Method and apparatus for achieving power augmentation in gas turbines via wet compression

• US 5,867,977 A
• Filed: 09/18/1996
• Issued: 02/09/1999
• Est. Priority Date: 05/14/1996
• Status: Expired due to Term

• Current Assignee: The Dow Chemical Company (Dow, Inc.)
• Original Assignee: The Dow Chemical Company (Dow, Inc.)
• Inventors: Hudson, Roger D., Zachary, Richard E.
• Primary Examiner(s): FREAY, CHARLES GRANT
• Application Number:
  US08/715,675
• Time in Patent Office: 874 Days
• Field of Search: 60/39.05, 60/39.091, 60/39.093, 60/39.3, 60/39.53
• US Class Current: 60/39.53
• CPC Class Codes: F01K 21/047 having at least one combustion gas turbine
• CPC Class Codes: F02C 3/305 Increasing the power, speed, torque or efficiency of a gas turbine or the thrust of a turbojet engine by injecting or adding water, steam or other fluids F01K21/04 takes precedence
• CPC Class Codes: F02C 7/05 having provisions for obviating the penetration of damaging objects or particles
• CPC Class Codes: F02C 7/1435 by water injection
• CPC Class Codes: F05D 2220/32 in gas turbines
• CPC Class Codes: F05D 2250/51 Inlet
• CPC Class Codes: F05D 2260/212 by water injection
• CPC Class Codes: F05D 2260/607 Preventing clogging or obstruction of flow paths by dirt, dust, or foreign particles
• CPC Class Codes: Y02E 20/16 Combined cycle power plant [CCPP], or combined cycle gas turbine [CCGT]
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft

Abstract

A wet compression power augmentation apparatus and method for effectively adding a mass flow of water particles to a gas turbine preferably by use of a spray rack group assembly having at least one spray rack water pipe and at least one spray rack water nozzle. Water mass flow is added preferably in increments such that operationally-induced thermal transients within the gas turbine are sufficiently minimized to preserve the structural integrity of the gas turbine. Monitoring of the temperature profile of fluid-cooled rotor blades in the turbine section with an optical pyrometer to detect clogging of cooling pathways in those rotor blades from impurities in the liquid added through the wet compression, monitoring of temperature in proximity to the gas turbine compressor inlet to guard against the possibility of icing, a deformation measurement device, preferably a laser emitter and laser target measuring system mounted to the exterior of the gas turbine housing to detect deformation in the housing of the gas turbine from associated cooling effects of the wet compression technique, and periodic addition of heat and humidity, preferably steam, to the compressor inlet are disclosed.

Claims

1. A method for augmenting the net output of a gas turbine characterized in operation by periods of continuous use exceeding about 4 hours in duration in driving a generator or compressor, the gas turbine having an axial-flow multistage compressor having an inlet for acquiring a working fluid comprising air, the method comprising the steps of:

providing liquid water comprising liquid droplets to the working fluid acquired by the axial-flow compressor to reduce the temperature increase of the working fluid caused by compression to achieve an increase in the net output of the gas turbine available to drive said generator or compressor as measured against the net output of the gas turbine under comparable conditions but without liquid water provided, and

said method including the further step of providing heat and humidity to the working fluid to allow continued power augmentation during periods when the temperature of the working fluid would otherwise drop to a level which would allow detrimental ice formation to occur in the inlet.

2. The method of claim 1 wherein the step of providing heat and humidity comprises the step of adding steam into the inlet.

3. The method of claim 1 further comprising the step of measuring the temperature of the working fluid to insure sufficiently uniform addition of heat and humidity to the working fluid to avoid detrimental ice formation from occurring in the inlet.

4. The method of claim 1 wherein the liquid water ultimately provided to the axial-flow multistage compressor is in an amount which achieves an increase of at least about 10% in the net output of the gas turbine as measured against the net output of the gas turbine under comparable conditions but without liquid water provided.

