Fuel flow control

Abstract

A method (30) of controlling fuel flow in a gas turbine engine. First, detect a surge condition. Set fuel flow demand (W.sub.f_D) proportional to compressor discharge pressure (P.sub.30). Detect actual fuel flow (W.sub.f_A). Then apply an enhanced schedule (50) for fuel flow demand (W.sub.f_D) while fuel flow demand (W.sub.f_D) is less than a predefined proportion (k) of actual fuel flow (W.sub.f_A). Also a gas turbine engine (10), fuel flow system (68) and fuel flow control system (76) each implementing the method (30).

Claims

1. A method of controlling fuel flow in a gas turbine engine, the method comprising: a. in response to a detected surge condition that occurs while controlling the fuel flow according to fuel control laws, setting a fuel flow demand (W.sub.f_D) proportional to compressor discharge pressure (P30), such that the fuel flow demand (W.sub.f_D) varies with varying compressor discharge pressure (P30); b. detecting actual fuel flow (W.sub.f_A); and c. applying a rate accelerator or a step change to the fuel flow demand (W.sub.f_D) that has been set in response to the detected surge condition to provide a first rate of increase of the fuel flow demand (W.sub.f_D), while the fuel flow demand (W.sub.f_D) is less than a predefined proportion (k) of the actual fuel flow (W.sub.f_A), the first rate of increase being greater than a rate of increase that would have occurred in response to the detected surge condition under the fuel control laws that were being used prior to setting the fuel flow demand (Wf_D) proportional to the compressor discharge pressure (P30).

2. The method (30) as claimed in claim 1, further comprising reverting to the fuel flow control laws that were being used prior to setting the fuel flow demand (W.sub.f_D) proportional to the compressor discharge pressure (P30), once the fuel flow demand (W.sub.f_D) equals or exceeds the predefined proportion (k) of the actual fuel flow (W.sub.f_A).

3. The method as claimed in claim 1, wherein the detecting the actual fuel flow (W.sub.f_A) precedes or occurs in parallel to the setting the fuel flow demand (Wf_D) proportional to the compressor discharge pressure (P30).

4. The method as claimed in claim 1, wherein the rate accelerator is applied to the fuel flow demand (W.sub.f_D), the method further comprising applying a second rate of increase for the fuel flow demand (W.sub.f_D) while the fuel flow demand (W.sub.f_D) is less than a second predefined proportion (R.sub.2) of the actual fuel flow (W.sub.f_A); wherein the second predefined proportion (R.sub.2) is smaller than the predefined proportion (k).

5. The method as claimed in claim 1, wherein the predefined proportion (k) is in a range of 0.5 to 1.5.

6. The method as claimed in claim 1, wherein the predefined proportion (k) is in a range of 0.5 to 1.

7. The method as claimed in claim 1, wherein the predefined proportion (k) is in a range of 0.75 to 1.

8. The method as claimed in claim 1, wherein the first rate of increase provided by either the rate accelerator or the step change comprises a rate of increase of fuel flow demand defined by (kW.sub.f_AW.sub.f_D)/t, or by k(W.sub.f_AW.sub.f_D)/t, where t is a time step.

9. The method as claimed in claim 1, wherein the first rate of increase provided by either the rate accelerator or the step change is defined by kW.sub.f_A+(1k)W.sub.f_D.

10. The method as claimed in claim 1, wherein the rate accelerator or the step change is limited by a maximum rate of change of fuel flow demand (W.sub.f_D).

11. The method as claimed in claim 4, wherein the second rate of increase comprises a higher rate of increase of fuel flow demand (W.sub.f_D) than that applied by the rate accelerator or the step change.

12. The method as claimed in claim 1, wherein the actual fuel flow (W.sub.f_A) is measured by determining a position of a fuel metering valve.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiments will now be described by way of example only, with reference to the Figures, in which:

(2) FIG. 1 is a sectional side view of a gas turbine engine;

(3) FIG. 2 is a graph of parameters during surge under conventional fuel flow control laws;

(4) FIG. 3 is a schematic of a fuel flow control system;

(5) FIG. 4 is a flow chart of the method of the present invention;

(6) FIG. 5 is a plot of the manner in which an enhanced fuel flow demand schedule acts;

(7) FIG. 6 is a plot of an enhanced fuel flow demand schedule;

(8) FIG. 7 is a graph of parameters during surge using the enhanced fuel flow demand schedule of FIG. 6;

(9) FIG. 8 is a graph of parameters during surge using another enhanced fuel flow demand schedule;

(10) FIG. 9 is a block diagram of an exemplary control arrangement.

