfer the mode of operation of the gas turbine from the first mode to the second mode without reducing a load of the gas turbine if the determined pressure drop meets the predetermined threshold range.

In another embodiment, a gas turbine monitoring and diagnostic system for a gas turbine includes an axial compressor and a low pressure turbine in flow communication, said system comprising a real-time DLN and diffusion combustion rule set, the rule set including a relational expression of a real-time data output relative to at least one of the temperature spread of the exhaust flow of the gas turbine, the swirl angle of the exhaust flow, the health of the plurality of flame detectors of the gas turbine, and the transfer of the gas turbine from the first mode of operation to the second lower NO_X mode of operation.

In yet another embodiment, one or more non-transitory computer-readable storage media has computer-executable instructions embodied thereon, wherein when executed by at least one processor, the computer-executable instructions cause the processor to store a plurality rule sets in the memory device, the rule sets relative to the output of the gas turbine, the rule sets including at least one rule expressed as a relational expression of a real-time data output relative to a real-time data input, the relational expression being specific to at least one of a temperature spread of an exhaust flow of the gas turbine, a swirl angle of the exhaust flow, a health of a plurality of flame detectors of the gas turbine, and a transfer of the gas turbine from a first mode of operation to a second lower NO_X mode of operation, receive real-time and historical data inputs from a condition monitoring system associated with the gas turbine, the data inputs relating to parameters affecting at least one of the temperature spread of the exhaust flow of the gas turbine, the swirl angle of the exhaust flow, the health of the plurality of flame detectors of the gas turbine, and the transfer of the gas turbine from the first mode of operation to the second lower NO_X mode of operation, receive a plurality of temperature outputs from one or more temperature sensors associated with the flow of gas turbine exhaust, and determine a temperature spread of the flow of gas turbine exhaust using the received plurality of temperature outputs.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-10 show exemplary embodiments of the method and system described herein.

FIG. 1 is a schematic block diagram of a remote monitoring and diagnostic system in accordance with an exemplary embodiment of the present invention.

FIG. 2 is a block diagram of an exemplary embodiment of a network architecture of a local industrial plant monitoring and diagnostic system, such as a distributed control system (DCS).

FIG. 3 is a block diagram of an exemplary rule set that may be used with LMDS shown in FIG. 1.

FIG. 4 is a side elevation view of a gas turbine engine in accordance with an exemplary embodiment of the present disclosure.

FIG. 5 is a schematic representation of the placement of twelve thermocouples spaced approximately evenly about diffuser in accordance with an exemplary embodiment of the present disclosure.

FIG. 6 is a graph illustrating a correlation between burner clogging and exhaust temperature spread.

FIG. 7 is a schematic block diagram of a flame detector (FD) circuit that may be used with gas turbine engine shown in FIG. 4 in accordance with an exemplary embodiment of the present disclosure.

FIG. 8 is a screen capture of a trace of flame detector circuit analog outputs and digital output.

FIG. 9 is a flow diagram of operation of gas turbine engine during a loading and an unloading process.

FIG. 10 is a schematic piping diagram of a portion of a fuel system 1000 that may be used with gas turbine engine shown in FIG. 4 in accordance with an exemplary embodiment of the present disclosure.

Although specific features of various embodiments may be shown in some drawings and not in others, this is for convenience only. Any feature of any drawing may be referenced and/or claimed in combination with any feature of any other drawing.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description illustrates embodiments of the invention by way of example and not by way of limitation. It is contemplated that the invention has general application to analytical and methodical embodiments of monitoring equipment operation in industrial, commercial, and residential applications.

The combustion system is an important item to be monitored in a gas turbine. Dry Low NOx (DLN) systems are more complicated and involve different combustion modes than traditional gas turbines. As used herein, NOx refers to mono-nitrogen oxides, NO and NO2 (nitric oxide and nitrogen dioxide). The real-time DLN and diffusion combustion rule set facilitates preventing incorrect combustion operation, identifying direct guidelines for troubleshooting, and warns against early signs of failure, giving gas turbine operators time to act and/or schedule shut downs.

The real-time DLN and diffusion combustion rule set includes the following combustion rules as part of an online monitoring system:

1. Exhaust temperature spread as a function of combustion mode and load: For a DLN system, specifying one constant threshold for the exhaust temperature spread will lead to either false alarms or too late alarms. There is a transition sequence during which the combustion transfers from one mode to another; for example: Primary, Lean-Lean, Secondary, Premix or Extended Lean-Lean. During each mode, a proper threshold for the spread is identified and when loading the machine in Lean-Lean mode, the spread is specified as a function of the firing temperature. For diffusion combustion the spread is compared with a threshold which is, for example, approximately 0.7 the allowable spread. A rule to highlight exhaust temperature thermocouple sensor failure is also defined.

Exhaust spread thresholds are set more accurately, because they are set for each combustion mode and as a function of load. The exhaust spread alarms are validated to ensure a real issue is the cause. The real-time DLN and diffusion combustion rule set facilitates and enhances troubleshooting: for example, the swirl angle calculator locates the source of fault (combustor(s) and/or fuel nozzles) and reduces troubleshooting time. On diffusion combustion gas turbine, a rule is also provided that determines whether a high spread is caused by a faulty sensor, so that the troubleshooting process can immediately proceed towards the right root cause identification.

2. The real-time DLN and diffusion combustion rule set also performs a swirl angle calculation to trace back the spread to a source or a faulty combustor(s), which will significantly reduce troubleshooting time. When a spread is detected on a multi-can gas turbine, it is not straightforward to judge on the source of the problem (faulty combustor), because the thermocouples are not placed adjacent to the combustor cans. The rule set traces back from the spread anomaly at the exhaust diffuser to the faulty combustor. A correlation used in the rule engine identifies the faulty combustor in the event of a real spread.

