Gas energy conversion apparatus and method

• US 20040146394A1
• Filed: 10/22/2003
• Published: 07/29/2004
• Est. Priority Date: 04/23/2001
• Status: Active Grant

• Current Assignee: John M. Turchetta
• Original Assignee: John M. Turchetta
• Inventors: Turchetta, John M.
• Granted Patent: US 6,907,727 B2
• Time in Patent Office: Days
• US Class Current: 415/13
• CPC Class Codes: F01D 15/10 Adaptations for driving, or combinations with, electric generators
• CPC Class Codes: F02C 1/02 the working fluid being an unheated pressurised gas
• CPC Class Codes: F02C 9/18 by bleeding, bypassing or acting on variable working fluid interconnections between turbines or compressors or their stages F02C3/113 takes precedence
• CPC Class Codes: F03G 7/00 Mechanical-power-producing mechanisms, not otherwise provided for or using energy sources not otherwise provided for
• CPC Class Codes: F05D 2270/024 to keep rotational speed constant
• CPC Class Codes: F05D 2270/053 Explicitly mentioned power
• CPC Class Codes: F05D 2270/54 by electronic means, e.g. electronic tubes, transistors or IC's within an electronic circuit

Abstract

An apparatus having a pressure control system that balances the natural gas flow rate passing through a multi-stage, axial-flow, impulse turbogenerator to produce an electrical power output is provided. The pressure control system includes a primary bypass conduit circuit; pressure regulator valves; modulating valves; and flow sensors. The pressure control system is operatively connected to the multi-stage, axial-flow, impulse turbogenerator. The turbogenerator is operatively connected to both a microprocessor based governor control and a generator for producing electrical output and is preferably contained within a section of bypass conduit that is directly connected to an existing gas distribution pipeline. As the electrical load on the generator and downstream customer demand for gas fluctuate, the pressure control system can provide the proper amount of gas flow through the primary by-pass and turbine that is required to produce a predetermined, steady state electrical output.

Claims

1. An apparatus for producing electrical power within the natural gas pipeline infrastructure including a distribution pipeline main that branches off the pipeline main, utilizing pressure energy from natural gas flowing through a natural gas pipeline, the apparatus comprising:

a pressure control system constructed and arranged to balance a flow rate of the natural gas, the control system including;

a) a primary bypass conduit circuit constructed and arranged to divert gas flow from the distribution pipeline main;

b) at least one pressure regulator valve constructed and arranged to reduce gas pressure within the primary bypass conduit circuit as needed;

c) at least one modulating valve constructed and arranged to control gas flow within the primary bypass conduit circuit; and

d) at least one or more flow sensors;

a multistage, axial flow, impulse turbine disposed within the primary bypass conduit circuit and operatively connected to a generator, the turbine receiving gas flow from the natural gas pipeline through the primary bypass conduit circuit and converting the flow of gas to electrical power output;

a microprocessor governor control system constructed and arranged to send and receive signals to initiate and regulate operation of the turbine; and

wherein as electrical load on the generator and downstream customer demand for gas fluctuates, the pressure control system regulates the amount of gas flowing through the turbine so as to produce a steady state electrical output.

2. The apparatus of claim 1, wherein the turbine includes a tapered outer shell.

3. The apparatus of claim 2, wherein the tapered outer shell includes a venturi section constructed and arranged to increase velocity of the gas flow rate within the turbine.

4. The apparatus of claim 3, wherein the tapered outer shell further includes a power section downstream from the venturi section.

5. The apparatus of claim 2, further comprising two or more rib elements constructed and arranged to support the outer shell.

6. The apparatus of claim 1, further comprising a secondary turbine bypass constructed and arranged to divert gas flow around the turbine.

7. The apparatus of claim 1, further comprising a secondary modulating valve bypass constructed and arranged to control gas pressurization of the primary bypass conduit circuit after the turbine is initially charged with gas.

8. The apparatus of claim 1, wherein the turbine further includes a turbine shaft rotationally supported at a downstream end within a front bearing housing and rotationally supported at an upstream end within a rear bearing housing.

9. The apparatus of claim 8, wherein the front bearing housing and rear bearing housing each include a center hub and one or more salient strut members constructed and arranged to restrain the respective front and rear bearing housings within the primary bypass conduit circuit.

10. The apparatus of claim 1, wherein the turbine is disposed within a conduit including a first half and a second half which are seperable from each other.