DETAILED DESCRIPTION OF EMBODIMENTS

(11) With reference to FIG. 1, a gas turbine engine is generally indicated at 10, having a principal and rotational axis 11. The engine 10 comprises, in axial flow series, an air intake 12, a propulsive fan 13, an intermediate pressure compressor 14, a high-pressure compressor 15, combustion equipment 16, a high-pressure turbine 17, an intermediate pressure turbine 18, a low-pressure turbine 19 and an exhaust nozzle 20. A nacelle 21 generally surrounds the engine 10 and defines both the intake 12 and the exhaust nozzle 20.

(12) The gas turbine engine 10 works in the conventional manner so that air entering the intake 12 is accelerated by the fan 13 to produce two air flows: a first air flow into the intermediate pressure compressor 14 and a second air flow which passes through a bypass duct 22 to provide propulsive thrust. The intermediate pressure compressor 14 compresses the air flow directed into it before delivering that air to the high pressure compressor 15 where further compression takes place.

(13) The compressed air exhausted from the high-pressure compressor 15 is directed into the combustion equipment 16 where it is mixed with fuel and the mixture combusted. The resultant hot combustion products then expand through, and thereby drive the high, intermediate and low-pressure turbines 17, 18, 19 before being exhausted through the nozzle 20 to provide additional propulsive thrust. The high 17, intermediate 18 and low 19 pressure turbines drive respectively the high pressure compressor 15, intermediate pressure compressor 14 and fan 13, each by suitable interconnecting shaft.

(14) Other gas turbine engines to which the present disclosure may be applied may have alternative configurations. By way of example such engines may have an alternative number of interconnecting shafts (e.g. two) and/or an alternative number of compressors and/or turbines. Further the engine may comprise a gearbox provided in the drive train from a turbine to a compressor and/or fan.

(15) A fuel flow system 68 is illustrated schematically in FIG. 3. Fuel is supplied to the gas turbine engine 10 from one or more fuel tanks 70, for example located in the aircraft body or wings where the gas turbine engine 10 powers an aircraft. The fuel may be pressurised through one or more pumps 72 and delivered to a fuel metering valve 74. The fuel metering valve 74 is controlled by a fuel flow control system 76 which implements methods of controlling the fuel flow in the gas turbine engine 10. The fuel metering valve 74 delivers the demanded fuel flow to the combustor 16, via one or more sets of fuel injectors.

(16) A method 30 of controlling fuel flow in a gas turbine engine 10 is described with respect to FIG. 4. The method 30 may be implemented in the fuel flow control system 76. The method 30 acts in response to a surge condition 32. Optionally a pre-step to detect the surge condition 32 by any conventional method may be implemented in the method 30. For example, surge may be detected from a rapid reduction in compressor discharge pressure P.sub.30. Alternatively the surge condition 32 need not be detected since the method 30 reacts to the effects of the surge without requiring explicit detection of the surge condition 32.

(17) In step 34 of the method 30 the fuel flow demand W.sub.f_D is set to be proportional to the compressor discharge pressure P.sub.30. The relationship between fuel flow demand W.sub.f_D and compressor discharge pressure P.sub.30 may be linear, with a constant of proportionality, or may be non-linear. The relationship between fuel flow demand W.sub.f_D and compressor discharge pressure P.sub.30 may be defined by the maximum flow limiter for the fuel flow control system. An exemplary maximum flow limit is calculated as the compressor discharge pressure P.sub.30 multiplied by a constant. The constant may itself be a function of engine speed.

(18) Also in response to the surge condition 32 the current actual fuel flow W.sub.f_A is detected, step 36. This step may occur before, during or after step 34 in which the fuel flow demand W.sub.f_D is set proportional to compressor discharge pressure P.sub.30.

(19) Step 38 is a comparison step. The actual fuel flow W.sub.f_A is multiplied by a predefined proportion k. The predefined proportion k may be a constant. It may be in the range 0.5 to 1. The demanded fuel flow W.sub.f_D is then compared to the product of the predefined proportion k and the actual fuel flow W.sub.f_A. If the demanded fuel flow W.sub.f_D is less than the product of the predefined proportion k and the actual fuel flow W.sub.f_A, thus W.sub.f_D<k.Math.W.sub.f_A, then an enhanced fuel flow demand schedule is applied at step 40. Conversely, if the demanded fuel flow W.sub.f_D is greater than or equal to the product of the predefined proportion k and the actual fuel flow W.sub.f_A, thus W.sub.f_Dk.Math.W.sub.f_A, then the normal fuel flow control laws set the demand schedule, step 42.