3. Flame detector health is important too, as flame detector degradation over time and other problems can lead to multiple trips with all associated costs and loss of production. The real time DLN and diffusion combustion rule set includes an algorithm that analyzes the health of flame detectors and generates warnings and recommendations related to this real time analysis, which facilitates performance of good maintenance of the flame detector system to avoid false loss-of-flame alarms and trips. The raw pulse signal coming from the flame sensor (UV sensor) is processed by the control system in two different ways; as analog output and digital output. Digital signals are used to detect a flame and are involved in the control panel logics, while analog signals are not used. Field testing and several tests have shown a high degree of variability and low repeatability of flame detector signals, which are the cause of “false” loss-of-flame on secondary and trips, running in Premix mode. The health of the flame detector depends on many factors including air humidity, dirt accumulate on the lens and electric wire connections. In the real-time DLN and diffusion combustion rule set, the analog output is used to monitor the secondary flame detectors: each signal is processed using a statistical approach to identify the noise and variation and generate a “health count metric”. This metric is used to define thresholds and indicate if it is needed to change or tune the sensors. The output recommendation is to either replace, tune, check, or clean the lens of the detector. The flame detector rule of the real-time DLN and diffusion combustion rule set monitors degradation over time and, thus, can predict early signs of failure. The output recommendations can distinguish a deteriorating detector from a dirty or foggy one.

4. Unnecessary unloading and excess flaring is currently needed to transfer from the Extended Lean-Lean (EXT-LL) mode to Premix mode. Hence, any benefits associated with low emissions are contradicted by this excess flare. Based on a fuel gas line pressure drop calculation, the real-time DLN and diffusion combustion rule set evaluates the possibility of transferring directly without unloading, which can reduce flaring and allowing the transfer without reducing gas turbine load. The DLN transfer rule allows operators to understand the possibility of avoiding unnecessary unloading to save time, fuel and emissions resulting from excess process gas flaring.

FIG. 1 is a schematic block diagram of remote monitoring and diagnostic system 100 in accordance with an exemplary embodiment of the present invention. In the exemplary embodiment, system 100 includes a remote monitoring and diagnostic center 102. Remote monitoring and diagnostic center 102 is operated by an entity, such as, an OEM of a plurality of equipment purchased and operated by a separate business entity, such as, an operating entity. In the exemplary embodiment, the OEM and operating entity enter into a support arrangement whereby the OEM provides services related to the purchased equipment to the operating entity. The operating entity may own and operate purchased equipment at a single site or multiple sites. Moreover, the OEM may enter into support arrangements with a plurality of operating entities, each operating their own single site or multiple sites. The multiple sites each may contain identical individual equipment or pluralities of identical sets of equipment, such as trains of equipment. Additionally, at least some of the equipment may be unique to a site or unique to all sites.

In the exemplary embodiment, a first site 104 includes one or more process analyzers 106, equipment monitoring systems 108, equipment local control centers 110, and/or monitoring and alarm panels 112 each configured to interface with respective equipment sensors and control equipment to effect control and operation of the respective equipment. The one or more process analyzers 106, equipment monitoring systems 108, equipment local control centers 110, and/or monitoring and alarm panels 112 are communicatively coupled to an intelligent monitoring and diagnostic system 114 through a network 116. Intelligent monitoring and diagnostic (IMAD) system 114 is further configured to communicate with other on-site systems (not shown in FIG. 1) and offsite systems, such as, but not limited to, remote monitoring and diagnostic center 102. In various embodiments, IMAD 114 is configured to communicate with remote monitoring and diagnostic center 102 using for example, a dedicated network 118, a wireless link 120, and the Internet 122.

Each of a plurality of other sites, for example, a second site 124 and an nth site 126 may be substantially similar to first site 104 although may or may not be exactly similar to first site 104.

FIG. 2 is a block diagram of an exemplary embodiment of a network architecture 200 of a local industrial plant monitoring and diagnostic system, such as a distributed control system (DCS) 201. The industrial plant may include a plurality of plant equipment, such as gas turbines, centrifugal compressors, gearboxes, generators, pumps, motors, fans, and process monitoring sensors that are coupled in flow communication through interconnecting piping, and coupled in signal communication with DCS 201 through one or more remote input/output (I/O) modules and interconnecting cabling and/or wireless communication. In the exemplary embodiment, the industrial plant includes DCS 201 including a network backbone 203. Network backbone 203 may be a hardwired data communication path fabricated from twisted pair cable, shielded coaxial cable or fiber optic cable, for example, or may be at least partially wireless. DCS 201 may also include a processor 205 that is communicatively coupled to the plant equipment, located at the industrial plant site or at remote locations, through network backbone 203. It is to be understood that any number of machines may be operatively connected to network backbone 203. A portion of the machines may be hardwired to network backbone 203, and another portion of the machines may be wirelessly coupled to backbone 203 via a wireless base station 207 that is communicatively coupled to DCS 201. Wireless base station 207 may be used to expand the effective communication range of DCS 201, such as with equipment or sensors located remotely from the industrial plant but, still interconnected to one or more systems within the industrial plant.

DCS 201 may be configured to receive and display operational parameters associated with a plurality of equipment, and to generate automatic control signals and receive manual control inputs for controlling the operation of the equipment of industrial plant. In the exemplary embodiment, DCS 201 may include a software code segment configured to control processor 205 to analyze data received at DCS 201 that allows for on-line monitoring and diagnosis of the industrial plant machines. Data may be collected from each machine, including gas turbines, centrifugal compressors, pumps and motors, associated process sensors, and local environmental sensors including, for example, vibration, seismic, temperature, pressure, current, voltage, ambient temperature and ambient humidity sensors. The data may be pre-processed by a local diagnostic module or a remote input/output module, or may transmitted to DCS 201 in raw form.

A local monitoring and diagnostic system (LMDS) 213 may be a separate add-on hardware device, such as, for example, a personal computer (PC), that communicates with DCS 201 and other control systems 209 and data sources through network backbone 203. LMDS 213 may also be embodied in a software program segment executing on DCS 201 and/or one or more of the other control systems 209. Accordingly, LMDS 213 may operate in a distributed manner, such that a portion of the software program segment executes on several processors concurrently. As such, LMDS 213 may be fully integrated into the operation of DCS 201 and other control systems 209. LMDS 213 analyzes data received by DCS 201, data sources, and other control systems 209 to determine an operational health of the machines and/or a process employing the machines using a global view of the industrial plant.

