Patent Application
20150377161
The subject matter disclosed herein relates to power generation systems such as engines. Specifically, the subject matter described below relates to systems and methods for adjusting a combustion engine in a power generation system based on certain fuel properties.
Power generation systems can be used for a variety of applications, such as agricultural and food processing systems, onsite power generation for commercial and industrial buildings, and landfills and wastewater treatment. A power generation system may include a combustion gas engine and an engine control system that oversees the operation of the combustion gas engine. The engine control system generally monitors and adjusts certain parameters of the gas engine. It would be beneficial to improve control of gas engine systems.
Certain embodiments commensurate in scope with the originally claimed invention are summarized below. These embodiments are not intended to limit the scope of the claimed invention, but rather these embodiments are intended only to provide a brief summary of possible forms of the invention. Indeed, the invention may encompass a variety of forms that may be similar to or different from the embodiments set forth below.
In a first embodiment, a method includes receiving a fuel composition analysis, deriving a fuel index based on the fuel composition analysis, deriving a control adjustment for a gas engine based on the fuel index, and applying the control adjustment to an actuator of the gas engine.
In a second embodiment, a system includes a fuel repository that provides fuel, a gas engine fluidly coupled to the fuel repository and configured to receive the fuel and provide power, and a fuel composition analyzer fluidly coupled to the fuel repository. The fuel composition analyzer is configured to receive a sample of fuel from the fuel repository, analyze the sample of fuel, and generate a fuel composition analysis. The system also includes a fuel index calculator communicatively coupled to the fuel composition analyzer. The fuel index calculator has a processor configured to receive the fuel composition analysis and derive a fuel index based on the fuel composition analysis. The system further includes an engine control system communicatively coupled to the fuel index calculator. The engine control system includes a processor configured to receive the fuel index, derive a control adjustment to the gas engine based on the fuel index, and apply the control adjustment to an actuator of the gas engine.
In a third embodiment, a tangible, non-transitory computer readable medium includes instructions. The instructions are configured to receive a fuel composition analysis, derive a fuel index based on the fuel composition analysis, derive a control adjustment for a gas engine based on the fuel index, and apply the control adjustment to an actuator of the gas engine.
These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
One or more specific embodiments of the present invention will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
When introducing elements of various embodiments of the present invention, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
Present embodiments relate to systems and methods for controlling an engine based on fuel composition. To determine the fuel composition, an operator performs a gas analysis on a sample of fuel to create a fuel composition analysis detailing the chemical constituents of the fuel. Before the techniques described hering, the operator may have entered the resulting data into a spreadsheet or database such as Excel, to calculate an index or rating that indicates fuel quality and composition. The systems and methods described herein relate to automating the creation of a fuel index that represents fuel composition or fuel quality and deriving control adjustments to an engine based on the fuel index. The fuel index may be calculated in substantially real-time, allowing a control system associated with the engine to derive control adjustments based on the fuel index in substantially real-time. Further, the fuel index may be a single number or ratio; accordingly, the latency and complexity of transmitting the fuel index between systems may be reduced compared to the latency and complexity of transmitting a complete fuel composition analysis. Additionally, the fuel index may be calculated by a separate device that may be installed on existing engine systems, or by software installed in the control system in existing engine systems.
Turning now to
After the engine system 14 burns the fuel, an exhaust system 16 receives the exhaust gases from the engine system 14. The exhaust system 16 then performs various types of chemical processing on the exhaust gases before the exhaust gases are released outside of the power generation system 10. For example, the exhaust system 16 may include a catalytic converter system, such as a three-way catalyst, suitable for removing certain emissions before release of the exhaust gases to ambient.
The power generation system 10 further includes an engine control system 18, which oversees the operation of the power generation system 10. The engine control system 18 includes a processor 20; a memory 22; a display 24; a user input device 26; a communicative link 28 to other systems, components, and devices; and a hardware interface 30 suitable for interfacing with sensors 32 and actuators 34.
The sensors 32 may provide various data to the engine control system 18. For example, the sensors 32 may include oxygen sensors, rotational speed sensors, temperature sensors, pressure sensors, flow sensors, and the like, disposed at different locations in the engine system 14 and the power generation system 10. The actuators 34 may include valves, pumps, positioners, inlet guide vanes, switches, and the like, useful in performing control actions and disposed at different locations in the engine system 14 and the power generation system 10.
In one embodiment of the power generation system 10, the engine control system 18 may monitor fuel properties or fuel composition (e.g., chemical composition, such as a hydrocarbon composition). The engine control system 18 can use the fuel composition to determine a variety of useful derivations including ignition timing, emissions timing, the power and fuel performance of the engine system 14, the engine torque, and the air-to-fuel ratio (AFR).
To that end, the power generation system 10 may include a gas chromatograph 36, as depicted in
The gas chromatograph 36 determines fuel composition and the relative or actual amounts of the chemical constituents of the fuel in substantially real-time. However, the fuel composition itself may not necessarily indicate the fuel quality. Further, in certain situations, the engine control system 18 may only use a portion of the fuel composition data relating to certain chemical constituents when determining control adjustments. For example, for certain control adjustments, the engine control system 18 may only use the carbon-hydrogen ratio of the fuel as input for certain derivations. To determine a representation of fuel quality or composition, the power generation system 10 may include a fuel index calculator 38, further described below.