(20) Where the enhanced fuel flow demand schedule is applied, step 40, an iteration loop 44 ensures that the method 30 is repeated until the outcome of the comparison at step 38 returns the fuel flow demand schedule to the normal control laws, step 42.

(21) The enhanced fuel flow demand schedule applied at step 40 of the method 30 provides a step increase to the fuel flow demand W.sub.f_D. Advantageously this allows the fuel flow demand W.sub.f_D, and thus the actual fuel flow W.sub.f_A, to recover to the pre-surge levels more quickly than in the known control methods. The maximum (and minimum) fuel flow limiters remain in operation throughout control of the fuel flow by the method 30. Therefore one or both of the limiters may override the fuel flow demand W.sub.f_D generated by the enhanced fuel flow schedule if it is too aggressive for the engine conditions.

(22) FIG. 5 is a schematic plot of the effect of applying the enhanced fuel flow demand schedule at step 40. At the time at which the maximum fuel flow limiter based on compressor discharge pressure P.sub.30 is no longer the controlling control law, the fuel flow demand W.sub.f_D is the level 45 shown. The actual fuel flow W.sub.f_A is higher and is shown by the dashed horizontal line. FIG. 5 is a simplified plot since, as seen in FIG. 2, the actual fuel flow W.sub.f_A continues to fall whilst the fuel flow demand W.sub.f_D is lower than the actual fuel flow W.sub.f_A and so the dashed line should have a downward trend.

(23) In a first embodiment the enhanced fuel flow demand schedule applies a rate accelerator 46 to the fuel flow demand W.sub.f_D to rapidly increase the fuel flow demand W.sub.f_D to the level of the actual fuel flow W.sub.f_A. The first embodiment is described in more detail with respect to FIG. 6. In second and third embodiments the enhanced fuel flow demand schedule applies a step change to the fuel flow demand W.sub.f_D, as shown by line 48, to a predefined proportion k of the actual fuel flow W.sub.f_A. The predefined proportion k may be less than one, as illustrated. Alternatively the predefined proportion k may be equal to one, in which case the fuel flow demand W.sub.f_D steps directly to the actual fuel flow W.sub.f_A. In a further alternative the predefined proportion k may be greater than one, in which case the fuel flow demand W.sub.f_D steps above the actual fuel flow W.sub.f_A and therefore has a greater effect on surge recovery.

(24) The larger the predefined proportion k, the quicker the surge recovery. However, the smaller the predefined proportion k, the more robust and stable the surge recovery. Therefore it is beneficial to set the predefined proportion k to a value that suitably balances the speed and stability of surge recovery for the particular application of the method 30.

(25) The first embodiment of the enhanced fuel flow demand schedule 50 is shown in FIG. 6. The x-axis represents the ratio of fuel flow demand W.sub.f_D to actual fuel flow W.sub.f_A. The y-axis represents the rate of change of fuel flow demand W.sub.f_D.sup..circle-solid. which is applied to the underlying fuel flow demand W.sub.f_D due to its relationship to compressor discharge pressure P.sub.30. The rate of change of fuel flow demand W.sub.f_D.sup..circle-solid. is normalised by division by the fuel flow demand W.sub.f_D, thus W.sub.f_D.sup..circle-solid./W.sub.f_D, which is a fuel flow rate limiter. When the ratio is below a first threshold R.sub.1 a high rate of increase of fuel flow demand W.sub.f_D.sup..circle-solid. is applied to the fuel flow demand W.sub.f_D at each time step. This is shown by the section of the fuel flow demand schedule 50 which is labelled 52.

(26) When the ratio shown on the x-axis is between the first threshold R.sub.1 and a second, higher threshold R.sub.2 a different rate of increase of fuel flow demand W.sub.f_D.sup..circle-solid. is applied to the fuel flow demand W.sub.f_D at each time step. This is the section labelled 54. The rate of increase between the thresholds R.sub.1, R.sub.2 may be a transitional rate of increase of fuel flow demand W.sub.f_D such that the rate is inversely proportional to the magnitude of the ratio. When the ratio is above the second threshold R.sub.2 there may be a further rate of increase of fuel flow demand W.sub.f_D.sup..circle-solid. applied. The further rate of increase may correspond to the normal fuel flow control laws. This is section 56 of the fuel flow demand schedule 50 shown in FIG. 6.