In the exemplary embodiment, network architecture 100 includes a server grade computer 202 and one or more client systems 203. Server grade computer 202 further includes a database server 206, an application server 208, a web server 210, a fax server 212, a directory server 214, and a mail server 216. Each of servers 206, 208, 210, 212, 214, and 216 may be embodied in software executing on server grade computer 202, or any combinations of servers 206, 208, 210, 212, 214, and 216 may be embodied alone or in combination on separate server grade computers coupled in a local area network (LAN) (not shown). A data storage unit 220 is coupled to server grade computer 202. In addition, a workstation 222, such as a system administrator's workstation, a user workstation, and/or a supervisor's workstation are coupled to network backbone 203. Alternatively, workstations 222 are coupled to network backbone 203 using an Internet link 226 or are connected through a wireless connection, such as, through wireless base station 207.

Each workstation 222 may be a personal computer having a web browser. Although the functions performed at the workstations typically are illustrated as being performed at respective workstations 222, such functions can be performed at one of many personal computers coupled to network backbone 203. Workstations 222 are described as being associated with separate exemplary functions only to facilitate an understanding of the different types of functions that can be performed by individuals having access to network backbone 203.

Server grade computer 202 is configured to be communicatively coupled to various individuals, including employees 228 and to third parties, e.g., service providers 230. The communication in the exemplary embodiment is illustrated as being performed using the Internet, however, any other wide area network (WAN) type communication can be utilized in other embodiments, i.e., the systems and processes are not limited to being practiced using the Internet.

In the exemplary embodiment, any authorized individual having a workstation 232 can access LMDS 213. At least one of the client systems may include a manager workstation 234 located at a remote location. Workstations 222 may be embodied on personal computers having a web browser. Also, workstations 222 are configured to communicate with server grade computer 202. Furthermore, fax server 212 communicates with remotely located client systems, including a client system 236 using a telephone link (not shown). Fax server 212 is configured to communicate with other client systems 228, 230, and 234, as well.

Computerized modeling and analysis tools of LMDS 213, as described below in more detail, may be stored in server 202 and can be accessed by a requester at any one of client systems 204. In one embodiment, client systems 204 are computers including a web browser, such that server grade computer 202 is accessible to client systems 204 using the Internet. Client systems 204 are interconnected to the Internet through many interfaces including a network, such as a local area network (LAN) or a wide area network (WAN), dial-in-connections, cable modems and special high-speed ISDN lines. Client systems 204 could be any device capable of interconnecting to the Internet including a web-based phone, personal digital assistant (PDA), or other web-based connectable equipment. Database server 206 is connected to a database 240 containing information about industrial plant 10, as described below in greater detail. In one embodiment, centralized database 240 is stored on server grade computer 202 and can be accessed by potential users at one of client systems 204 by logging onto server grade computer 202 through one of client systems 204. In an alternative embodiment, database 240 is stored remotely from server grade computer 202 and may be non-centralized.

Other industrial plant systems may provide data that is accessible to server grade computer 202 and/or client systems 204 through independent connections to network backbone 204. An interactive electronic tech manual server 242 services requests for machine data relating to a configuration of each machine. Such data may include operational capabilities, such as pump curves, motor horsepower rating, insulation class, and frame size, design parameters, such as dimensions, number of rotor bars or impeller blades, and machinery maintenance history, such as field alterations to the machine, as-found and as-left alignment measurements, and repairs implemented on the machine that do not return the machine to its original design condition.

A portable vibration monitor 244 may be intermittently coupled to LAN directly or through a computer input port such as ports included in workstations 222 or client systems 204. Typically, vibration data is collected in a route, collecting data from a predetermined list of machines on a periodic basis, for example, monthly or other periodicity. Vibration data may also be collected in conjunction with troubleshooting, maintenance, and commissioning activities. Further, vibration data may be collected continuously in a real-time or near real-time basis. Such data may provide a new baseline for algorithms of LMDS 213. Process data may similarly, be collected on a route basis or during troubleshooting, maintenance, and commissioning activities. Moreover, some process data may be collected continuously in a real-time or near real-time basis. Certain process parameters may not be permanently instrumented and a portable process data collector 245 may be used to collect process parameter data that can be downloaded to DCS 201 through workstation 222 so that it is accessible to LMDS 213. Other process parameter data, such as process fluid composition analyzers and pollution emission analyzers may be provided to DCS 201 through a plurality of on-line monitors 246.

Electrical power supplied to various machines or generated by generated by generators with the industrial plant may be monitored by a motor protection relay 248 associated with each machine. Typically, such relays 248 are located remotely from the monitored equipment in a motor control center (MCC) or in switchgear 250 supplying the machine. In addition, to protection relays 248, switchgear 250 may also include a supervisory control and data acquisition system (SCADA) that provides LMDS 213 with power supply or power delivery system (not shown) equipment located at the industrial plant, for example, in a switchyard, or remote transmission line breakers and line parameters.

FIG. 3 is a block diagram of an exemplary rule set 280 that may be used with LMDS 213 (shown in FIG. 1). Rule set 280 may be a combination of one or more custom rules, and a series of properties that define the behavior and state of the custom rules. The rules and properties may be bundled and stored in a format of an XML string, which may be encrypted based on a 25 character alphanumeric key when stored to a file. Rule set 280 is a modular knowledge cell that includes one or more inputs 282 and one or more outputs 284. Inputs 282 may be software ports that direct data from specific locations in LMDS 213 to rule set 280. For example, an input from a pump outboard vibration sensor may be transmitted to a hardware input termination in DCS 201. DCS 201 may sample the signal at that termination to receive the signal thereon. The signal may then be processed and stored at a location in a memory accessible and/or integral to DCS 201. A first input 286 of rule set 280 may be mapped to the location in memory such that the contents of the location in memory is available to rule set 280 as an input. Similarly, an output 288 may be mapped to another location in the memory accessible to DCS 201 or to another memory such that the location in memory contains the output 288 of rule set 280.

