Fuel-Gas Cooler Coolant Level Control for Compressor Protection
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Solution Overview
Problem
Low-calorific-value gases, such as blast furnace gas, contain contaminants that can block fuel-gas cooler outlets and pipes, leading to coolant overflow and potential damage to fuel-gas compressors and gas turbines, especially in cold conditions where coolant freezing occurs.
Innovation Solution
A power-generation plant equipped with a fuel-gas cooler, level detectors, and a controller that stops the coolant pump and emergency shut-off valves to prevent coolant from flowing into fuel-gas compressors and turbines by detecting coolant levels in hoppers and bypass lines, and a bypass pipe to circulate coolant without spraying it in cold conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If coolant is sprayed from spray nozzle to cool fuel gas, then cooling effect is improved, but coolant may overflow and flow into fuel-gas compressor and gas turbine causing damage
Solution Approach 1:
The patent installs level detectors before coolant overflow can occur to detect predetermined coolant levels in advance. When the level detector detects that the coolant level has reached a predetermined level, it immediately stops the coolant pump, preventing coolant from overflowing into the fuel-gas compressor and gas turbine. This preliminary detection and prevention mechanism resolves the contradiction by maintaining reliable operation while allowing effective cooling.
2Quantity of substance
If hopper outlet and pipes are blocked by contaminants, then coolant recovery is impaired, but coolant may overflow and flow into fuel-gas compressor and gas turbine
Solution Approach 1:
The patent implements a feedback control system where level detectors continuously monitor coolant levels in the hopper and bypass line. When contaminants block the hopper outlet or pipes, preventing proper coolant recovery, the level detector detects the abnormal coolant level accumulation and immediately stops the coolant pump. This feedback mechanism prevents coolant overflow into the fuel-gas compressor and gas turbine, resolving the contradiction between coolant recovery and system safety.
3Temperature
If coolant is sprayed when power-generation plant is stopped in cold regions, then coolant freezing is prevented, but interior of fuel-gas cooler becomes over-saturated and liquid may flow into fuel-gas compressor and gas turbine
Solution Approach 1:
The patent employs a dynamic control system that adjusts coolant spraying based on operational conditions. In cold regions, when the power-generation plant is stopped, the level detector monitors coolant levels to prevent freezing. However, if the detector determines that spraying would cause over-saturation and liquid flow into the fuel-gas compressor or gas turbine, it stops the coolant pump. This dynamic adjustment resolves the contradiction between preventing coolant freezing and avoiding liquid overflow damage.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Prevents coolant from flowing into fuel-gas compressors and turbines, preventing damage and ensuring safe operation by blocking fuel gas supply and stopping the coolant pump when predetermined coolant levels are reached, and maintains coolant circulation to prevent freezing in cold conditions.
Implementation Method 1
a fuel-gas cooler that cools the fuel gas with coolant sprayed from a spray nozzle
Implementation Method 2
a fuel-gas cooler that cools the fuel gas, which is pressurized at a fuel-gas compressor and recirculated, with coolant sprayed from a spray nozzle
Implementation Method 3
a first level detector that detects whether a level of the coolant accumulated at a bottom portion of the fuel-gas cooler has reached a predetermined level
Data Source
AI summary
A power-generation plant 10 including a gas turbine 11; a fuel-gas cooler 13; and an extraction line 24 that guides the fuel gas extracted from an intermediate stage of a fuel-gas compressor 12 to the fuel-gas cooler 13; a first level detector 61 that detects whether a level of the coolant accumulated at a bottom portion of the fuel-gas cooler 13 has reached a predetermined level; and a controller that stops the gas turbine 11 on the basis of a detection signal sent from the first level detector 61 and that outputs a command signal for stopping a coolant pump 53 that supplies the coolant to the spray nozzles 44 and 45.