Method for heating the working fluid of a gas turbine engine and compressor.

Abstract

An integrated system for use with a turbine, the integrated system comprising an inlet extraction heat (IBH) system, an exhaust gas recirculation (EGR) system, and a controller.

Description

Technical Field

[0001] The field of the present disclosure generally relates to turbine engine assemblies, and more particularly to methods and systems for heating compressor inlet air to facilitate improvement of gas turbine engine efficiency.

Background Art

[0002] Gas turbines are widely used in various commercial operations such as power generation operations. Known gas turbines generally include a compressor, one or more combustors, and a turbine. Conventionally, the compressor compresses a working fluid, such as air, and discharges the compressed working fluid to the combustor. Fuel is injected into the flow of the compressed working fluid, and the mixture is ignited to produce combustion gases having a relatively high temperature, pressure, and velocity. The combustion gases exit the combustor and flow to the turbine, where they expand to produce work that can be converted into electrical and / or mechanical power.

[0003] The working fluid entering the inlet of the compressor, such as the inlet transition duct or the filter housing, may be heated, for example, to prevent icing when operating in a low-temperature environment. Heating the inlet working fluid can also improve the part or part-load efficiency of the gas turbine. In some gas turbines, the compressed working fluid is extracted from an extraction location near the outlet of the compressor and can be recirculated to heat the inlet working fluid using a system conventionally called an inlet bleed heat system. However, known inlet bleed heat systems reduce the overall operating efficiency of the associated gas turbine engine because at least a portion of the compressed working fluid that should have been sent to perform work in the turbine is extracted and recirculated to the inlet.

[0004] Therefore, there is a need for systems and methods that more efficiently heat the inlet working fluid before it enters the compressor inlet to facilitate reducing the overall loss of turbine efficiency.

Prior Art Documents

Patent Documents

[0005] [Patent Document 1] U.S. Patent Application Publication No. 2018 / 0156136 [Overview of the project]

[0006] In one embodiment, an integrated system for use with a turbine is provided. The integrated system includes an EGR system, which includes an EGR flow control device for directing a flow extracted from the turbine exhaust to an exhaust gas recirculation (EGR) return position upstream of the compressor inlet, and an IBH system, which includes an IBH flow control device for directing a flow extracted downstream of the compressor outlet to an inlet extraction heat (IBH) return position upstream of the compressor inlet. The system further includes a controller communicatively coupled to the EGR flow control device and the IBH flow control device, the controller variably adjusting the relative flow rates of the EGR system and the IBH system.

[0007] In another embodiment, a power generation system is provided. The power generation system includes a compressor for compressing a working fluid, a combustor, and an integrated system. The integrated system includes an EGR system, which includes an EGR flow control device for directing a flow extracted from turbine exhaust to an exhaust gas recirculation (EGR) return position upstream of the compressor inlet, and an IBH system, which includes an IBH flow control device for directing a flow extracted downstream of the compressor outlet to an inlet extraction heat (IBH) return position upstream of the compressor inlet. The system further includes a controller communicatively coupled to the EGR flow control device and the IBH flow control device, the controller variably adjusting the relative flow rates of the EGR system and the IBH system.

[0008] In yet another embodiment, a method is provided for using an integrated system for a gas turbine engine. This method includes receiving sensor data from a plurality of sensors coupled at various locations within the integrated system, determining current operating conditions based on the received sensor data, and adjusting at least one of the flow parameters of the EGR system and the IBH system to facilitate improvement of the operating efficiency of the gas turbine engine.

[0009] These and other features, aspects and advantages of this disclosure will be better understood by reading the following detailed description with reference to the accompanying drawings, where similar reference numerals in the accompanying drawings represent similar parts throughout the drawings. [Brief explanation of the drawing]

[0010] [Figure 1] This is a schematic diagram of an exemplary power generation system, including a gas turbine engine and an integrated efficiency (IE) system. [Figure 2] For example, this is a schematic diagram of an exemplary integrated efficiency system that includes an inlet extraction heat (IBH) system that can be used with the power generation system shown in Figure 1. [Figure 3] For example, it can be used in conjunction with the power generation system shown in Figure 1, and is a schematic diagram of another exemplary integrated efficiency system including an IBH system and an exhaust gas recirculation (EGR) system. [Figure 4] This is a block diagram of an exemplary control system that can be used with the IE system shown in Figures 1 to 3. [Figure 5] For example, this is a first perspective view of an exemplary filter that can be used with the IE system shown in Figures 1 to 3. [Figure 6] Figure 5 shows a second perspective view of the filter. [Figure 7] Figure 5 shows a cross-sectional view of the filter. [Figure 8] Figures 1-3 show a perspective view of an exemplary IBH manifold that can be used with the IE system. [Figure 9]Figure 8 shows a detailed view of the IBH manifold. [Figure 10] Figures 1-3 show an exemplary front perspective view of an EGR manifold that can be used with the IE system. [Figure 11] Figure 10 is a rear perspective view of an exemplary EGR manifold. [Figure 12] Figure 10 is a rear view of an exemplary EGR manifold. [Figure 13] For example, Figures 1 to 3 are process flow diagrams illustrating an exemplary method for controlling the IE system. [Modes for carrying out the invention]

[0011] Unless otherwise indicated, the drawings provided herein are intended to illustrate features of embodiments of the disclosure. These features are considered applicable to a wide variety of systems comprising one or more embodiments of the disclosure. Accordingly, the drawings are not intended to include all prior features known to those skilled in the art that are necessary for the practice of embodiments disclosed herein.

[0012] In the following specification and claims, certain terms are used with the following meanings: The singular forms “a, an” and “the” include plural references unless the context specifically indicates otherwise. “Optional” or “optionally” means that the event or situation described thereafter may or may not occur, and that the description includes both cases in which the event occurs and cases in which it does not. Furthermore, a reference to “one embodiment” is not intended to be construed as excluding the existence of additional embodiments that also incorporate the enumerated features. Furthermore, unless explicitly stated otherwise, an embodiment that “includes” or “has” one or more elements having a particular characteristic may include additional such elements that do not possess that characteristic.

[0013] As used herein, the term “real time” refers to the time when the relevant events occur, the time when the specified data is measured and collected, the time when the data is processed, or the time when the system responds to the events and the environment. In the embodiments described herein, these activities and events occur substantially simultaneously.