In the exemplary embodiment, rule set 280 includes one or more rules relating to monitoring and diagnosis of specific problems associated with equipment operating in an industrial plant, such as, for example, a gas reinjection plant, a liquid natural gas (LNG) plant, a power plant, a refinery, and a chemical processing facility. Although rule set 280 is described in terms of being used with an industrial plant, rule set 280 may be appropriately constructed to capture any knowledge and be used for determining solutions in any field. For example, rule set 280 may contain knowledge pertaining to economic behavior, financial activity, weather phenomenon, and design processes. Rule set 280 may then be used to determine solutions to problems in these fields. Rule set 280 includes knowledge from one or many sources, such that the knowledge is transmitted to any system where rule set 280 is applied. Knowledge is captured in the form of rules that relate outputs 284 to inputs 282 such that a specification of inputs 282 and outputs 284 allows rule set 280 to be applied to LMDS 213. Rule set 280 may include only rules specific to a specific plant asset and may be directed to only one possible problem associated with that specific plant asset. For example, rule set 280 may include only rules that are applicable to a motor or a motor/pump combination. Rule set 280 may only include rules that determine a health of the motor/pump combination using vibration data. Rule set 280 may also include rules that determine the health of the motor/pump combination using a suite of diagnostic tools that include, in addition to vibration analysis techniques, but may also include, for example, performance calculational tools and/or financial calculational tools for the motor/pump combination.

In operation, rule set 280 is created in a software developmental tool that prompts a user for relationships between inputs 282 and outputs 284. Inputs 282 may receive data representing, for example digital signals, analog signals, waveforms, processed signals, manually entered and/or configuration parameters, and outputs from other rule sets. Rules within rule set 280 may include logical rules, numerical algorithms, application of waveform and signal processing techniques, expert system and artificial intelligence algorithms, statistical tools, and any other expression that may relate outputs 284 to inputs 282. Outputs 284 may be mapped to respective locations in the memory that are reserved and configured to receive each output 284. LMDS 213 and DCS 201 may then use the locations in memory to accomplish any monitoring and/or control functions LMDS 213 and DCS 201 may be programmed to perform. The rules of rule set 280 operate independently of LMDS 213 and DCS 201, although inputs 282 may be supplied to rule set 280 and outputs 284 may be supplied to rule set 280, directly or indirectly through intervening devices.

During creation of rule set 280, a human expert in the field divulges knowledge of the field particular to a specific asset using a development tool by programming one or more rules. The rules are created by generating expressions of relationship between outputs 284 and inputs 282. Operands may be selected from a library of operands, using graphical methods, for example, using drag and drop on a graphical user interface built into the development tool. A graphical representation of an operand may be selected from a library portion of a screen display (not shown) and dragged and dropped into a rule creation portion. Relationships between input 282 and operands are arranged in a logical display fashion and the user is prompted for values, such as, constants, when appropriate based on specific operands and specific ones of inputs 282 that are selected. As many rules that are needed to capture the knowledge of the expert are created. Accordingly, rule set 280 may include a robust set of diagnostic and/or monitoring rules or a relatively less robust set of diagnostic and/or monitoring rules based on a customer's requirements and a state of the art in the particular field of rule set 280. The development tool provides resources for testing rule set 280 during the development to ensure various combinations and values of inputs 282 produce expected outputs at outputs 284.

As described below, rule sets are defined to assess exhaust temperature spread as a function of combustion mode and load, a swirl angle calculation to trace back the exhaust temperature spread to a source or a faulty combustor(s), the health of flame detectors and generates warnings and recommendations to avoid false loss-of-flame alarms and trips, unnecessary unloading and excess flaring currently needed to transfer from the Extended Lean-Lean (EXT-LL) mode to Premix mode of gas turbine operation.

FIG. 4 is a side elevation view of a gas turbine engine 400 in accordance with an exemplary embodiment of the present disclosure. In the exemplary embodiment, gas turbine engine 400 includes a plurality of partialized combustion chambers 402 positioned in flow communication with a downstream low pressure or load turbine 404, and a diffuser 406 positioned downstream of low pressure turbine 404. Diffuser 406 includes a plurality of thermocouples 408 positioned about an interior of diffuser 406 in a flowpath of exhaust gases exiting low-pressure turbine 404. In the exemplary embodiment, thermocouples 408 number thirteen, which are evenly spaced circumferentially about diffuser 406. In various embodiments, other numbers of thermocouples 408 are used, which may be spaced as is convenient in diffuser 406.

In the exemplary embodiment, thermocouples 408 are communicatively coupled to high spread detector 410, which is configured to receive temperature signals and to apply one or more exhaust spread detection rule sets to the signals. The partialized combustion chambers 402 are spaced circumferentially about gas turbine engine 400. The exhaust gases exiting each combustion chamber 402 vary in temperature based on combustion conditions within each combustion chamber 402. The exhaust gases of each combustion chamber 402 tend to mix only somewhat with the exhaust gases exiting others of the plurality of combustion chambers 402. Depending on the gas turbine engine operating conditions, including but not limited to load, airflow, and combustion chamber 402 operating condition, each thermocouple 408 may be closely associated with a discernible one or more of combustion chambers 402. Such close association permits a detection of a problem with a burner in one of combustion chambers 402 by detecting anomalies in the temperature spread in diffuser 406 as sensed by thermocouples 408.