12. The method of any of claims 1 through 11 wherein the liquid water ultimately provided to the axial-flow multistage compressor is in an amount which achieves an increase in the range of between about 20% to about 40% in the net output of the gas turbine as measured against the net output of the gas turbine under comparable conditions but without water provided.

13. The method of claim 12 wherein the gas turbine is a heavy duty industrial gas turbine.

21. The method of any of claims 1, 5, 9, 14, and 16 through 18 wherein the working fluid acquired by the compressor over a period of continuous operation exceeding about 4 hours comprises at least about three-quarters of one weight percent of liquid water in admixture with fully-humidified air.

22. The method of claim 21 for augmenting the net output of a heavy duty industrial gas turbine.

23. The method of any of claims 1, 5, 9, and 14 wherein the working fluid acquired by the compressor over a period of continuous operation exceeding about 4 hours comprises from about two weight percent to about eight weight percent of liquid water in admixture with fully-humidified air.

24. The method of claim 23 for augmenting the net output of a heavy duty industrial gas turbine.

26. The apparatus of claim 23, wherein the means for providing heat and humidity comprises means for providing steam to the inlet.

27. The apparatus of claim 23, wherein the apparatus includes means for measuring the temperature of the working fluid to insure sufficiently uniform addition of heat and humidity to the working fluid to avoid detrimental icing in the inlet.

28. The apparatus of any of claims 23 through 27 wherein the apparatus comprises means for providing a working fluid acquired by the compressor which comprises essentially at least about three-quarters of one weight percent liquid water in admixture with fully humidified air.

5. A method for augmenting the net output of an industrial gas turbine characterized in operation by periods of continuous use exceeding about 4 hours in length in driving a generator or compressor, the industrial gas turbine having an axial-flow multistage compressor having an inlet for acquiring a working fluid comprising air, said axial-flow multistage compressor having a housing, the method comprising the steps of:

providing liquid water comprising liquid droplets to the working fluid acquired by the axial-flow compressor to reduce the temperature increase of the working fluid caused by compression to achieve an increase in the net output of the industrial gas turbine available to drive said generator or compressor as measured against the net output of the industrial gas turbine under comparable conditions but without liquid water provided,

said method including the further step of insuring a sufficiently uniform distribution of liquid water in the working fluid to limit angular deformation of the housing to a generally predetermined acceptable limit that prevents damage to the axial-flow multistage compressor.

6. The method of claim 5 wherein the liquid water ultimately provided to the axial-flow multistage compressor is in an amount which achieves an increase of at least about 10% in the net output of the industrial gas turbine as measured against the net output of the industrial gas turbine under comparable conditions but without liquid water provided.

7. The method of claim 6 further comprising the step of measuring angular deformation in the housing which is related to the providing of liquid water to the working fluid.

8. The method of claim 7 wherein the step of measuring angular deformation comprises using a laser emitter and a laser target for measuring angular deformation of the housing.

9. A method for augmenting the net output of an industrial gas turbine characterized in operation by periods of continuous use exceeding about 4 hours in length in driving a generator or compressor, the industrial gas turbine having an axial-flow multistage compressor having an inlet for acquiring a working fluid comprising air, said axial-flow multistage compressor having a housing, the method comprising the steps of:

providing liquid water comprising liquid droplets to the working fluid acquired by the axial-flow compressor to reduce the temperature increase of the working fluid caused by compression to achieve an increase in the net output of the industrial gas turbine available to drive said generator or compressor as measured against the net output of the industrial gas turbine under comparable conditions but without liquid water provided,

said method including the further step of measuring angular deformation in the housing which is related to the providing of liquid water to the working fluid.

10. The method of claim 9 wherein the liquid water ultimately provided to the axial-flow multistage compressor is in an amount which achieves an increase of at least about 10% in the net output of the industrial gas turbine as measured against the net output of the industrial gas turbine under comparable conditions but without liquid water provided.

11. The method of claim 9 wherein the step of measuring angular deformation comprises using a laser emitter and a laser target to for measuring angular deformation of the housing.

