Air-free spray intercooler and water washing system

Abstract

The present application provides a spray intercooler and water wash system (100) for injecting a volume of water (200) into a compressor (15) of a gas turbine engine (10). The spray intercooler and wash system (100) may include a plurality of spray nozzles (120) positioned around the compressor (15), a water manifold (110) in communication with the spray nozzles (120), a pump (260) in communication with the water manifold (110), and a variable frequency drive (275) in communication with the pump (260).

Description

Technical Field

[0001] The present application and the resultant patent relate generally to gas turbine engines and, more particularly, to an airless spray intercooler and water wash system that utilizes a single pump and manifold to achieve a simplified system that improves overall engine efficiency. Background Art

[0002] Gas turbine engines typically include a compressor for compressing ambient air and a plurality of combustors for mixing the air flow with a fuel flow to produce hot combustion gases. The turbine receives the hot combustion gas flow and extracts energy from it to power the compressor and produce output power for an external load such as an electrical generator.

[0003] Since the compressor consumes a large amount of air, small amounts of dust, aerosols, and water can pass through and possibly form deposits on the compressor blades, etc. These deposits can impede the flow of air through the compressor and, over time, can reduce the overall performance and efficiency of the gas turbine engine. Therefore, the gas turbine engine can be periodically cleaned to clean and remove contaminants from the compressor. Such cleaning operations can be either offline cleaning operations or online cleaning operations. Offline cleaning operations are performed when the gas turbine engine is shut down. While online water washing operations allow cleaning to be performed while the engine is running, online cleaning can, to some extent, reduce the performance of the entire gas turbine engine.

[0004] In a somewhat similar manner, a gas turbine compressor may require less power to operate at a given pressure ratio if intercooling is implemented within the compressor. One method of implementing intercooling involves spraying coolant droplets into the inlet of the compressor, a spray intercooler, or "SPRINT." When a mixture of gas and water is compressed (commonly referred to as wet compression), the temperature of the gas increases and provides a driving force for evaporation. The evaporation of the water cools the gas, thereby acting as an intercooler. In this case, the size of the coolant droplets can be small enough so that the inertial force is dominated by the drag force, which tends to cause the droplets to flow through the compressor inlet and travel to the subsequent stages of the compressor where the droplets evaporate and achieve the desired intercooling. However, spray intercoolers generally require air to be extracted from the subsequent stages of the compressor in order to operate. Such extraction reduces the overall efficiency of the gas turbine engine. Summary of the invention

[0005] The present application and the resultant patent provide a spray intercooler and water wash system for spraying a volume of water into a compressor of a gas turbine engine. The spray intercooler and water wash system may include a plurality of spray nozzles positioned around the compressor, a water manifold in communication with the spray nozzles, a pump in communication with the water manifold, and a variable frequency drive in communication with the pump.

[0006] The present application and the resulting patent may also provide a method of operating a spray intercooler and a water wash system to spray a volume of water into the inlet of a compressor. The method may include the steps of instructing a pump to pump a volume of water at a first flow rate, spraying a volume of water into the inlet of the compressor at the first flow rate to produce droplets of a first size, instructing the pump to pump a volume of water at a second flow rate, and spraying a volume of water into the inlet of the compressor at the second flow rate to produce droplets of a second size.

[0007] The present application and the resulting patent may also provide a spray intercooler and water wash system for spraying a volume of water into a compressor of a gas turbine engine. The spray intercooler and water wash system may include a plurality of spray nozzles positioned around the compressor, a water manifold in communication with the spray nozzles, a piston pump driven by a pump motor in communication with the water manifold, and a variable frequency drive in communication with the piston pump and the pump motor.

[0008] These and other features and improvements of the present application and the resultant patent will become apparent to one of ordinary skill in the art upon reading the following detailed description, taken in conjunction with the several drawings and the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is a schematic diagram of a gas turbine engine including a compressor, combustor, turbine, external load, water manifold, and water supply skid.