An exhaust spread rule set associated with high spread detector 410 evaluates swirl angle, which, as used herein, refers to the angle between the measured representative exhaust gas temperature, at varying loads, and the combustion chamber 402 source-location. In the exemplary embodiment, the exhaust spread rule set is a transfer function with the following inputs:

Exhaust temperature thermocouples readings (TTXD_—1, . . . TTXD_—13*)

Exhaust temperature spread (TTXSP1*)

High pressure turbine speed—percentage (TNH*)

Low pressure turbine speed—percentage (TNL*)

Absolute Pressure compressor discharge (PCD_abs*)

Ambient pressure (AFPAP*)

The exhaust spread rule set is configured to output a swirl angle and a cold/hot spots evaluation. The output is used to identify a location of a probable cause of temperature spread around diffuser 406. The exhaust spread rule set is configured to output steps to be performed for troubleshooting when a swirl angle that exceeds a predetermined threshold range or when another indicator of temperature spread anomaly is detected. For example, the exhaust spread rule set may output troubleshooting steps that include for example, 1. Correctly identify the hot and cold spots in the exhaust temperature profile, 2. Trace the exhaust temperature anomaly through the gas swirl angle to a particular combustion chamber location, 3. Identify hardware which is capable of producing a variation in the combustion pattern.

The applied methodology of the exhaust spread rule set includes evaluating the presence of a cold/hot spot, locating the cold/hot region, selecting the coldest/hottest thermocouples and its corresponding location in the exhaust plenum, perform a check of adjacent thermocouples, calculating the swirl angle using the exhaust spread rule set transfer function, from the location of the low thermocouple, back-trace the amount of the swirl angle to identify the location of the probable cause.

FIG. 5 is a schematic representation of the placement of twelve thermocouples 408 spaced approximately evenly about diffuser 406 in accordance with an exemplary embodiment of the present disclosure. A flow of exhaust gases through diffuser 406 would be oriented into or out of the page on FIG. 5. Based on each thermocouples 408 fixed position in diffuser 406 a relationship between the temperatures sensed by each of thermocouples 408 and associated combustion chambers 402 may be determined and monitored. An uncertainty band 500 may be used to describe a relative uncertainty of the determined swirl angle. Such uncertainty may be affected by for example, load on gas turbine engine 400.

FIG. 6 is a graph 550 illustrating a correlation between burner clogging and exhaust temperature spread. Graph 550 include a an x-axis 552 graduated in units of % burner clogging and a y-axis 554 graduated in units of temperature of the exhaust spread. A trace 556 is a curve-fit over several data points from field analysis illustrating the correlation between burner clogging and exhaust temperature spread.

The temperature spread at the exit of the combustion chambers 402 is a function of for example, but not limited to the combustion mode of gas turbine engine 400, a fuel split, and a power output of gas turbine engine 400. The DLN-1 combustion monitoring rule set is a simple rule based on a predetermined threshold range.

The DLN-1 combustion monitoring rule set receives as inputs:

Combustion mode (DLN_MODE_GAS*)

Average exhaust temperature (TTXM*)

Exhaust temperature spread (TTXSP1*)

Exhaust temperature spread limit (TTXSPL*)

Combustion reference temperature (CTF*)

Exhaust temperature thermocouples readings (TTXD_—1, . . . TTXD_—13*)

The threshold used to signal a monitoring anomaly depends primarily on the combustion mode and gas turbine engine load. For example:

Warm-Up: 60° F.

Primary Mode: 45° F.

Lean-Lean Mode: (TTXM-CTF)*0.075+30° F.

Premix-Steady State Mode: 75° F.

Extended-Lean Lean Mode load: 80° F.

The DLN-1 combustion monitoring rule set outputs alarms, indications, such as, but not limited to, check for broken thermocouple or check for plugged burners. The DLN-1 combustion monitoring rule set also outputs steps for troubleshooting, for example:

1. Correctly identify the hot and cold spots in the exhaust temperature profile

2. Trace the exhaust temperature anomaly through a known threshold

3. Investigate primary and secondary burner involvement

The applied methodology of the DLN-1 combustion monitoring rule set includes locating the cold region by analyzing the exhaust temperature data, selecting the coldest/hottest thermocouples and its corresponding location in the exhaust plenum, evaluating the presence of a cold/hot spot, detect any sudden spread increase higher than 25° F., calculating (S1) Spread#1 (TTXSP1)=hottest−coldest thermocouple temperature, (S2) Spread#2 (TTXSP2)=hottest−2nd coldest thermocouple temperature, checking adjacent thermocouple for consistency, recording spreads in relevant conditions (Primary HL, Secondary, . . . ), defining threshold from DLN-1 Combustor good practice, and comparing both spreads with the given threshold.

FIG. 7 is a schematic block diagram of a flame detector (FD) circuit 600 that may be used with gas turbine engine 400 (shown in FIG. 4) in accordance with an exemplary embodiment of the present disclosure. In the exemplary embodiment, flame detector circuit 600 may be used with a flame detection rule set to provide an indication of the health, sensitivity, and operability of the flame detectors (not shown), which leads to a reduced occurrence of trip due to instrumentation failure. The rule set associated with a secondary FDs sensitivity check is a simple rule set based on values for monitored parameters being within a predetermined threshold.

The inputs to the FD rule set include:

FDs analog signals (fd_intens_—1, . . . fd_intens_—8)

FDs logical signals (L28FDA, . . . L28FDH)

Relative humidity signal (CMHUM)

The output of the FD rule set includes alarms, such as, but not limited to “Flame detectors changing” and “Flame detector to be tuned.”

In the exemplary embodiment, a raw pulse signal from a flame sensor is processed by the FD rule set in two different ways, the analog outputs (FD_INTENS_n) 602 are frequency outputs generated by using a fixed time window of one second for monitoring purposes. The digital output (L28FDn) 604 is generated by comparing a frequency output based on a different time window, for example, 1/16 second with the corresponding count thresholds set-up in the control system's interfaces flame-on/flame-off logic.

FIG. 8 is a screen capture 700 of a trace of analog outputs 602 and digital output 604. Detection levels, and detection time are the control parameters used for FD threshold tuning. The frequency threshold level is calculated and defined by:

Detection level=14, (frequency threshold=87.5 Hz), digital signal is flat and equal to 1.