[0014] In the exemplary embodiments described herein, the power generation system includes an integrated efficiency (IE) system used with a gas turbine engine. In some embodiments, the IE system includes an inlet extraction heat (IBH) system and an exhaust gas recirculation (EGR) system. In at least some of the embodiments described herein, the IE system returns the working fluid and / or exhaust gas to one or more locations upstream of the compressor section, for example, an inlet transition duct that leads the working fluid to the compressor. In exemplary embodiments, the IBH system draws in the working fluid from an extraction position near the compressor outlet and returns the compressed working fluid to a location upstream of the compressor inlet, and the EGR system draws in the exhaust gas leaving the turbine outlet and returns the exhaust gas to a location upstream of the compressor inlet. In the embodiments described herein, the IE system heats the inlet working fluid before it enters the compressor inlet, thus improving the partial load efficiency of the gas turbine or the turbine efficiency under operating conditions other than its full load design point, while simultaneously preventing freezing and / or compressor surges. The power generation system may include a gas turbine simple cycle, cogeneration, or combined cycle.

[0015] In some embodiments, the IE system includes a controller that adjusts flow parameters of the fluid of the EGR and IBH systems, such as the amount of exhaust gas or compressed air, that enable achieving the mass flow rate, relative mass flow rate, and / or desired operating conditions of the gas turbine engine. In some embodiments, the controller is communicatively coupled to one or more sensors and can selectively adjust the flow parameters in real time or periodically based on the received sensor data and the target operating conditions. In some embodiments, the controller can determine one or more parameters, such as temperature, and selectively adjust the flow parameters based on the determined parameters. Since the EGR system and the IBH system can be used in combination, the IBH system is more compact, has a smaller physical footprint, can draw in a smaller amount of compressed fluid, and thus can facilitate improving the efficiency of the power generation system 100. In some embodiments, the IBH system may be used only to prevent compressor surge, complement the EGR system, and / or function as a backup when heating of the inlet air is mainly achieved by the EGR system. In some embodiments, the controller can selectively turn on / off the IBH system to prevent compressor surge, while the EGR is operated continuously to heat the inlet air.

[0016] In some embodiments, the IE system prevents icing by heating one or more components of the gas turbine system and / or heating the inlet working fluid before the heated working fluid enters the compressor. The IE system can return the compressed working fluid by the IBH system and / or return the exhaust gas by the EGR system to heat the inlet working fluid upstream of the inlet transition duct and / or the compressor. In particular, the exhaust gas and / or the extracted compressed air can have a temperature higher than the temperature of the drawn-in inlet air.

[0017] In some embodiments, the IE system facilitates the reduction of emissions from the gas turbine engine. More specifically, in some embodiments, the EGR system draws exhaust from the turbine outlet and returns it to a location upstream of the compressor inlet, thus controlling the release of emissions from the gas turbine engine.

[0018] In some embodiments, the IE system also facilitates reducing the likelihood of compressor surge. Compressor surge can refer to operating conditions where the air flow within the compressor becomes unstable and / or turbulent, causing undesirable vibrations and noise. In some embodiments, the IE system includes an IBH system that draws in compressed working fluid exiting the compressor extraction location and returns the compressed working fluid upstream of the compressor inlet. Since the compressed working fluid is drawn out from the compressor extraction location, the load at the front end of the compressor is reduced, and thus the likelihood of compressor surge is substantially reduced.

[0019] In some embodiments, the IE system improves part - load efficiency, compressor efficiency, and / or turbine efficiency by preheating the inlet working fluid. Heating the working fluid allows the gas turbine to remain under premixed operating conditions, while maintaining a higher ignition temperature, compressor and combustor stability, and emissions compliance, and while reducing current IBH extraction flow requirements, fuel is mixed with the compressed working fluid prior to combustion over a larger load range. The reduction in IBH extraction facilitates a reduction in fuel consumption for the same work / power output of the gas turbine engine, thus improving part - load efficiency. Additionally, inlet heating raises the compressor discharge temperature and the gas turbine exhaust temperature, thus increasing the efficiency of the bottoming cycle and, as follows, the output and efficiency of the combined cycle.

[0020] In some embodiments, the IE system facilitates the reduction of acoustic noise levels and thus enables the meeting of plant acoustic requirements. In some embodiments, the IE system reduces the amount of noise by silencers and / or acoustic nozzles on the IBH manifold.

[0021] In some embodiments, the IE system includes one or more sensors that detect one or more operating conditions of a gas turbine engine, an IBH system, and / or an EGR system. The sensors may include, but are not limited to, temperature sensors, pressure sensors, flow sensors, and / or exhaust sensors. In some embodiments, the IE system can use data obtained from the sensors to detect surge events, potential surge events, and / or early stages of surge events. For example, a sensor may detect airflow and / or pressure at and / or near a compressor, e.g., the compressor outlet, and the detected changes may be indicators of a surge event. In some embodiments, the controller may determine surge conditions using, for example, a compressor map including a surge line, by any suitable method. In some embodiments, the IE system can use data provided by such sensors to detect freezing events. For example, in some embodiments, one or more sensors may be arranged to detect inlet temperature, working fluid temperature, and / or ambient temperature, humidity or relative humidity outside the gas turbine engine, e.g., and / or any other temperature readings upstream of the compressor inlet. In some embodiments, the IE system can utilize data obtained from the sensors to detect emissions from the power generation system.

[0022] In some embodiments, the IE system can determine one or more operating conditions of a gas turbine engine, IBH system, and / or EGR system without using, for example, a controller, to directly measure them using, for example, sensors. For example, the controller can calculate or retrieve one or more values ​​of pressure, temperature, flow rate, and / or emissions at one or more locations in the IE system and / or gas turbine engine.

[0023] In exemplary embodiments, the controller is coupled to the IBH system and the EGR system, enabling selective control of the operation or relative operation of the IBH system and / or the EGR system. The controller may also be coupled to one or more sensors. In some embodiments, the controller can selectively control flow parameters such as the flow rate of the working fluid delivered through the IBH system and / or the exhaust gas flow parameters delivered through the EGR system (e.g., by controlling the position of a control valve) to achieve desired operating conditions while improving operational efficiency. In some embodiments, the controller can selectively adjust one or more parameters of the IE system, such as parameters of the IBH system and / or parameters of the EGR system, using data received from sensors and / or data determined by the controller. For example, in some embodiments, the controller can predict possible surge events, the amount of time until freezing events, and / or the amount of time until emission levels exceed a predetermined operating threshold.