[0010] Figure 2 yes Figure 1 Schematic diagram of the water supply skid. DETAILED DESCRIPTION

[0011] Referring now to the drawings, in which like numerals refer to like elements throughout the several views, Figure 1A schematic diagram of a gas turbine engine 10 as described herein is shown. The gas turbine engine 10 may contain a compressor 15. The compressor 15 compresses an incoming air flow 20. The compressor 15 delivers the compressed air flow 20 to a plurality of combustor cans 25. The combustor cans 25 mix the compressed air flow 20 with a pressurized fuel flow 30 and ignite the mixture, thereby producing a hot combustion gas flow 35. Although only a single combustor can 25 is shown, the gas turbine engine 10 may include any number of combustor cans 25 positioned in a circumferential array or the like. Alternatively, the combustor 25 may be an annular combustor. The combustion gas flow 35 is then delivered to a turbine 40. The combustion gas flow 35 drives the turbine 40 to produce mechanical work. The mechanical work produced in the turbine 40 drives the compressor 15 through a rotor shaft 45. The turbine 40 and the rotor shaft 45 may also drive an external load 50 such as a generator.

[0012] The gas turbine engine 10 may use natural gas, hydrogen, various types of synthetic gas, liquid fuels and / or other types of fuels and blends thereof. The gas turbine engine 10 may be any of a variety of different gas turbine engines provided by General Electric Company of Schenectady, New York, including but not limited to heavy duty gas turbine engines such as the 7 series or 9 series and LM6000 and LM9000 aeroderivative gas turbine engines. The gas turbine engine 10 may be part of a single cycle or combined cycle power generation system or other types of power generation systems. The gas turbine engine 10 may have different configurations and may use other types of components. Other types of gas turbine engines may also be used herein. Multiple gas turbine engines, other types of turbines, and other types of power generation equipment may also be used herein.

[0013] Figure 1 Also shown is an example of a spray intercooler and water wash system 100 that can be as described herein. The spray intercooler and water wash system 100 may include a water manifold 110. The water manifold 110 may have any convenient size, shape, or configuration. The spray intercooler and water wash system 100 may include a plurality of spray nozzles 120 positioned around an inlet 130 of the compressor 15. More than 10 spray nozzles 120 may be used. In this example, 17 spray nozzles 120 may be used. The total number and size of the spray nozzles 120 may vary with the geometry of the compressor 15 and other types of performance parameters. The spray nozzles 120 may be in communication with the water manifold 110 via a plurality of nozzle ducts 140.

[0014] The water manifold 110 of the spray intercooler and water wash system 100 may be in communication with a water supply skid 150. The water supply skid 150 may be positioned away from the gas turbine engine 10 or otherwise located at any distance. The water manifold 110 may be in communication with the water supply skid 150 via a manifold conduit 160. The manifold conduit 160 may have a manifold conduit valve 170 and a manifold conduit pressure sensor 180 on the manifold conduit. The manifold conduit valve 170 and the manifold conduit pressure sensor 180 may be of conventional design. Other components and other configurations may also be used herein.

[0015] Figure 2 Detailed information of the water supply skid 150 is shown. The water supply skid 150 may include a water supply device 190. The water supply device 190 may have any convenient size, shape or configuration. The water supply device 190 may contain a volume of water 200. Preferably, the volume of water 200 may be a volume of demineralized water or the like. The volume of water 200 may be supplied to the spray intercooler and water wash system 100 through a skid conduit 210 and a water inlet skid valve 220. The water inlet skid valve 220 may be an on / off valve such as a ball valve.

[0016] Then, a volume of water 200 may flow through a low pressure filter 230. The low pressure filter 230 may be of conventional design. A low differential pressure filter pressure sensor 240 may be used therewith. As the low pressure filter 230 intercepts contaminants and the like in a volume of water 200, the pressure through the low pressure filter 230 may increase. The low pressure filter pressure sensor 240 may indicate when the pressure through it has exceeded normal operating parameters. The low pressure filter pressure sensor 240 may be of conventional design. A temperature sensor 250 may be positioned downstream of the low pressure filter pressure sensor 240. The temperature sensor 250 may be of conventional design.

[0017] The water supply skid 150 also includes a pump 260 driven by a pump motor 270. The pump 260 can be a piston pump. The pump motor 270 can have a variable frequency drive 275 (i.e., a frequency converter) so that the pump 260 can run at any desired speed. In view of this, the pump 260 can provide a certain volume of water 200 at any desired pressure and flow rate. The operation of the pump 260 and the pump motor 270 is controlled by a controller 280, as will be described in more detail below. Other components and other configurations may also be used herein.