Detection level=16, (frequency threshold=100 Hz), digital signal begins to flicker, switching from 0 to 1.

Detection level=18, (frequency threshold=112.5 Hz), digital signal flickering.

Detection level=20, (frequency threshold=120 Hz), residual spike of L28fdf

Detection level=22, (frequency level=137.5 Hz), digital signal is flat and equal to 0.

From analysis performed on several field data, for each secondary flame sensor the following condition is used:

If: (Avg−7*STDV_calculated)*detection time ( 1/16 s)<1—the flame detector will be replaced.

If: (Avg−7*STDV_calculated)*detection time ( 1/16 s)<2—the flame detector will be tuned.

FIG. 9 is a flow diagram 900 of operation of gas turbine engine 400 during a loading and an unloading process. An axis 902 indicates GT load for the loading operating area 904 and unloading operating area 906. Arrows indicate a path gas turbine engine 400 may take in traversing the operating areas. A direct transfer rule set is used to calculate the possibility of transferring directly from EXT-LL mode of operation directly into the PREMIX mode of operation.

In the exemplary embodiment, direct transfer rule set is a transfer function type rule set. Direct transfer rule set receives as inputs:

Fuel gas pressure upstream SVR

Intervalve pressure (FPG2*)

Compressor discharge pressure (PCD*)

Ambient pressure (AFPAP*)

Fuel gas temperature (FGT2*)

Gas control valve (GCV), Stop-Ratio Valve (SRV), Gas control valve (GCV) characterization—kv and Xt

Secondary burner effective area

Direct transfer rule set outputs:

Pressure downstream GCV

Fuel gas flow estimation

Indication of unit capability to transfer directly from EXT-LL into PREMIX

DLN-1 operation, from start-up to full load, involves five different modes of combustion in the multi-zone combustion liner. The distribution of the fuel and flame to the different zones is matched to turbine speed and load conditions to obtain the best performance and emissions with stable flames operation.

If the unit is running in EXTENDED LEAN-LEAN, with the Current DLN-1 logic in order to get PREMIX STEADY STATE it is necessary to:

Unload the unit below ˜40% Base Load*, transferring back into LEAN-LEAN POSITIVE.

Transfer into PREMIX STEADY-STATE by increasing load.

Moreover the ignition transformer protection logic introduces another limitation inhibiting PREMIX transfer-in, if the transformer duty cycle is exceeded.

FIG. 10 is a schematic piping diagram of a portion of a fuel system 1000 that may be used with gas turbine engine 400 (shown in FIG. 4) in accordance with an exemplary embodiment of the present disclosure.

The DLN-1 capability of transfer into PREMIX is related to the ability of maintaining choking condition on a GCV valve 1002 during SECONDARY transfer mode.

GCV upstream pressure 1004 and SRV upstream pressure 1006 are defined in order to feed all the amount of gas into a “Transferless” secondary fuel nozzle 1008, without drops in unit load during SECONDARY transfer mode.

The condition for having a good transfer into PREMIX mode can be calculated in real time in order to identify an enlarged window for PREMIX availability including a direct transfer from EXT-LL to PREMIX.

Direct transfer EXT-LL PREMIX—rule development includes

1st Step—Fuel mass flow calculation.

Assuming the gas control valve (GCV) choked and N=1:

$\text{?}=\left({\text{?}}_{\text{?}}\right)\text{?}=1.23$ $M=\text{?}\text{?}\text{?}\sqrt{{\text{?}}^{\text{?}}\left(\text{?}\right)\text{?}},\text{?}\text{indicates text missing or illegible when filed}$

where

k=cp/cv is the one of the leanest gas from job CSO

R is the one of the leanest gas from fuel job CSO

A_ev=effective area as a function of stroke (from table or correlations)

2^nd STEP—Primary fuel nozzle pressure [P8] 1010 calculation, when only secondary nozzle is fed.

P_CC=PCD (1−PLF)—with PLF ˜4%

$\text{?}·\sqrt{(\text{?},[1-\left(\text{?}\right]}=\text{?}\sqrt{\text{?}},\text{?}\text{indicates text missing or illegible when filed}$

where:

T8=FGT fuel gas temperature

R is the one of the leanest gas

Aeff=effective area as a function of pressure ratio across the burner

k=cp/cv is the one of the leanest gas from job CSO

R is the one of the leanest gas of the leanest gas from job CSO

3^rd STEP—GCV downstream 1012 calculation, when only secondary nozzle is fed and P7˜P8.

$\text{?}=\text{?}\{\begin{array}{c}\text{?}\\ \text{?}\end{array}\text{?}=\frac{k}{1.4}\text{?}\text{indicates text missing or illegible when filed}$

Where:

Cv=at 0% GSV opening

k=cp/cv is the one of the leanest gas from job CSO

Sg is the one of the leanest gas from fuel job CSO

4^th STEP—GCV choking verification

If,

$\left(\text{?}\right)>1.23,\text{?}\text{indicates text missing or illegible when filed}$

then the unit is able to transfer into PREMIX aside from EXT-LL mode.

The logic flows depicted in the figures do not require the particular order shown, or sequential order, to achieve desirable results. In addition, other steps may be provided, or steps may be eliminated, from the described flows, and other components may be added to, or removed from, the described systems. Accordingly, other embodiments are within the scope of the following claims.

It will be appreciated that the above embodiments that have been described in particular detail are merely example or possible embodiments, and that there are many other combinations, additions, or alternatives that may be included.

Also, the particular naming of the components, capitalization of terms, the attributes, data structures, or any other programming or structural aspect is not mandatory or significant, and the mechanisms that implement the invention or its features may have different names, formats, or protocols. Further, the system may be implemented via a combination of hardware and software, as described, or entirely in hardware elements. Also, the particular division of functionality between the various system components described herein is merely one example, and not mandatory; functions performed by a single system component may instead be performed by multiple components, and functions performed by multiple components may instead performed by a single component.