[0024] Referring here to the drawings, Figure 1 is a schematic diagram of an exemplary power generation or mechanical drive system 100, which includes a turbine engine 110 and an integrated efficiency (IE) system 200 including an exhaust gas recovery (EGR) system 202 and an inlet extraction heat (IBH) system 204. Although exemplary embodiments are shown in relation to a gas turbine engine, the present invention is not limited to any particular engine, and those skilled in the art will understand that the present invention may be used in relation to other turbine engines. As used herein, the terms “turbine,” “turbine assembly,” and “turbine engine” shall be used interchangeably.

[0025] The IE system 200 may include a controller 206 coupled to the EGR system 202 and the IBH system 204. The controller 206 can control the flow of working fluid moving through the IBH system 204 and / or the flow of exhaust gas moving through the EGR system 202, as described in detail herein. The IE system 200 may further include at least one sensor 208 that detects one or more parameters or operating conditions of the IE system 200 and / or the gas turbine engine 110. The controller 206 may be integrated into a controller associated with the gas turbine engine 110. Additionally and / or alternatively, the controller 206 may be separate from the controller associated with the gas turbine engine 110.

[0026] In an exemplary embodiment, the turbine engine 110 includes an intake section 112, a compressor section 114 coupled downstream of the intake section 112, a combustor section 116 coupled downstream of the compressor section 114, a turbine section 118 coupled downstream of the combustor section 116, and an exhaust section 120. The turbine section 118 is coupled to the compressor section 114 via a rotor shaft 122. The combustor section 116 may include a plurality of combustors (not shown). The combustor section 116 is coupled to the compressor section 114 in flow communication.

[0027] The fuel injectors 124 are coupled to the combustor section 116. In some embodiments, the turbine engine 110 includes one or more manifolds 126, each containing a plurality of fuel injectors 124. The turbine section 118 is coupled to the compressor section 114 and to a load 128, such as a generator and / or mechanical drive application, but is not limited. In exemplary embodiments, each of the compressor section 114 and the turbine section 118 includes at least one rotor disc assembly 130, which is coupled to the rotor shaft 122 to form a rotor assembly 132.

[0028] During operation, the intake section 112 directs air toward the compressor inlet 134 of the compressor section 114, where the air is compressed to a higher pressure and temperature. The pressurized air is then mixed with fuel, and the resulting mixture is discharged toward the combustor section 116. More specifically, the compressed air is mixed with the fuel mixture, ignited to produce combustion gases, which are directed toward the turbine section 118. The turbine section 118 converts the thermal energy from the gas stream into mechanical rotational energy so that the combustion gases impart rotational energy to the turbine section 118 and the rotor assembly 132.

[0029] In some embodiments, the fuel source 150 may be a variable fuel source that delivers various types and / or mixtures of fuels. The fuel source 150 can store and / or supply, for example, natural gas, liquefied petroleum gas (LPG) blends, methane, hydrogen, hydrogen / natural gas blends, fuel oil, coke oven gas, refinery gas, and any suitable gas fuel or gas fuel mixture. The fuels supplied and / or stored by the fuel source can be variably selected based on the operating conditions and / or availability of one or more fuel sources.

[0030] The turbine engine 110 may include one or more conduits, pipes, ducts, and / or tubes, commonly referred to herein as conduits 140, used to transfer fuel between its components. The fuel may be propelled using gravity to move through the conduits 140 from upstream components to downstream components. Alternatively and / or additionally, the fuel may be pressurized through the conduits 140 using, for example, a compressor or pump or blower 142.

[0031] In some embodiments, the gas turbine engine 110 includes a variable inlet guide vane assembly 148 located upstream of the compressor inlet 134. In such embodiments, the controller 206 can selectively adjust the angles of one or more vanes of the variable inlet guide vane assembly 148 to adjust the mass flow rate and / or to change the amount of working fluid entering the compressor section 114. For example, the gas turbine engine 110 can be facilitated to reduce the amount of working fluid delivered to the compressor section 114 by adjusting the inlet guide vane assembly 148 so that a desired ratio of working fluid to fuel is maintained, for example, during component loading operating conditions. In some embodiments, the controller 206 can selectively adjust both the temperature of the inlet guide vane assembly 148 and the working fluid delivered to the compressor section 114 by selectively controlling the IBH and EGR systems to control the amount of working fluid delivered to the compressor section 114.

[0032] As described above, the IE system 200 controls the temperature of the working fluid upstream of the compressor section 114. An increase in the inlet working temperature reduces the density of the working fluid, thereby reducing the mass of working fluid entering the compressor section 114. The controller 206 can determine the amount of heat, such as thermal energy, that needs to be supplied to the upstream working fluid to ensure precise heating of the working fluid and the necessary reduction in the density of the working fluid, in order to adjust the amount of working fluid delivered to the compressor section 114. The controller 206 can control the mass flow rate of the working fluid entering the compressor section 114 by adjusting both the variable inlet guide vane assembly 148 and the IE system 200. For example, the controller 206 can set the variable inlet guide vane assembly 148 to the fully open or maximum open position, and the controller can use the IE system 200 to adjust the amount of working fluid delivered to the compressor section 114. For example, the controller 206 can use the EGR system 202 to increase the amount of exhaust gas delivered upstream from the compressor inlet 134, heat the inlet working fluid, decrease the density of the working fluid, and therefore reduce the amount of working fluid delivered to the compressor section 114.

[0033] In exemplary embodiments, the IBH system 204 draws in compressed working fluid downstream of the compressor outlet 136 and reintroduces the compressed working fluid to a position upstream of the compressor inlet 134. The drawn-in compressed working fluid may be propelled to move through the IBH system 204 by the pressure difference of the drawn-in working fluid. For example, the working fluid in the IBH system 204 drawn from the compressor section 114 may have a higher pressure compared to the working fluid and / or air upstream of the compressor inlet 134. In some alternative embodiments, the drawn-in compressed working fluid may be propelled via a flow propulsion device. In some embodiments, the IBH system 204 includes one or more flow control devices 144, such as valves, to control the flow of the compressed working fluid. The IBH system 204 may also include a conduit leading compressed air from the compressor outlet 136 to a position upstream of the compressor inlet 134. The IBH system 204 is shown and described in more detail with respect to Figures 2 and 3.