Turning now to
The memory 22 may be a mass storage device, a FLASH memory device, removable memory, or any other non-transitory computer-readable medium. Additionally or alternatively, the instructions may be stored in an additional suitable article of manufacture that includes at least one tangible, non-transitory computer-readable medium that at least collectively stores these instructions or routines in a manner similar to the memory 22 as described above. The display 24 enables a user to view various data regarding the engine system 14 and, to a certain extent, the power generation system 10. The user input device 26 allows the user (e.g., engine operator) to interact with the engine control system 16. The communicative link 28 may be a wired (e.g., a wired telecommunication infrastructure or a local area network employing Ethernet) or wireless (e.g., a cellular network or an 802.11x Wi-Fi network) connection between the engine control system 18 and other systems (e.g., the gas chromatograph 36), components, and devices.
Turning now to
The fuel indices may include a Waukesha Knock Index (WKI), which may be calculated via software such as Waukesha's Windows™ based WKI software available from General Electric Company, of Schenectady, N.Y., using, for example, a nine-gas mix matrix as input. Additionally or alternatively, the fuel indices may include a knock resistance rating derived via models or calibration curves as described in U.S. Pat. No. 6,061,637 by Sorge et al., incorporated by reference in its entirety herein. For example, an algorithm may consider concentrations of the following molar constituents: methane (60%-100%); ethane (0%-20%); propane (0%-40%); normal-butane (0%-10%); normal-pentane (0%-3%); mixture of hexane and heptane (0%-2%); nitrogen (0%-15%); and carbon dioxide (0%-10%). For samples having gas constituent concentrations lying within expected limits, the algorithm is implemented in the following manner First, concentrations of non-hydrocarbon combustibles such as hydrogen, carbon monoxide, hydrogen sulfide, etc., are temporarily removed from the analysis, and the concentration values of the above listed modeled constituents (e.g., gaseous hydrocarbon combustibles, carbon dioxide and nitrogen) are normalized. It has been found that isomers of butane (iso-butane) and pentane (iso-pentane) affect knock resistance differently than normal-pentane and normal butane. Therefore, it is desirable to account for these isomer constituents by: 1) assigning approximately 58% of the iso-butane concentration to the propane concentration and approximately 42% of the iso-butane concentration to the n-butane concentration; and 2) assigning approximately 68% of the iso-pentane concentration to the n-butane concentration and approximately 32% of the iso-pentane concentration to the n-pentane concentration. The adjusted and normalized concentration values for the modeled constituents of the sample (e.g. the gaseous hydrocarbon combustibles, carbon dioxide, and nitrogen) are processed through empirical models to determine a preliminary knock resistance rating. The preliminary knock resistance rating is then adjusted for non-hydrocarbon combustibles, such as hydrogen, in a manner consistent with the conventional methane number (MN) test.
As illustrated in
Beginning at block 52, the process 50 may direct the gas chromatograph 36 to analyze the fuel and to generate a fuel composition analysis 54. The gas chromatograph 36 may take one or more samples of fuel from the fuel repository 12 for analysis. For example, an average sample may be taken every 1 to 1000 milliseconds, 1 second to 1 minute, 1 minute to 10 minutes, three to five minutes, and so on. The process 50 may then direct for the fuel sample to be injected into a carrier gas stream that passes through a narrow tube (e.g., called the “column”) Different chemical constituents of the fuel sample pass through the column at different rates based on their various chemical and physical properties and their interactions with the specific column material (e.g., glass, plastic). As the different chemical constituents exit the column, a detector (e.g., flame ionization detector, thermal conductive detector, catalytic combustion detector, etc.) detects the type and amount of the chemical constituents. The gas chromatograph 38 then generates the fuel composition analysis 54 which includes a listing of each chemical constituent in the fuel as well as the relative or actual amount of each chemical constituent, as mentioned above.
Next, at block 56, process 50 may direct the fuel index calculator 38 to derive one or more fuel indices 58 based on the fuel composition analysis 54. The process 50 may then direct the fuel index calculator 38 to send the fuel index 58 to the engine control system 18, which may derive control adjustments for the engine system 14 based on the fuel index 58 at block 60. For example, as mentioned above, the engine control system 18 may determine ignition timing, emissions timing, the power and fuel performance of the engine system 14, the engine torque, and the air-to-fuel ratio based in part on the fuel composition. For instance, using the fuel index 58, the engine control system 18 may detect an increase in the methane number of the fuel, which may prompt the engine control system 18 to change emissions timing Finally, at block 62, the engine control system 18 applies the control adjustment to the engine system 14. For example, to adjust the engine torque, the engine control system 18 may adjust the inlet guide vanes (i.e., actuators 32) of a torque converter within the engine system 14 that provides power to the gas engine. In another instance, the engine control system 18 may adjust a throttle within the engine system 14 to change the amount of air or fuel provided to the gas engine, thereby adjusting the air-to-fuel ratio.
As noted above, the gas chromatograph 36 takes and analyzes samples of fuel every three to five minutes on average. That is, the fuel composition analysis 54 may be generated in substantially real-time. As a result, the fuel index 58 may be calculated in substantially real-time. As such, the engine control system 18 may optimize certain parameters in real-time based on the fuel index 58. This may prove especially advantageous for applications in which the power generation system 10 uses multiple types of fuel that vary in quality or composition. Further, since the fuel index 58 may be a single number or ratio, the latency and complexity of transmitting the fuel index 58 between systems may be reduced compared to the latency and complexity of transmitting the complete fuel composition analysis 54.
Additionally, as mentioned above, the fuel index calculator 38 may be a separate device or software installed in the engine control system 18 or the gas chromatograph 36. Accordingly, the fuel index calculator 38, as a device or a software component, may be easily installed in existing power generation systems. As will be appreciated, the technical effects and technical problems described above in the specification are exemplary and not limiting. It should be noted that the embodiments described in the specification may have other technical effects and can solve other technical problems.
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 invention 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 language of the claims.