Some portions of above description present features in terms of algorithms and symbolic representations of operations on information. These algorithmic descriptions and representations may be used by those skilled in the data processing arts to most effectively convey the substance of their work to others skilled in the art. These operations, while described functionally or logically, are understood to be implemented by computer programs. Furthermore, it has also proven convenient at times, to refer to these arrangements of operations as modules or by functional names, without loss of generality.

Unless specifically stated otherwise as apparent from the above discussion, it is appreciated that throughout the description, discussions utilizing terms such as “processing” or “computing” or “calculating” or “determining” or “displaying” or “providing” or the like, refer to the action and processes of a computer system, or similar electronic computing device, that manipulates and transforms data represented as physical (electronic) quantities within the computer system memories or registers or other such information storage, transmission or display devices.

While the disclosure has been described in terms of various specific embodiments, it will be recognized that the disclosure can be practiced with modification within the spirit and scope of the claims.

The term processor, as used herein, refers to central processing units, microprocessors, microcontrollers, reduced instruction set circuits (RISC), application specific integrated circuits (ASIC), logic circuits, and any other circuit or processor capable of executing the functions described herein.

As used herein, the terms “software” and “firmware” are interchangeable, and include any computer program stored in memory for execution by processor 205, including RAM memory, ROM memory, EPROM memory, EEPROM memory, and non-volatile RAM (NVRAM) memory. The above memory types are exemplary only, and are thus not limiting as to the types of memory usable for storage of a computer program.

As will be appreciated based on the foregoing specification, the above-described embodiments of the disclosure may be implemented using computer programming or engineering techniques including computer software, firmware, hardware or any combination or subset thereof, wherein the technical effect includes (a) storing a plurality rule sets in the memory device, the rule sets relative to the operation of the gas turbine, the rule sets including at least one rule expressed as a relational expression of a real-time data output relative to a real-time data input, the relational expression being specific to at least one of a temperature spread of an exhaust flow of the gas turbine, a swirl angle of the exhaust flow, a health of a plurality of flame detectors of the gas turbine, and a transfer of the gas turbine from a first mode of operation to a second lower NOX mode of operation, (b) receiving real-time and historical data inputs from a condition monitoring system associated with the gas turbine, the data inputs relating to parameters affecting at least one of the temperature spread of the exhaust flow of the gas turbine, the swirl angle of the exhaust flow, the health of the plurality of flame detectors of the gas turbine, and the transfer of the gas turbine from the first mode of operation to the second lower NOX mode of operation, (c) determining a fuel gas line pressure drop using the received data, (d) comparing the determined pressure drop to a predetermined threshold range; and (e) recommending to an operator of the gas turbine to transfer the mode of operation of the gas turbine from the first mode to the second mode without reducing a load of the gas turbine if the determined pressure drop meets the predetermined threshold range. Any such resulting program, having computer-readable code means, may be embodied or provided within one or more computer-readable media, thereby making a computer program product, i.e., an article of manufacture, according to the discussed embodiments of the disclosure. The computer readable media may be, for example, but is not limited to, a fixed (hard) drive, diskette, optical disk, magnetic tape, semiconductor memory such as read-only memory (ROM), and/or any transmitting/receiving medium such as the Internet or other communication network or link. The article of manufacture containing the computer code may be made and/or used by executing the code directly from one medium, by copying the code from one medium to another medium, or by transmitting the code over a network.

Many of the functional units described in this specification have been labeled as modules, in order to more particularly emphasize their implementation independence. For example, a module may be implemented as a hardware circuit comprising custom very large scale integration (“VLSI”) circuits or gate arrays, off-the-shelf semiconductors such as logic chips, transistors, or other discrete components. A module may also be implemented in programmable hardware devices such as field programmable gate arrays (FPGAs), programmable array logic, programmable logic devices (PLDs) or the like.

Modules may also be implemented in software for execution by various types of processors. An identified module of executable code may, for instance, comprise one or more physical or logical blocks of computer instructions, which may, for instance, be organized as an object, procedure, or function. Nevertheless, the executables of an identified module need not be physically located together, but may comprise disparate instructions stored in different locations which, when joined logically together, comprise the module and achieve the stated purpose for the module.

A module of executable code may be a single instruction, or many instructions, and may even be distributed over several different code segments, among different programs, and across several memory devices. Similarly, operational data may be identified and illustrated herein within modules, and may be embodied in any suitable form and organized within any suitable type of data structure. The operational data may be collected as a single data set, or may be distributed over different locations including over different storage devices, and may exist, at least partially, merely as electronic signals on a system or network.

The above-described embodiments of a method and monitoring and diagnostic system for a gas turbine that includes a rule module provides a cost-effective and reliable means for providing meaningful operational recommendations and troubleshooting actions. Moreover, the system is more accurate and less prone to false alarms. More specifically, the methods and systems described herein can predict component failure at a much earlier stage than known systems to facilitate significantly reducing outage time and preventing trips. In addition, the above-described methods and systems facilitate predicting anomalies at an early stage enabling site personnel to prepare and plan for a shutdown of the equipment. As a result, the methods and systems described herein facilitate operating gas turbines and other equipment in a cost-effective and reliable manner.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

1. A computer-implemented method for monitoring and diagnosing combustion anomalies in an operation of a gas turbine, the method implemented using a computer device coupled to a user interface and a memory device, the method comprising:

storing a plurality rule sets in a memory device, the rule sets relative to the operation of the gas turbine, the rule sets comprising at least one rule expressed as a relational expression of a real-time data output relative to a real-time data input, the relational expression being specific to at least one of a temperature spread of an exhaust flow of the gas turbine, a swirl angle of the exhaust flow, a health of a plurality of secondary flame detectors of the gas turbine, and a transfer of the gas turbine from a first mode of operation to a second lower NOX mode of operation;

receiving real-time and historical data inputs from a condition monitoring system associated with the gas turbine, the data inputs relating to parameters affecting at least one of the temperature spread of the exhaust flow of the gas turbine, the swirl angle of the exhaust flow, the health of the plurality of flame detectors of the gas turbine, and the transfer of the gas turbine from the first mode of operation to the second lower NOX mode of operation;

determining a fuel gas line pressure drop using the received data;

comparing the determined pressure drop to a predetermined threshold range; and

recommending to an operator of the gas turbine to transfer the mode of operation of the gas turbine from the first mode to the second mode without reducing a load of the gas turbine if the determined pressure drop meets the predetermined threshold range.