[0034] In exemplary embodiments, the EGR system 202 draws in exhaust gases exiting the turbine section 118 and reintroduces them upstream of the compressor inlet 134. In some embodiments, the EGR system 202 may include one or more flow propulsion devices to propel the exhaust gas flow through the EGR system 202 from the combustor outlet to the upstream reintroduction location. In some embodiments, the pressure of the drawn-in exhaust gases may be lower than the pressure of the working fluid upstream of the compressor inlet 134. In some embodiments, the temperature of the drawn-in exhaust gases is higher than the temperature of the working fluid and / or the temperature of the air upstream of the compressor inlet 134. The EGR system 202 may include one or more conduits that guide the exhaust flow from the combustor outlet toward the upstream location of the compressor inlet 134. The EGR system 202 is shown and described in more detail with respect to Figures 2 and 3.

[0035] In exemplary embodiments, the IE system 200 can operate in any of several operating modes, enabling the IE system 200 to achieve one or more desired operating conditions, including, but not limited to, de-icing, surge protection, and / or emission compliance, while improving the efficiency of the power generation system 100 or gas turbine engine 110. The controller 206 can variably select the operating mode based on the target operating conditions. At least one operating mode is an EGR mode in which the controller 206 causes the IE system 200 to utilize the EGR system 202, during which the IBH system 204 is in an unenergized and / or standby mode. At least one other operating mode includes an EGR-dominant mode, in which the IE system 200 supplies more exhaust gas through the EGR system 202 in a greater volume or greater mass flow compared to the volume or mass flow of compressed working fluid drawn in at the extraction position downstream of the compressor outlet 136, passing through the IBH system 204.

[0036] As used herein, the terms “processor” and “computer,” as well as related terms such as “processing device,” “computing device,” and “controller,” are not limited to those integrated circuits that are called computers in the prior art, but rather broadly refer to microcontrollers, microcomputers, programmable logic controllers (PLCs), application-specific integrated circuits, and / or other programmable circuits, and such terms are used interchangeably herein. In the embodiments described herein, memory may include, but is not limited to, computer-readable media such as random access memory (RAM) and computer-readable non-volatile media such as flash memory. Alternatively, floppy disks, compact disc read-only memory (CD-ROM), magneto-optical disks (MOD), and / or digital multi-purpose disks (DVDs) may also be used. In addition, in the embodiments described herein, additional input channels may include, but is not limited to, computer peripherals related to an operator interface, such as a mouse and keyboard. Alternatively, other computer peripherals such as a scanner or touchscreen may also be used. Furthermore, in the embodiments described herein, additional output channels may include, but is not limited to, an operator interface monitor.

[0037] Figure 2 is a schematic diagram of an exemplary embodiment of an IBH system 204 that can be used with the IE system 200 shown in Figure 1. Figure 3 is a schematic diagram of the IE system 200, which includes both the IBH system 204 and the EGR system 202. In exemplary embodiments, the IE system 200 may include a filter 210, a silencer 212, and / or an IBH manifold 214. The filter 210, the silencer 212, and / or the IBH manifold 214 may be located within an internal passage 216 defined by an inlet transition duct 218. The inlet transition duct 218 may be coupled in flow communication with the compressor inlet 134 so that the inlet transition duct 218 guides inlet working fluid, air, and / or exhaust gases toward the compressor inlet 134. In some embodiments, the inlet transition duct 218 may incorporate at least a portion of the intake section 112 that draws inlet fluid 220 into the compressor section 114. The duct 218 can have any suitable shape or size that allows the IE system to function as described herein. In some embodiments, the IBH manifold 214 can extend across, for example, the entire internal passage 216 defined by the duct 218. The inlet transition duct 218 can include a transition duct that connects the inlet filter house duct to the compressor inlet, for example, the transition duct can connect two duct portions having different cross-sectional areas to each other. The filter 210 can include one or more filter elements 222. The filter 210, silencer 212, and / or IBH manifold 214 may be located upstream of the compressor inlet 134. In some embodiments, the silencer 212 is located downstream of the filter 210 and upstream of the compressor inlet 134. The IBH manifold 214 distributes the fluid used in the IBH system 204. In some embodiments, the IE system 200 includes an EGR manifold 224 for distributing exhaust gas upstream of the compressor inlet 134.

[0038] The sensors 208 of the IE system 200 may include, for example, temperature sensors, pressure sensors, flow sensors, relative humidity sensors, and / or emission sensors. The sensors 208 can be placed at various suitable locations inside or near the IE system 200 and / or the power generation system 100. In some embodiments, the IE system 200 can use data supplied from at least one of the sensors 208, or data determined by the controller 206, to detect surge events, potential surge events, and / or their initial stages. For example, the IE system 200 can detect a surge event by detecting or determining changes in airflow and / or pressure on and / or near the compressor and / or near the compressor outlet 136. In some embodiments, the controller 206 can determine surge conditions using, for example, a compressor map including surge lines, by any suitable method. In some embodiments, the IE system 200 can use one or more sensors 208 to detect current emission levels or determine emission performance or compliance.

[0039] In some embodiments, at least one sensor 208 may be configured to detect ambient temperature or humidity, for example, the temperature outside the gas turbine engine 110, and / or the temperature upstream of the compressor inlet 134. In some embodiments, the sensor 208 and / or the controller 206 may detect freezing conditions. For example, freezing conditions may be detected based on the temperature sensor 208 detecting a predetermined temperature upstream of the compressor inlet 134, and the controller 206 may receive the temperature data for processing. In such an example, the controller 206 may compare the temperature data with one or more temperature thresholds to determine whether a freezing event is likely to occur or has occurred.

[0040] Referring further to Figures 2 and 3, the IBH system 204 draws compressed working fluid from an extraction position near or downstream of the compressor outlet 136 and returns the drawn-in compressed fluid to a position upstream of the compressor inlet 134. The IBH system 204 includes a position 250 from which the compressed working fluid is extracted from the gas turbine engine 110. In some embodiments, the extraction position 250 is downstream of the compressor outlet 136 and upstream of the combustor section 116. In some embodiments, the extraction position 250 is at or near the compressor outlet 136. The drawn-in working fluid extracted from the compressor section 114 may have a higher pressure than the inlet fluid 220 upstream of the compressor inlet 134. In some embodiments, the drawn-in working fluid is extracted from any suitable extraction position near the compressor section 114 or directly from the compressor section 114.