[0018] The back pressure regulator 290 may be positioned downstream of the pump 260. The back pressure regulator 290 may be of conventional design. The back pressure regulator 290 may protect the pump 260 at a minimum flow / pressure state. The pump pressure sensor 300 may be positioned downstream of the back pressure regulator 290. The pump pressure sensor 300 may be of conventional design. The pump pressure sensor 300 ensures that the pump 260 operates within a safe pressure range. The flow meter 310 may be positioned downstream of the pump pressure sensor 300. The flow meter 310 may be of conventional design. The flow meter 310 ensures that the pump 260 operates within a safe flow rate range. The high pressure filter 320 may be positioned downstream of the flow meter 310. The high pressure filter 320 may be of conventional design. A high differential pressure filter pressure sensor 330 may be used therewith. Since the high pressure filter 320 intercepts contaminants and the like in a certain volume of water 200, the pressure passing through the high differential pressure filter 320 may increase. The high pressure filter pressure sensor 330 may indicate when the pressure passing through it has exceeded normal operating parameters. The high pressure filter pressure sensor 330 may be of conventional design. The outlet valve 340 may be positioned downstream of the high pressure filter 320. The outlet valve 340 may be an on / off valve such as a solenoid valve. Other components and other configurations may also be used herein.

[0019] The water supply skid 150 may also include a purge air source 350. The purge air source 350 may be any convenient source of pressurized air of any volume. The purge air source may be combined with the skid conduit 210 at a T-junction downstream of the water outlet valve 340 via a purge air conduit 360 and a purge air valve 370. The purge air valve 370 may be of conventional design.

[0020] The sled conduit 210 may continue to extend to the sled outlet conduit 380 at the T-connection. The sled outlet conduit 380 may have a sled outlet conduit valve 390 on the sled outlet conduit. The sled outlet conduit valve 390 may be of conventional design and may be an on / off valve such as a solenoid valve. The sled outlet conduit 390 merges into the sled conduit 210 at the T-connection so that a volume of water 200 may flow to the water manifold 110. Other components and other configurations may also be used herein.

[0021] The water supply skid 150 may also include a drain system 400 to drain water out of the spray intercooler and water wash system 100 to ensure that no excess volume of water is delivered to the compressor 15. The drain system 400 system includes a vacuum jet venturi pump 410. Generally, the vacuum jet venturi pump 410 can be a mechanical device with no moving parts. The vacuum jet venturi pump 410 mixes two fluid streams based on momentum transfer. The vacuum jet venturi pump 410 can be connected to the skid conduit 210 through the incoming venturi pump conduit 420 at a T-junction through the incoming venturi pump conduit valve 430. The incoming venturi pump conduit valve 430 can be of conventional design and can be an on / off valve such as a solenoid valve.

[0022] The vacuum jet venturi pump 410 may also be in communication with the skid discharge device 440 via a discharge conduit 450 and a discharge valve 460. The skid discharge device 440 may have any convenient size, shape, or configuration. The discharge valve 460 may be of conventional design and may be an on / off valve such as a solenoid valve. Other components and other configurations may also be used herein.

[0023] As described above, the operation of the spray intercooler and water wash system 100 can be managed by the controller 280. Typically, the controller 280 is a conventional microprocessor-based system. The controller 280 may include a memory, an input / output (I / O) interface, an external I / O device / resource, and an external storage system. Typically, the controller 280 executes a computer program code, which may be stored in a memory and / or storage system. The controller 280 is only an example of various possible combinations of hardware and software that may be used herein.

[0024] When in use, the controller 280 directs the pump 260 / pump motor 270 to operate in the spray intercooler mode or the water wash mode. As described above, the piston-driven pump 260 is controlled by the variable frequency drive 275 to provide the required flow rate in the high flow, medium flow and low flow range for the spray intercooler mode. The variable frequency drive 275 also meets the main frequency requirements of the spray intercooler that requires variable flow to maintain frequency stability in a short time. The size of the spray nozzle 120 can be set to provide the required droplet size for the two modes, which means providing larger droplets for water washing and smaller droplets for the spray intercooler. The corresponding droplet size of the spray intercooler mode can be described by the Sauter mean diameter (SMD). The droplet size can be varied and can be increased by reducing the pressure of the back pressure regulator 290 of the water wash mode as needed. Similarly, the pump 260 can provide the required flow rate for the two modes. For example, for water washing, the flow rate can be less than about 8gpm, and for the spray intercooler, the flow rate can be about 9gpm to 22gpm. The flow rate can vary. These ranges also ensure that pump 260 operates within safe pressure and flow ranges.

