Intercooled Cooling Air Pressure Dump to Prevent Compressor Surge
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Solution Overview
Problem
Gas turbine engines face inefficiencies in utilizing cooling air, particularly during lower power operations where compressed air can lead to undesirable pressure ratios and potential surge in the compressor, necessitating a system to selectively manage air distribution to rotatable components.
Innovation Solution
A system that taps compressed air upstream of the main compressor section, passes it through a heat exchanger, and directs it to a cooling compressor, which is connected to rotate at a proportional speed. This system includes a check valve to block or allow air flow to rotatable components and a dump valve to divert excess air, ensuring efficient air utilization and preventing surge during lower power operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If compressed air is used for cooling rotatable components, then cooling effectiveness is improved, but compressor surge risk increases during lower power operations
Solution Approach 1:
The system dynamically adjusts the cooling air supply based on operating conditions. During lower power operations, the check valve blocks the flow of compressed air to the cooling compressor, preventing compressor surge. During higher power operations when cooling demand increases, the check valve opens to allow compressed air flow, providing effective cooling without causing surge under low-power conditions.
Solution Approach 2:
The check valve acts as an intermediary device between the main compressor and the cooling compressor. It selectively controls whether compressed air flows to the cooling compressor based on operating conditions, thereby mediating between the need for effective cooling and the need to prevent compressor surge during lower power operations.
2Temperature
If cooling air is continuously supplied to rotatable components, then cooling performance is maintained, but air utilization efficiency decreases
Solution Approach 1:
The system implements periodic or conditional action rather than continuous cooling air supply. The check valve enables compressed air flow only during periods when the engine requires it (higher power operations), and blocks flow during periods when it is not needed (lower power operations). This periodic activation maintains cooling performance when necessary while eliminating wasted air compression during periods when cooling demand is low.
Solution Approach 2:
The system changes the operational parameters of the cooling air supply based on engine operating conditions. By monitoring power operation levels, the system adjusts whether the check valve is open or closed, thereby changing the flow parameter from continuous to conditional. This parameter change optimizes air utilization efficiency by matching cooling air supply actual cooling demand.
3Reliability
If a check valve is added to control air flow, then compressor surge is prevented, but device complexity increases
Solution Approach 1:
The check valve is designed to operate automatically based on pressure differential without requiring external control systems. During lower power operations, the pressure differential causes the check valve to close, blocking compressed air flow and preventing surge. During higher power operations, the pressure differential opens the valve to allow flow. This self-service operation prevents compressor surge while minimizing control system complexity.
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 air flow efficiency by selectively distributing cooling air, preventing surge and maintaining optimal compressor operation across varying power conditions, thereby improving overall engine efficiency and reducing fuel consumption.
Implementation Method 1
passes it through a heat exchanger
Implementation Method 2
A valve system includes a check valve for selectively blocking flow downstream of the cooling compressor
Data Source
AI summary
A gas turbine engine includes a main compressor section having a downstream most location, and a turbine section, with both the main compressor section and the turbine section housing rotatable components. A first tap taps air compressed by the main compressor section at an upstream location upstream of the downstream most location. The first tap passes through a heat exchanger, and to a cooling compressor. Air downstream of the cooling compressor is selectively connected to reach at least one of the rotatable components. The cooling compressor is connected to rotate at a speed proportional to a rotational speed in one of the main compressor section and the turbine section. A valve system includes a check valve for selectively blocking flow downstream of the cooling compressor from reaching the at least one rotatable component. A dump valve selectively dumps air downstream of the cooling compressor. A method is also disclosed.