11. The apparatus of claim 1, further including one or more valves constructed and arranged to isolate gas flow to the primary bypass circuit conduit from the distribution pipeline main, as needed.

12. The apparatus of claim 1, further comprising a combustible gas detector.

13. The apparatus of claim 1, further comprising a gas flow transmitter.

14. The apparatus of claim 1, further comprising a frequency transducer constructed and arranged to signal the governor control system when the electrical output reaches or deviates from a predetermined level.

15. The apparatus of claim 1, wherein the turbine includes a plurality of intermittent stage stationary nozzle elements supported therein.

16. The apparatus of claim 15, wherein the turbine includes a plurality of intermittent stage rotor blade elements rotationally supported therein.

17. A method of converting gas energy from a pipeline main into electrical power comprising the steps of:

providing a multi-stage, axial flow, impulse turbogenerator disposed within a primary bypass conduit circuit, the conduit circuit constructed and arranged to divert flow from a distribution pipeline main;

detecting the amount of the gas flow within the distribution pipeline main and signaling a governor control system;

diverting gas flow from the pipeline main to the primary bypass conduit circuit, such that the gas flow is received within the turbine;

actuating an electrohydraulic starter so as to begin rotation of the turbine;

actuating one or more modulating valves to control gas flow within the primary bypass conduit;

increasing turbine speed by increasing the gas flow through the turbine until the electrical output produced by the turbine reaches a predetermined, steady state frequency level.

18. The method of claim 17, wherein the step of diverting gas flow further comprises the steps of:

sending a control signal from the governor control to actuate a loading valve to pressurize the primary bypass conduit;

closing the loading valve upon completion of primary bypass loading.

19. The method of claim 17 further comprising the steps of:

closing a secondary bypass modulating valve to increase the turbine speed;

disengaging the electrohydraulic starter from the turbine;

opening and closing the one or more modulating valves, as needed, to increase or decrease gas flow into the primary bypass conduit circuit as needed;

continuously sending feedback signals to the governor control system in order to adjust the gas flow into the primary bypass conduit so as to maintain the electrical output at the predetermined steady state frequency.

20. The method of claim 19 further comprising the step of:

initiating turbine shutdown when the frequency falls below the predetermined level.

21. The method of claim 20 further comprising the step of stopping rotation of the turbine comprising the steps of:

opening a circuit breaker;

activating a magnetic brake;

opening a primary bypass valve;

closing a modulating valve;

opening the secondary bypass valve; and

performing the above steps until the turbine comes to a stop.

22. The method of claim 21 further comprising the step of:

keeping the turbine stopped until gas demand is restored to a minimum level required for producing the electrical output at the predetermined steady state frequency.

23. An apparatus for producing electrical power within a natural gas pipeline infrastructure utilizing pressure energy from natural gas flowing through the natural gas pipeline, the pipeline including a distribution pipeline main that branches off the pipeline, the apparatus comprising:

a pressure control system constructed and arranged to balance a flow rate of the natural gas, the control system including;

a) a primary bypass conduit circuit constructed and arranged to divert gas flow from the distribution pipeline main;

b) at least one pressure regulator valve constructed and arranged to reduce gas pressure within the primary bypass conduit circuit as needed;

c) at least one modulating valve constructed and arranged to control gas flow within the primary bypass conduit circuit; and

d) at least one or more flow sensors;

a multistage, axial flow, impulse turbine disposed within the primary bypass conduit circuit and operatively connected to a generator, the turbine including a tapered outer shell and receiving gas flow from the natural gas pipeline through the primary bypass conduit circuit and converting the flow of gas to electrical power output;

a microprocessor governor control system constructed and arranged to send and receive signals to initiate and regulate operation of the turbine;

a secondary turbine bypass constructed and arranged to divert gas flow around the turbine;

a secondary modulating valve bypass constructed and arranged to control gas pressurization of the primary bypass conduit circuit after the turbine is initially charged with gas; and

wherein as electrical load on the generator and downstream customer demand for gas fluctuates, the pressure control system regulates the amount of gas flowing through the turbine so as to produce a steady state electrical output.

24. The apparatus of claim 23, wherein the tapered outer shell includes a venturi section constructed and arranged to increase velocity of the gas flow rate within the turbine.

25. The apparatus of claim 24, wherein the tapered outer shell further includes a power section downstream from the venturi section.

26. The apparatus of claim 23, further comprising two or more rib elements constructed and arranged to support the outer shell.

27. The apparatus of claim 23, wherein the turbine is disposed within a conduit including a first half and a second half which are separable from each other.