[0025] In either mode, the controller instructs the pump 260 / pump motor 270 to pump at the desired pressure and flow rate. Specifically, a volume of water 200 from the water supply device 190 on the water supply skid 150 is pumped through the skid conduit 210 to the manifold conduit 160 to the water manifold 110. Then, a volume of water 200 flows through the nozzle conduit 140 to the spray nozzle 120, where the water is sprayed into the inlet 130 of the compressor 15.

[0026] Specifically, when the spray intercooler mode is completed, it is important not to inject excess water into the compressor 15. Therefore, the controller 280 turns off the pump 260 / pump motor 270, closes the water outlet valve 340, and opens the purge air valve 370 on the purge air source 350. Likewise, the incoming venturi pump conduit valve 430 on the incoming venturi pump conduit 420 of the drain system 400 is opened. Thus, the purge air flow creates suction in the vacuum jet venturi pump 410. This suction pushes any water remaining in the manifold conduit 160 and the water manifold 110 into the vacuum jet venturi pump 410 and into the skid drain 440.

[0027] Thus, the spray intercooler and water wash system 100 uses a single water manifold 110 and a single set of spray nozzles 120 for both the spray intercooler mode and the water wash mode. Specifically, the variable frequency drive 275 allows the pump 260 / pump motor 270 to provide the required droplet size and flow rate for either mode. Thus, the spray intercooler and water wash system 100 provides a simplified system that reduces overall cost by merging corresponding systems. Notably, the spray intercooler mode does not require air to be extracted from the compressor 15 as in conventional systems. Therefore, eliminating air extraction improves the overall efficiency of the gas turbine engine.

[0028] It will be apparent that the foregoing relates only to certain embodiments of the present application and the resultant patent. Numerous changes and modifications may be made herein by one of ordinary skill in the art without departing from the general spirit and scope of the invention as defined by the appended claims and their equivalents.

[0029] Further aspects of the invention are provided by the subject matter of the following clauses:

[0030] 1. A spray intercooler and water wash system for spraying a volume of water into a compressor of a gas turbine engine, the spray intercooler and water wash system comprising: a plurality of spray nozzles positioned around the compressor; a water manifold in communication with the plurality of spray nozzles; a pump in communication with the water manifold; and a variable frequency drive in communication with the pump.

[0031] 2. A spray intercooler and water wash system according to any preceding clause, wherein the plurality of spray nozzles comprises more than 10 spray nozzles.

[0032] 3. A spray intercooler and water wash system according to any preceding clause, further comprising a water supply skid in communication with the water manifold.

[0033] 4. A spray intercooler and water wash system according to any preceding clause, wherein the water supply skid comprises a water supply device having a volume of water therein.

[0034] 5. A spray intercooler and water wash system according to any preceding clause, wherein the water supply skid comprises a filter on the water supply skid.

[0035] 6. A spray intercooler and water wash system according to any preceding clause, wherein the water supply skid comprises a pressure sensor on the water supply skid.

[0036] 7. A spray intercooler and water wash system according to any preceding clause, wherein the water supply skid comprises a temperature sensor on the water supply skid.

[0037] 8. A spray intercooler and water wash system according to any preceding clause, wherein the water supply skid comprises a flow meter on the water supply skid.

[0038] 9. A spray intercooler and water wash system according to any preceding clause, wherein the pump is positioned on the water supply skid.

[0039] 10. A spray intercooler and water wash system according to any preceding clause, wherein the pump comprises a piston pump.

[0040] 11. A spray intercooler and water wash system according to any preceding clause, further comprising a pump motor in communication with the pump and the variable frequency drive.

[0041] 12. A spray intercooler and water wash system according to any preceding clause, further comprising a drainage system.

[0042] 13. A spray intercooler and water wash system according to any preceding clause, wherein the drainage system comprises a vacuum ejector pump.

[0043] 14. A spray intercooler and water wash system according to any preceding clause, wherein the drainage system comprises a purge air source in communication with the vacuum ejector pump.