2. The method of claim 1, wherein storing a plurality rule sets comprises storing a gas turbine transfer rule set wherein the first mode of operation is an Extended Lean-Lean (EXT-LL) mode and the second lower NOX mode of operation is a Premix mode.

3. The method of claim 1, further comprising:

receiving an analog signal output of at least some of the plurality of flame detectors;

statistically analyzing each analog signal output to identify a noise component of the signal and a variation of the signal;

generating a health count metric of the signals to define a plurality of thresholds based on the analysis;

comparing a current analog signal output to respective threshold; and

outputting a recommendation to at least one of replace one of the plurality of flame detectors, tune one of the plurality of flame detectors, check the operation of one of the plurality of flame detectors, and clean a lens of one of the plurality of flame detectors.

4. The method of claim 1, further comprising:

determining a swirl angle of a flow of gas turbine exhaust;

determining a faulty combustor using the determined swirl angle; and

outputting the determined faulty combustor to an operator.

5. The method of claim 4, wherein determining a swirl angle comprises:

receiving a plurality of temperature outputs from one or more temperature sensors associated with the flow of gas turbine exhaust; and

determining a temperature spread of the flow of gas turbine exhaust using the received plurality of temperature outputs.

6. The method of claim 5, further comprising correlating the determined temperature spread to a predetermined allowable temperature spread to determine an identity of a source combustor of the temperature spread.

7. The method of claim 5, wherein determining a temperature spread of the flow of gas turbine exhaust comprises determining a temperature spread of the flow of gas turbine exhaust at an exhaust diffuser of the gas turbine.

8. The method of claim 5, wherein determining a temperature spread of the flow of gas turbine exhaust comprises determining a temperature spread of the flow of gas turbine exhaust as a function of combustion mode and load.

9. The method of claim 5, wherein the gas turbine is capable of operating in a plurality of different combustion modes, the method further comprising determining a temperature spread threshold for each different combustion mode.

10. The method of claim 9, further comprising setting a temperature spread threshold to a value corresponding to a combustion mode being entered at least one of coincident to the transition into the combustion mode being entered and prior to the transition into the combustion mode being entered.

11. A system for monitoring and diagnosing combustion anomalies in an operation of a gas turbine, the system comprising:

a memory device;

a condition monitoring system associated with the gas turbine;

an user interface; and

a process configured to: store a plurality rule sets in the memory device, the rule sets relative to the operation of the gas turbine, the rule sets comprising at least one rule expressed as a relational expression of a real-time data output relative to a real-time data input, the relational expression being specific to at least one of a temperature spread of an exhaust flow of the gas turbine, a swirl angle of the exhaust flow, a health of a plurality of secondary flame detectors of the gas turbine, and a transfer of the gas turbine from a first mode of operation to a second lower NOX mode of operation, receive real-time and historical data inputs from the condition monitoring system, the data inputs relating to parameters affecting at least one of the temperature spread of the exhaust flow of the gas turbine, the swirl angle of the exhaust flow, the health of the plurality of flame detectors of the gas turbine, and the transfer of the gas turbine from the first mode of operation to the second lower NOX mode of operation, determine a fuel gas line pressure drop using the received data, compare the determined pressure drop to a predetermined threshold range, and recommend through the user interface to an operator of the gas turbine to transfer the mode of operation of the gas turbine from the first mode to the second mode without reducing a load of the gas turbine if the determined pressure drop meets the predetermined threshold range.

12. The system of claim 11, wherein storing a plurality rule sets comprises storing a gas turbine transfer rule set wherein the first mode of operation is an Extended Lean-Lean (EXT-LL) mode and the second lower NOX mode of operation is a Premix mode.

13. The system of claim 11, wherein the processor is further configured to:

receive an analog signal output of at least some of the plurality of flame detectors,

statistically analyze each analog signal output to identify a noise component of the signal and a variation of the signal,

generate a health count metric of the signals to define a plurality of thresholds based on the analysis,

compare a current analog signal output to respective threshold, and

output a recommendation to at least one of replace one of the plurality of flame detectors, tune one of the plurality of flame detectors, check the operation of one of the plurality of flame detectors, and clean a lens of one of the plurality of flame detectors.

14. The system of claim 11, wherein the processor is further configured to:

determine a swirl angle of a flow of gas turbine exhaust,

determine a faulty combustor using the determined swirl angle, and

output the determined faulty combustor to an operator.

15. The system of claim 14, wherein determining a swirl angle comprises:

receiving a plurality of temperature outputs from one or more temperature sensors associated with the flow of gas turbine exhaust; and

determining a temperature spread of the flow of gas turbine exhaust using the received plurality of temperature outputs.

16. The system of claim 15, wherein the processor is further configured to correlate the determined temperature spread to a predetermined allowable temperature spread to determine an identity of a source combustor of the temperature spread.

17. The system of claim 15, wherein determining a temperature spread of the flow of gas turbine exhaust comprises determining a temperature spread of the flow of gas turbine exhaust at an exhaust diffuser of the gas turbine.

18. The system of claim 15, wherein determining a temperature spread of the flow of gas turbine exhaust comprises determining a temperature spread of the flow of gas turbine exhaust as a function of combustion mode and load.

19. The system of claim 15, wherein the gas turbine is capable of operating in a plurality of different combustion modes, and the processor is further configured to determine a temperature spread threshold for each different combustion mode.

20. The system of claim 19, wherein the processor is further configured to set a temperature spread threshold to a value corresponding to a combustion mode being entered at least one of coincident to the transition into the combustion mode being entered and prior to the transition into the combustion mode being entered.