[0041] The IBH system 204 includes a conduit 252, such as a duct or pipe, used to transfer the extracted compressed working fluid to a return position 254. The IBH system 204 may include one or more flow control devices 144 to provide enhanced control of the flow of working fluid through the IBH system 204. In an exemplary embodiment, the IBH system 204 includes a first flow control device 258 and a second flow control device 260. More specifically, in an exemplary embodiment, the first flow control device 258 is a manual valve that can be selectively adjusted to prevent or control the flow of drawn working fluid moving through the IBH system 204, and the second flow control device 260 may be an automatic control valve that is selectively adjusted by a controller 206.

[0042] The IBH system 204 shown in Figure 2 includes three different potential return positions 254 that can be used with the IBH system 204 and / or the IE system 200. More specifically, in exemplary embodiments, the IBH system 204 includes a first return position 262 and / or a second return position 264. The first return position 262 is located downstream of the silencer 212. The second return position 264 is located upstream of the silencer 212 and downstream of the filter 210. Alternatively, the return position 254 may be any other suitable location upstream of the compressor inlet 134 that enables the IBH system 204 to function as described herein.

[0043] The IBH system 204 can return compressed working fluid to the duct via the IBH manifold 214 such that the returned working fluid is combined with the existing working fluid contained in the duct, increasing the pressure and temperature of the existing working fluid, respectively. In particular, the drawn-in compressed working fluid extracted from position 250 has a higher pressure and temperature than the working fluid and / or inlet fluid 220 contained in the internal passage 216, respectively.

[0044] The EGR system 202 extracts exhaust gases downstream of the turbine outlet 138. The EGR system 202 includes a return position 280 upstream of the compressor inlet 134. The EGR system 202 includes a conduit 282, such as a duct or pipe, for transporting the extracted exhaust gases to the return position 280, and also includes a flow control device 146 (variable or fixed-speed controlled) which includes one or more flow control devices, such as, but not limited to, blowers, ejectors, and compressors coupled in parallel or in series. In alternative embodiments, the EGR system 202 may include one or more flow control devices, such as valves or regulators, which are not shown.

[0045] The IE system 200 shown in Figure 3 includes an IBH system 204 having a return position upstream of the silencer 212, and the return position of the IBH system 204 is downstream of the return position used by the EGR system 202. In other embodiments, the relative return positions of the IBH system and the EGR system 202 may be any suitable position and orientation relative to each other that enables the IE system 200 to function as described herein. For example, the IBH system 204 may include either the return position 264 or 262 shown in Figure 2. Additionally and / or alternatively, the IBH system 204 and / or the EGR system 202 may each include one or more return positions located in any other suitable positions that enable the IE system 200 to function as described herein.

[0046] In some embodiments, the EGR system 202 includes a flow control damper 270, for example, located upstream of the flow control device 146, to enhance control of the exhaust gas flow through the conduit 282. In some embodiments, the EGR system 202 may include a variable speed drive or any other suitable flow control device. The EGR system 202 may include a shut-off valve 272 for closing or stopping the exhaust gas flow through the conduit 282. The EGR system 202 may also include an EGR injection manifold 224. See Figures 10-12. In some embodiments, the EGR manifold 224 used with the EGR system and the IBH manifold 214 used with the IBH system 204 have two different configurations suitable for the respective pressures and temperatures of the IBH system 204 and the EGR system 202.

[0047] In some embodiments, an auxiliary working fluid 274, such as air, may be selectively added to the EGR system 202 to control the temperature or pressure of the exhaust gas returned to the inlet duct 218. For example, in some embodiments, the IE system 200 includes one or more flow control devices 276 for controlling the introduction of the auxiliary working fluid 274 into the exhaust gas encompassed within the EGR system 202, for example, in a conduit 282. The auxiliary working fluid 274 may be introduced into the EGR system 202 downstream of the flow control device 146 and / or valve 272, and upstream of the return position 280. A controller 206 is communicatively connected to the flow control device 276 and can selectively control the amount of auxiliary working fluid 274 added to the EGR system 202. The controller 206 can selectively adjust the amount of auxiliary working fluid 274 added to the EGR system 202 to selectively control the temperature of the exhaust gas introduced to position 280, thereby controlling the amount of thermal energy supplied to the inlet working fluid entering the compressor section 114.

[0048] Figure 4 is a block diagram of an exemplary controller 206 that can be used with system 200. The controller 206 includes a processor 402 and memory 404. The controller 206 is communicatively coupled to sensor 208 to receive data from sensor 208 in real time or at predetermined time intervals. In some embodiments, the controller 206 can determine data, such as pressure, temperature, and / or flow rate. The controller 206 can use the received sensor data to determine conditions of the power generation system 100. For example, the controller 206 can determine whether freezing conditions, surge conditions, and / or discharge conditions are present or likely to be present. In some embodiments, the controller 206 can determine temperature conditions, such as a threshold temperature required to maintain the inlet temperature, such as an operating temperature required to prevent freezing or improve partial load efficiency.

[0049] Controller 206 is communicatively coupled to the EGR system 202 and the IBH system 204 to control the amount of fluid moving through each system. Controller 206 can transmit one or more signals to the flow control device 146 to control the flow of exhaust gas through the EGR system 202. Controller 206 can transmit one or more signals to the flow control device 260 to control the flow of compressed fluid through the IBH system 204.

[0050] Figures 5 to 8 show a filter 210 that can be used, for example, with the IE system 200 shown in Figures 1 to 3. The filter 210 may be located upstream of the compressor section 114 and may include one or more filter elements 222 (not shown) used to process air or the working fluid before the working fluid is introduced into the compressor inlet 134. For example, the filter 210 can remove contaminants entrained in the working fluid. Furthermore, the filter 210 may include a filter compartment 504 including one or more weatherproof hoods 502 and / or an outlet 508 for discharging the filtered working fluid into the duct 218.