[0044] 15. A method for operating a spray intercooler and a water wash system to spray a volume of water into the inlet of a compressor, the method comprising: instructing a pump to pump a volume of water at a first flow rate; spraying the volume of water into the inlet of the compressor at the first flow rate to produce droplets of a first size; instructing the pump to pump the volume of water at a second flow rate; and spraying the volume of water into the inlet of the compressor at the second flow rate to produce droplets of a second size.

[0045] 16. A spray intercooler and water wash system, which is used to spray a certain volume of water into a compressor of a gas turbine engine, and the spray intercooler and water wash system includes: a plurality of spray nozzles, which are positioned to surround the compressor; a water manifold, which is connected to the plurality of spray nozzles; a piston pump, which is driven by a pump motor connected to the water manifold; and a variable frequency drive, which is connected to the piston pump and the pump motor.

[0046] 17. A spray intercooler and water wash system according to any preceding clause, further comprising a water supply skid in communication with the water manifold.

[0047] 18. A spray intercooler and water wash system according to any preceding clause, wherein the water supply skid comprises a water supply having a volume of water therein, a filter, a pressure sensor, a temperature sensor and a flow meter.

[0048] 19. A spray intercooler and water wash system according to any preceding clause, further comprising a drainage system.

[0049] 20. A spray intercooler and water wash system according to any preceding clause, wherein the drainage system comprises a vacuum ejector pump in communication with a source of clean air.

Claims

1. A spray intercooler and water wash system (100), the spray intercooler and water wash system being used to spray a certain volume of water (200) into a compressor (15) of a gas turbine engine (10), the spray intercooler and water wash system comprising: a plurality of spray nozzles (120) positioned around the compressor (15); a water manifold (110), the water manifold being in communication with the plurality of spray nozzles (120); a pump (260) in communication with the water manifold (110); and A variable frequency drive (275) is in communication with the pump (260).

2. The spray intercooler and water wash system (100) of claim 1, wherein the plurality of spray nozzles (120) comprises more than 10 spray nozzles (120).

3. The spray intercooler and water wash system (100) according to claim 1, further comprising a water supply skid (150), wherein the water supply skid is in communication with the water manifold (110).

4. The spray intercooler and water wash system (100) according to claim 3, wherein the water supply skid (150) comprises a water supply device (190), wherein the water supply device has the certain volume of water (200).

5. The spray intercooler and water wash system (100) of claim 3, wherein the water supply skid (140) includes a filter (230, 320) on the water supply skid.

6. The spray intercooler and water wash system (100) of claim 3, wherein the water supply skid (150) includes a pressure sensor (240, 300, 330) on the water supply skid.

7. The spray intercooler and water wash system (100) of claim 3, wherein the water supply skid (150) includes a temperature sensor (250) on the water supply skid.

8. The spray intercooler and water wash system (100) of claim 3, wherein the water supply skid (150) includes a flow meter (310) on the water supply skid.

9. The spray intercooler and water wash system (100) of claim 3, wherein the pump (260) is positioned on the water supply skid (150).

10. The spray intercooler and water wash system (100) of claim 1, wherein the pump (260) comprises a piston pump (260).

11. The spray intercooler and water wash system (100) according to claim 1, further comprising a pump motor (270), wherein the pump motor is in communication with the pump (260) and the variable frequency drive (275).

12. The spray intercooler and water wash system (100) according to claim 1, further comprising a drainage system (400).

13. The spray intercooler and water wash system (100) of claim 12, wherein the drainage system (400) comprises a vacuum ejector pump (410).

14. The spray intercooler and water wash system (100) according to claim 13, wherein the drainage system (400) comprises a purified air source (300), and the purified air source is connected to the vacuum ejector pump (410).

15. A method of operating a spray intercooler and water wash system (100) to spray a volume of water (200) into an inlet (130) of a compressor (15), the method comprising: instructing the pump (260) to pump the volume of water (200) at a first flow rate; injecting the volume of water (200) into the inlet (130) of the compressor (15) at the first flow rate to produce droplets of a first size; instructing the pump (260) to pump the volume of water (200) at a second flow rate; and The volume of water (200) is injected into the inlet (130) of the compressor (15) at the second flow rate to produce droplets of a second size.

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