(27) The first threshold R.sub.1 may be in the range 0 to 0.7, for example around 0.5. Thus when the fuel flow demand W.sub.f_D is less than half of the actual fuel flow W.sub.f_A the high rate of increase 52 of fuel flow demand W.sub.f_D.sup..circle-solid. is applied. The second threshold R.sub.2 may be in the range 0.5 to 1, for example around 0.7 to 0.85. Thus when the fuel flow demand W.sub.f_D is 50% to 85% of the actual fuel flow W.sub.f_A the transitional rate of increase 54 of fuel flow demand W.sub.f_D.sup..circle-solid. is applied. The high and transitional rates of increase 52, 54 may be, for example, expressed as slew rates for a mechanical fuel metering valve.

(28) The effect of the first embodiment of the fuel flow demand schedule 50 can be seen in FIG. 7. The dotted lines correspond to the lines in FIG. 2. The fuel flow demand W.sub.f_D is modified in that it begins to rise more quickly than when controlled by the normal fuel flow control laws. The vertical distance between the fuel flow demand W.sub.f_D and the actual fuel flow W.sub.f_A is the ratio. At the time indicated by dashed line 58 the vertical distance between the fuel flow demand W.sub.f_D and the actual fuel flow W.sub.f_A is less than or equal to the first threshold R.sub.1. Thus the fuel flow demand W.sub.f_D is approximately 35% of the actual fuel flow W.sub.f_A. At the time indicated by dashed line 60 the vertical distance between the fuel flow demand W.sub.f_D and the actual fuel flow W.sub.f_A is equal to the second threshold R.sub.2. Thus the fuel flow demand W.sub.f_D is approximately 80% of the actual fuel flow W.sub.f_A.

(29) During the time interval marked by double-headed arrows 62 the transitional rate 54 of increase of fuel flow demand W.sub.f_D is applied by the enhanced fuel flow demand schedule 50. After time 60 the normal control laws are applied, for example comprising an exponential rate of increase of fuel flow demand W.sub.f_D. The increase in fuel flow demand W.sub.f_D causes a consequential, lagged increase in the actual fuel flow W.sub.f_A. This is shown in FIG. 7. Advantageously the fuel flow demand W.sub.f_D grows more rapidly than in the conventional situation where the enhanced demand schedule 50 is not applied because the base fuel flow demand W.sub.f_D, to which the exponential rate of fuel flow demand increase W.sub.f_D.sup..circle-solid. (normal control laws) is applied, is higher.

(30) Advantageously the effect of the enhanced fuel flow demand schedule 50 is that the fuel flow demand W.sub.f_D is driven to track the compressor discharge pressure P.sub.30 not only as it reduces following a surge event but also as it rises rapidly as the engine 10 recovers from the surge condition 32.

(31) A second embodiment of the enhanced fuel flow demand schedule 50 has a single threshold ratio R.sub.3. The schedule 50 is arranged to calculate the fuel flow demand W.sub.f_D necessary to match the threshold ratio R.sub.3 of the fuel flow demand W.sub.f_D to the actual fuel flow W.sub.f_A. The threshold R.sub.3 may be, for example, 0.85. The threshold R.sub.3 is chosen so that the fuel flow demand W.sub.f_D does not fall below this proportion of the actual fuel flow W.sub.f_A during normal rapid engine decelerations but only falls below the proportion during surge events. Recovery from surge is quicker the closer the threshold R.sub.3 is to one.

(32) Where the fuel flow demand W.sub.f_D is greater than or equal to the threshold R.sub.3 multiplied by the actual fuel flow W.sub.f_A, thus W.sub.f_DR.sub.3.Math.W.sub.f_A, the rate of increase of fuel flow demand W.sub.f_D.sup..circle-solid. from the normal control laws is applied. As in the first embodiment, this rate W.sub.f_D.sup..circle-solid. may be exponential.

(33) Where the fuel flow demand W.sub.f_D is less than the predefined proportion k multiplied by the actual fuel flow (for example 0.85.Math.W.sub.f_A) the second embodiment of the enhanced fuel flow demand schedule 50 performs a calculation, compares it to the fuel flow rate W.sub.f_D.sup..circle-solid. from the normal control laws, and applies the larger value. The calculation is the difference between the product of the threshold ratio R.sub.3 and the actual fuel flow W.sub.f_A, R.sub.3.Math.W.sub.f_A, and the fuel flow demand W.sub.f_D. The difference is then divided by the controller time step being the time step in which updated control instructions can be implemented. The predefined proportion k is the proportion of the actual fuel flow W.sub.f_A to which it is desired that the fuel flow demand W.sub.f_D steps, as shown by line 48 in FIG. 5. Thus the calculation is:

(34) $\frac{R_3.W_{\mathrm{f\_A}}-W_{\mathrm{f\_D}}}{\mathrm{timestep}}.$
Alternatively the calculation is the difference between the actual fuel flow W.sub.f_A and the fuel flow demand W.sub.f_D, multiplied by the threshold ratio R.sub.3 and divided by the time step:

(35) $\frac{R_3\left(W_{\mathrm{f\_A}}-W_{\mathrm{f\_D}}\right)}{\mathrm{timestep}}.$
The enhanced fuel flow demand schedule 50 applies this calculated rate when the fuel flow demand W.sub.f_D is less than the predetermined proportion k of the actual fuel flow W.sub.f_A unless the normal fuel flow control laws give a larger rate of increase W.sub.f_D.sup..circle-solid..

(36) In a third embodiment of the enhanced fuel flow demand schedule 50 the fuel flow demand W.sub.f_D is set to be a sum of two components: one related to the actual fuel flow W.sub.f_A and one related to the fuel flow demand W.sub.f_D. A constant n is multiplied by the actual fuel flow W.sub.f_A to give the first component, W.sub.f_A. One minus the constant n is multiplied by the fuel flow demand W.sub.f_D to give the second component, (1n).Math.W.sub.f_D. The constant n may be, for example, in the range 0.25 to 1.25 inclusive. By changing the value of the constant n the speed and robustness of the recovery of the engine 10 from the surge event can be optimised. Since the constant n is selected to be around unity it biases the schedule 50 to have more influence from the actual fuel flow W.sub.f_A than the fuel flow demand W.sub.f_D. As can be seen in FIG. 8 the actual fuel flow W.sub.f_A is considerably larger than the fuel flow demand W.sub.f_D within a short time after the surge event, which occurs around time 0.3, and so this bias forces the fuel flow demand W.sub.f_D to rise quickly. Once the maximum fuel flow limiter is no longer limiting the fuel flow demand W.sub.f_D the normal control laws take over control of the fuel flow demand W.sub.f_D, for example applying an exponential rate of increase W.sub.f_D.sup..circle-solid..

(37) A block diagram of an example implementation of the third embodiment is shown in FIG. 9.

(38) Advantageously the third embodiment of the enhanced fuel flow demand schedule 50 applies a more aggressive increase in fuel flow demand W.sub.f_D, from the nadir of the compressor discharge pressure P.sub.30, than the first embodiment and so the base fuel flow demand W.sub.f_D to which the normal, exponential, rate of increase W.sub.f_D.sup..circle-solid. is applied is higher. Thus the fuel flow demand W.sub.f_D recovers to its pre-surge level more rapidly than the first embodiment and much more rapidly than the conventional method in which no enhanced schedule 50 was applied.

(39) Advantageously the third embodiment of the enhanced fuel flow demand schedule 50 does not require a step of determining if the ratio of fuel flow demand W.sub.f_D to actual fuel flow W.sub.f_A is less than a threshold ratio before applying the enhanced schedule 50. Instead the calculation can be operational throughout fuel flow control but will only control the fuel flow demand W.sub.f_D in response to a surge condition 32 and when the maximum fuel flow rate limiter based on compressor discharge pressure P.sub.30 stops being in control of the fuel flow. Optionally a step to determine if the fuel flow demand W.sub.f_D is less than a threshold ratio R of the actual fuel flow W.sub.f_A may be used to trigger application of the third embodiment of the enhanced fuel flow demand schedule 50.

(40) Although the method 30 is most accurate when the actual fuel flow W.sub.f_A can be measured at step 36, for example from the physical position of the fuel metering valve 74, the method 30 can also be implemented by using a simulated value of actual fuel flow W.sub.f_A. Such a simulated value may be derived from a model of the dynamic response of the fuel flow system 68.

(41) Advantageously the method 30 enables other methods to be applied in an engine control system which have an adverse effect on surge recovery. For example some methods to detect and/or accommodate shaft break events, which have some similar characteristics to surge events, have the effect of degrading surge recovery. The method 30 described herein overcomes that degraded surge recovery and so makes use of both methods feasible.

(42) The method 30 is also applicable to marine and industrial gas turbine engines.

(43) It will be understood that the invention is not limited to the embodiments above-described and various modifications and improvements can be made without departing from the concepts described herein. Except where mutually exclusive, any of the features may be employed separately or in combination with any other features and the disclosure extends to and includes all combinations and sub-combinations of one or more features described herein.