[0051] Figure 9 shows an exemplary IBH manifold 214 that can be used with system 200. In an exemplary embodiment, the IBH manifold 214 can introduce or return the recirculated compressed working fluid of the IBH system 204 to or from the inlet transition duct 218. The IBH manifold 214 may include a horizontal member 602 and a plurality of vertical members 604 that extend substantially vertically from the horizontal member 602 and are fluidically coupled to the horizontal member 602. The plurality of vertical members 604 are located along the length L of the horizontal member 602. 214They may be arranged at equal intervals along the line. The IBH manifold 214 includes a plurality of outlet members 606 fluidly coupled to the vertical member 604. The horizontal member 602, the vertical member 604, and the outlet members 606 may be hollow, for example, hollow pipes or tubes, to allow the recirculated compressed working fluid to move through the horizontal member 602 into the vertical member 604 before the compressed working fluid is discharged through the array of outlet members 606.

[0052] The recirculated compressed working fluid can be propelled by the pressure difference to move through the IBH manifold 214. For example, compressed working fluid extracted from the compressor outlet 136 has a higher pressure compared to the operating pressure downstream of the compressor outlet 136 in the IBH system 204, and therefore propels the flow through the IBH manifold 214. The array of outlet members 606 distributes compressed air across the duct 218.

[0053] Referring to Figures 10 to 12, in some embodiments, the IE system includes an EGR manifold 224 for introducing the exhaust flow into the duct 218. The EGR manifold 224 may include a housing 702 having an inlet 704 and an outlet 706. The housing 702 may be part of the duct 218. The EGR manifold 224 may include one or more pipes 708 extending from and fluidly coupled to the conduit 282. The pipes 708 extend from the conduit 282 over a vertical length L 282 They can be arranged at equal intervals along the duct 218. The pipe 708 may extend horizontally, for example, across the duct 218 so that exhaust gases are evenly distributed across the duct 218. The length of the pipe 708 is L 708 It may include a number of spaced openings 710 arranged across it. The exhaust gas travels through the conduit 282 and through the pipe 708, exits the pipe 708 through the openings 710, and distributes the exhaust gas to the inlet duct 218 without introducing turbulence. The exhaust gas may be propelled or regulated to travel through the EGR manifold 224 by a flow control device 146 and / or damper 270.

[0054] Figure 13 shows a process flow of an exemplary method for operating an integrated efficiency system 200 (IE system 200), which includes an EGR system 202 and an IBH system 204, for use with a power generation system such as power generation system 100. Any or all of the processes 800 can be performed, for example, by a controller 206.

[0055] In some embodiments, process 800 may include selecting operating conditions or operating modes. In some embodiments, controller 206 may select an operating mode based on target or desired operating conditions. In some embodiments, the operating mode may be selected by an operator, for example, using a user interface. In some embodiments, controller 206 may select an operating mode based on received sensor data. The operating modes may include an EGR mode in which controller 206 causes the IE system 200 to utilize the EGR system 202, while the IBH system 204 is in an unenergized and / or standby mode. At least one other operating mode may include an EGR-dominant mode in which the IE system 200 supplies exhaust gas through the EGR system 202 at a higher mass flow or mass flow rate compared to the compressed working fluid drawn downstream of the compressor outlet 136, passing through the IBH system 204. Operating conditions may include, for example, anti-freezing, compressor surge prevention, and efficiency targets. In the embodiments described herein, the IE system 200 can operate in one or more of a plurality of operating modes, including EGR mode, and the controller 206 causes the IE system 200 to operate the EGR system 202 while the IBH system 204 is in an unenergized and / or standby mode. Alternatively, the controller 206 can cause the IE system 200 to operate in an EGR-dominant mode, in which case both the EGR system 202 and the IBH system 204 are operated, while the IBH system 204 supplies a minimum amount of compressed working fluid to the inlet.

[0056] Process 800 may include detecting one or more parameters of the power generation system 100 and / or IE system 200. Detecting a parameter 802 may include temperature detected using a temperature sensor at one or more locations upstream of the compressor inlet 134. Detecting a parameter 802 may include pressure detected using a pressure sensor at one or more locations downstream of the compressor inlet 134. In some embodiments, process 800 may include determining one or more parameters of the power generation system 100 and / or IE system 200 using, for example, a controller 206.

[0057] Process 800 may include determining conditions 804 based on parameters detected or determined in 802. In some embodiments, process 800 includes determining surge conditions 806. In some embodiments, the surge conditions 806 can be determined using a controller 206. The controller 206 may determine surge conditions using any suitable method, for example, a compressor map including surge lines. In some embodiments, the controller 206 may determine surge conditions based on detected 802 parameters and / or determined parameters. In some embodiments, process 800 includes determining freezing conditions 806 based on parameters detected and / or determined parameters in 802.

[0058] Process 800 may include determining target flow parameters for the IBH system 204 and target flow parameters for the EGR system 202. In some embodiments, the flow parameters may be mass flow rates. In some embodiments, process 800 may include determining mass parameters for the IBH and / or EGR system 202. For example, controller 206 may determine the IBH mass parameters and / or EGR mass parameters. The IBH mass parameters represent the amount of compressed working fluid delivered upstream of the compressor using the IBH system 204, and the EGR mass parameters represent the amount of exhaust gas delivered upstream of the compressor using the EGR system 202.

[0059] In some embodiments, process 800 includes using a controller 206 to determine a target temperature for the return exhaust gas in the EGR system 202 introduced at position 280. Process 800 may include the controller 206 selectively adjusting the amount of auxiliary working fluid 274 added to the exhaust gas to achieve the determined target temperature. The controller 206 may selectively adjust the amount of auxiliary working fluid 274 added by transmitting one or more signals to a flow control device 276.

[0060] In some embodiments, process 800 includes determining a target amount of working fluid to be delivered to the compressor section 114, for example, using a controller 206. Process 800 may include the controller 206 sending one or more signals to the inlet guide vane assembly 148, the IBH system 204, and the EGR system 202 in order to control the amount of working fluid delivered to the compressor section 114. In some embodiments, process 800 may include determining the amount of working fluid to be delivered to the compressor section 114 based on the temperature of the working fluid upstream of the compressor section 114, for example, using the controller 206.

