Inlet Air Heating Coils for Gas Turbines
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Solution Overview
Problem
Conventional inlet air heating systems for gas turbine systems in combined cycle power plants are standalone systems that increase costs and maintenance due to additional components, and they use water-glycol mixtures for anti-freezing, which have less effective heat transfer characteristics, leading to inefficiencies and operational challenges in cold weather.
Innovation Solution
An integrated inlet air heating system within the gas turbine system, utilizing heating coil assemblies positioned within the inlet housing, with a vent valve, supply line, hot water line, and drain line, allowing for efficient air heating and water management, including drainage during shutdowns to prevent freezing, and utilizing hot water from the combined cycle power plant for heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional standalone heat exchanger systems are used to warm intake air, then the gas turbine system can meet part load demands with inlet guide vanes completely open, but the system complexity and cost increase due to additional independent components and resources
Solution Approach 1:
The patent integrates the heat exchanger system directly into the inlet housing of the gas turbine system, merging previously standalone components (heating coils, fluid circulation system) with the existing inlet structure. This consolidation eliminates the need for separate independent systems while maintaining the air warming function, thereby reducing overall system complexity and component count.
Solution Approach 2:
The integrated heat exchanger system serves multiple functions: it warms intake air to maintain inlet guide vane opening for part load efficiency, provides anti-icing protection for internal components, and utilizes the gas turbine's own exhaust heat through the HRSG. This multi-functionality reduces the need for separate dedicated systems.
2Reliability
If water-glycol mixture is used in conventional heat exchanger systems for anti-freezing, then the system can operate in cold weather, but the heat transfer effectiveness is reduced
Solution Approach 1:
The patent changes the fluid parameter from water-glycol mixture to pure water by implementing a drainage system that completely empties the heat exchanger channels during shutdown. This parameter change (from mixed fluid to pure water) restores optimal heat transfer properties while maintaining anti-freezing protection through drainage capability.
Solution Approach 2:
The system performs preliminary drainage of the heat exchanger channels before freezing conditions can cause damage. By draining the fluid during shutdown, the system proactively prevents freezing rather than relying on freeze-resistant additives, thereby maintaining full heat transfer effectiveness during operation.
3Duration of action of stationary object
If conventional heat exchanger systems are not drained during shutdown, then the system remains ready for immediate operation, but the pipes and conduits may freeze and become damaged in cold weather
Solution Approach 1:
The patent extracts the fluid from the heat exchanger channels during shutdown through the drainage system, removing the substance that would otherwise freeze and cause damage. This extraction allows the system to withstand cold weather shutdowns without requiring freeze protection additives, and the channels can be quickly refilled upon restart.
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
The system enhances operational efficiency by maintaining compressor efficiency and reducing fuel consumption while minimizing the risk of freezing and damage during non-operational states, by using hot water from the power plant for heating and ensuring the heating coils can be drained during shutdowns.
Implementation Method 1
The ambient air may contact and/or flow over the heat exchanger components, and may undergo a heat exchanging process (e.g., warmed) prior to the ambient air entering the compressor
Implementation Method 2
The ambient air may contact and/or flow over the heat exchanger components, and may undergo a heat exchanging process
Data Source
AI summary
Inlet air heating systems for combined cycle power plants and combined cycle power plants including inlet air heating systems are disclosed. The inlet air heating systems may include a plurality of heating coil assemblies partially positioned within an inlet housing of a gas turbine system, and a vent valve in fluid communication with each of the heating coils. The inlet air heating system may also include a supply line in fluid communication with the heating coils to provide water to the heating coils, and a hot water line in fluid communication with the supply line and a component positioned downstream of a condenser of the combined cycle power plant. The hot water line may provide hot water from the combined cycle power plant to the supply line. Additionally, the inlet air heating system may include a drain line in fluid communication with the heating coils and the condenser.