[0061] The controller 206 can determine flow parameters based on one or more conditions detected by the sensor 208 or conditions determined by the controller 206. In some embodiments, the controller 206 can determine flow parameters based on selected conditions. In some embodiments, the controller 206 can determine flow parameters based on a selected operating mode, for example, a mode selected by the operator.

[0062] Process 800 includes simultaneously controlling the EGR system 202 and the IBH system 204 by the controller 206 based on the flow parameters determined in 806 808.

[0063] In some embodiments, process 800 includes, for example, detecting operating conditions such as flow parameters in real time or periodically and iteratively, and simultaneously controlling the EGR system 202 and the IBH system 204 based on the detected conditions to facilitate the optimization of the power generation system 100 by using a combination of the EGR system 202 and the IBH system 204 to prevent freezing and / or surge events. Furthermore, process 800 can be used to facilitate the improvement of the overall efficiency of the power generation system 100.

[0064] Further aspects of this disclosure are provided by the subject matter of the following clauses.

[0065] 1. An integrated system for use with a turbine, comprising: an EGR system including an EGR flow control device for directing a flow extracted from turbine exhaust to an exhaust gas recirculation (EGR) return position upstream of the compressor inlet; an IBH system including an IBH flow control device for directing a flow extracted downstream of the compressor outlet to an inlet extraction heat (IBH) return position upstream of the compressor inlet; and a controller communicatively coupled to the EGR flow control device and the IBH flow control device, the controller variably adjusting the relative flow rates of the EGR system and the IBH system.

[0066] 2. The integrated efficiency system described in the above clause, wherein the EGR flow control device is at least one of a pump, a blower, or an ejector.

[0067] 3. An integrated efficiency system as described in any of the above clauses, wherein the IBH flow control device is a control valve.

[0068] 4. An integrated efficiency system as described in any of the above clauses, in which the IBH is reintroduced to the IBH return position via the IBH manifold.

[0069] 5. The integrated efficiency system described in any of the above clauses, further comprising a temperature sensor configured to detect the temperature upstream of the compressor inlet.

[0070] 6. An integrated efficiency system as described in any of the above clauses, wherein the controller is configured to determine freezing events using data received from at least a temperature sensor.

[0071] 7. The integrated efficiency system described in any of the above clauses, further comprising a pressure sensor configured to detect the operating pressure downstream of the compressor outlet.

[0072] 8. An integrated efficiency system as described in any of the above clauses, wherein the controller is configured to determine potential compressor surge events based on data received from pressure sensors.

[0073] 9. A power generation system comprising: a compressor for compressing a working fluid; a combustor; and an integrated system for use with a turbine, the integrated system comprising: an EGR system including an EGR flow control device for use in directing a flow extracted from the exhaust of the combustor to an exhaust gas recirculation (EGR) return position upstream of the compressor inlet; an IBH system including an IBH flow control device for use in directing a flow extracted downstream of the compressor outlet to an inlet extraction heat (IBH) return position upstream of the compressor inlet; and a controller communicatively coupled to the EGR flow control device and the IBH flow control device, the controller selectively adjusting the relative flow rates of the EGR system and the IBH system.

[0074] 10. The power generation system described in the above clause, wherein the EGR flow control device is at least one of a pump, a blower, or an ejector.

[0075] 11. A power generation system as described in any of the above clauses, wherein the IBH flow control device is a control valve.

[0076] 12. A power generation system as described in any of the above clauses, wherein the IBH is reintroduced to the IBH return position through the IBH manifold.

[0077] 13. The power generation system according to any of the above clauses, further comprising a temperature sensor configured to detect the temperature upstream of the compressor inlet.

[0078] 14. The power generation system described in any of the above clauses, further comprising a pressure sensor configured to detect the operating pressure downstream of the compressor outlet.

[0079] 15. A power generation system as described in any of the above clauses, wherein the controller is configured to determine a potential compressor surge event based on data received from a pressure sensor.

[0080] 16. A method for using an integrated system for a gas turbine engine, the method comprising: receiving sensor data from a plurality of sensors coupled at various locations within the integrated system; determining current operating conditions based on the received sensor data; and adjusting at least one of the flow parameters of an EGR system and an IBH system to facilitate improvement of the operating efficiency of the gas turbine engine.

[0081] 17. The method of the above clause, further comprising adjusting at least one of the flow parameters of the EGR system to transmit a signal indicating the flow rate to an EGR flow control device.

[0082] 18. The method of any of the above clauses, further comprising receiving sensor data from a temperature sensor located upstream of the compressor.

[0083] 19. The method of any of the above clauses, further comprising receiving sensor data from a pressure sensor located downstream of the compressor.

[0084] 20. The method according to any of the above clauses, further comprising adjusting at least one of the flow parameters of the EGR system to heat the working fluid upstream of the compressor, and adjusting the flow parameters of the IBH system to prevent compressor surges.

[0085] Specific features of various embodiments of this disclosure are shown in some drawings, and not in others, for convenience only. According to the principles of this disclosure, any feature in the drawings may be referenced and / or claimed in combination with any feature in any other drawing.

[0086] In exemplary embodiments described herein, an integrated efficiency (IE) system for use with a gas turbine engine is provided. The IE system includes an inlet extraction heat (IBH) system and an exhaust gas recirculation (EGR) system, which can be used selectively in combination and / or separately, respectively, to improve the efficiency of the power generation system, improve partial load efficiency, improve control of emissions, and / or prevent freezing and compressor surges. The combination of the EGR system and the IBH system allows a controller to selectively control the use of these systems, and thus the EGR system complements the use of the IBH system, thus allowing for a significant reduction in the size and complexity of the IBH system. In some embodiments, the controller can selectively use the EGR system in isolation so that the IBH system is in standby mode, and thus the IBH system does not need to draw in compressed working fluid, improving the efficiency of the power generation system.

[0087] In embodiments described herein, the IE system heats the inlet working fluid before it enters the compressor inlet, thereby improving the partial load efficiency of the gas turbine and / or the turbine efficiency under operating conditions other than its full load design point, while simultaneously preventing freezing and / or compressor surges. In some embodiments, the IE system includes a controller that variably adjusts the mass flow rate or relative mass flow rate of the EGR and IBH systems to achieve desired operating conditions of the gas turbine engine. In some embodiments, the controller is communicatively coupled to one or more sensors and can adjust the mass flow rate in real time or periodically based on received sensor data and target operating conditions. In some embodiments, the IBH system may be used solely to prevent compressor surges, with inlet air heating primarily achieved by the EGR system. In some embodiments, the controller can selectively turn the IBH system on / off to prevent compressor surges, while the EGR operates continuously to heat the inlet air.

[0088] This specification uses examples to disclose embodiments of the system and method, including the best mode, and to enable any person skilled in the art to practice the system and method, including the fabrication and use of any device or system and the implementation of any incorporated method. The patentable scope of the system and method is defined by the claims and may include other examples that a person skilled in the art may conceive. Such other examples are intended to be within the claims if they have structural elements that are no different from the language of the claims, or if they include equivalent structural elements that are no substantially different from the language of the claims. [Explanation of Symbols]

[0089] 100 Power generation systems, mechanical drive systems 110 Gas Turbine Engine 112 Intake Section 114 Compressor Section 116 Combustor Section 118 Turbine Section 120 Exhaust Section 122 Rotor Shaft 124 Fuel Injector 126 Manifold 128 load 130 Rotor Disc Assembly 132 Rotor Assembly 134 Compressor Inlet 136 Compressor Outlet 138 Turbine Outlet 140 Conduit 142 Blower 144 Flow control devices 146 Flow control devices 148 Variable Inlet Guide Vane Assembly 150 fuel source 200 Integrated Efficiency (IE) Systems 202 Exhaust Gas Recovery (EGR) System 204 Inlet Extraction Heat (IBH) System 206 Controller 208 Sensors, Temperature Sensors 210 filters 212 Silencer 214 IBH Manifold 216 Internal passage 218 Inlet transition duct 220 Inlet fluid 222 filter elements 224 EGR manifold, EGR injection manifold 250 Extraction position 252 Conduit 254 Return position 258 First flow control device 260 Second flow control device 262 First return position 264 Second return position 270 Flow control damper 272 Shut-off valve 274 Auxiliary working fluid 276 Flow control devices 280 Return position 282 Conduit 402 Processors 404 memory 502 Weatherproof Hood 504 Filter Section 508 Exit 602 Horizontal member 604 Vertical member 606 Outlet member 702 Housing 704 Entrance 706 Exit 708 Pipe 710 Opening

Claims

1. An integrated system for use with a turbine, wherein the integrated system is An EGR system (202) including an EGR flow control device (276) for guiding the flow extracted from the turbine exhaust to an exhaust gas recirculation (EGR) return position (280) upstream of the compressor inlet (134), An IBH system (204) including an IBH flow control device (144) for guiding the flow extracted downstream of the compressor outlet (136) to an inlet extraction heat (IBH) return position (254) upstream of the compressor inlet (134), A controller (206) is communicatively coupled to the EGR flow control device (276) and the IBH flow control device (144), wherein the controller (206) variably adjusts the relative flow rates of the EGR system (202) and the IBH system (204), An integrated system equipped with [the following features].

2. The integrated system according to claim 1, wherein the EGR flow control device (276) is at least one of a pump, a blower, or an ejector.

3. The integrated system according to claim 1, wherein the IBH flow control device (144) is a control valve.

4. The integrated system according to claim 1, wherein the IBH is reintroduced to the IBH return position (254) via the IBH manifold (214).

5. The integrated system according to claim 1, further comprising a temperature sensor (208) configured to detect the temperature upstream of the compressor inlet (134).

6. The integrated system according to claim 1, wherein the controller (206) is configured to determine a freezing event using data received from at least the temperature sensor (208).

7. The integrated system according to claim 1, further comprising a pressure sensor (208) configured to detect the operating pressure downstream of the compressor outlet (136).

8. The integrated system according to claim 1, wherein the controller (206) is configured to determine a potential compressor surge event based on data received from a pressure sensor (208).

9. A compressor (114) for compressing the working fluid, Combustor (116), An integrated system for use with a turbine, wherein the integrated system is An EGR system (202) including an EGR flow control device (276) used to guide the flow extracted from the exhaust of the combustor (116) to an exhaust gas recirculation (EGR) return position (280) upstream of the inlet (134) of the compressor (114), An IBH system (204) including an IBH flow control device (144) used to guide the flow extracted downstream of the outlet (136) of the compressor (114) to an inlet extraction heat (IBH) return position (254) upstream of the inlet (134) of the compressor (114), A controller (206) is communicatively coupled to the EGR flow control device (276) and the IBH flow control device (144), wherein the controller (206) selectively adjusts the relative flow rates of the EGR system (202) and the IBH system (204), An integrated system equipped with, A power generation system (100) equipped with the following.

10. The power generation system (100) according to claim 9, wherein the EGR flow control device (276) is at least one of a pump, a blower, or an ejector.

11. The power generation system (100) according to claim 9, wherein the IBH flow control device (144) is a control valve.

12. The power generation system (100) according to claim 9, wherein the IBH is reintroduced to the IBH return position (254) through the IBH manifold (214).

13. The power generation system (100) according to claim 9, further comprising a temperature sensor (208) configured to detect the temperature upstream of the compressor inlet (134).

14. The power generation system (100) according to claim 9, further comprising a pressure sensor (208) configured to detect the operating pressure downstream of the compressor outlet (136).

15. The power generation system (100) according to claim 9, wherein the controller (206) is configured to determine a potential compressor surge event based on data received from a pressure sensor (208).

16. A method using an integrated system for a gas turbine engine (110), wherein the method is The integrated system receives sensor data from multiple sensors (208) coupled at various locations within the system, Determining the current operating conditions based on the received sensor data, To facilitate improvement of the operating efficiency of the gas turbine engine (110), at least one of the flow parameters of the EGR system (202) and the IBH system (204) is adjusted. A method for providing this.

17. The method according to claim 16, further comprising adjusting at least one of the flow parameters of the EGR system (202) to transmit a signal indicating the flow rate to an EGR flow control device (276).

18. The method according to claim 16, further comprising receiving sensor data from a temperature sensor (208) located upstream of the compressor (114).

19. The method according to claim 16, further comprising receiving sensor data from a pressure sensor (208) located downstream of the compressor (114).

20. Adjusting at least one of the flow parameters of the EGR system (202) Heating the working fluid upstream of the compressor (114), To prevent compressor surges, the flow parameters of the IBH system (204) are adjusted, The method according to claim 16, further comprising:

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