14. A method for augmenting the net output of a gas turbine having an axial flow multistage compressor for acquiring and compressing a working fluid comprising air, the method comprising the steps of:

adding increasing amounts of liquid water comprising liquid droplets to the working fluid acquired by the compressor, with the mass flow rate of the liquid droplets being increased over time to avoid destructive thermal stresses within the gas turbine which are related to the providing of increased amounts of liquid water to the working fluid, and thereafter, after achieving a desired mass flow rate,

providing liquid water comprising liquid droplets to the working fluid acquired by the compressor at a substantially constant mass flow rate over a period of continuous operation exceeding about 4 hours to augment the net output of the gas turbine by wet compression.

15. The method of claim 14 wherein the liquid water ultimately provided to the axial-flow multistage compressor is in an amount which achieves an increase of at least about 10% in the net output of the gas turbine as measured against the net output of the gas turbine under comparable conditions but without liquid water provided.

16. The method of claim 14 wherein liquid water is provided to the working fluid in the form of a plurality of nebulized mass flow increments.

17. The method of claim 16 wherein the mass flow rate is varied in an incremental manner.

18. The method of claim 14 wherein the axial-flow compressor has a housing and wherein angular distortion of the housing related to providing liquid water to the axial-flow compressor is controlled by a method comprising providing nebulized mass flow increments in a balanced manner to the working fluid which insures that angular deformation of the housing related to adding liquid water to the working fluid is controlled within generally predictable limits.

19. The method of any of claims 14 and 16 through 18 wherein the liquid water ultimately provided to the axial-flow multistage compressor is in an amount which achieves an increase in the range of between about 20% to about 40% in the net output of the gas turbine as measured against the net output of the gas turbine under comparable conditions but without liquid water provided.

20. The method of claim 19 for augmenting the net output of a heavy duty industrial gas turbine.

25. Apparatus comprising a gas turbine having an axial-flow multistage compressor having an inlet for acquiring a working fluid comprising air, the apparatus further comprising:

means for providing liquid water particles to the working fluid acquired by the compressor, and

means for providing heat and humidity to the working fluid acquired by the compressor to allow liquid water to be provided to the working fluid during periods when the temperature of the working fluid would otherwise drop to a level which would allow detrimental ice formation to occur in the inlet.

29. Apparatus comprising an industrial gas turbine having an axial-flow multistage compressor having an inlet for acquiring a working fluid comprising air, the apparatus further comprising:

means for providing liquid water particles to the working fluid acquired by the compressor, and

means for controlling angular distortion of the housing which is related to the providing of liquid water to the working fluid to a generally predetermined acceptable limit that prevents damage to the axial-flow multistage compressor.

30. The apparatus of claim 29 wherein said means for controlling angular distortion of the housing comprises means for insuring a sufficiently uniform distribution of liquid water in the working fluid to limit angular deformation of the housing to a generally predetermined acceptable limit that prevents damage to the axial-flow multistage compressor.

31. The apparatus of claim 29 wherein said means for controlling angular distortion of the housing comprises means for measuring angular distortion of the housing.

32. The apparatus of claim 30 wherein said means for controlling angular distortion of the housing comprises means for measuring angular distortion of the housing.

33. The apparatus of claim 32 wherein said means for measuring angular distortion of the housing comprises a laser emitter and a laser target.

34. The apparatus of claim 29 wherein the industrial gas turbine is a heavy duty industrial gas turbine.

35. The apparatus of claim 34 wherein the means for providing liquid water comprises means to provide a plurality of water mass flow increments essentially entrained in the working fluid, and means for varying the total mass flow of water supplied to the working fluid with respect to time.

36. The apparatus of claim 35, wherein the means for varying the total mass flow of water with respect to time comprises means for varying the mass flow in a balanced incremental manner to generally insure the uniform distribution of the liquid water in the working fluid.

37. The apparatus of any of claims 29 through 36 wherein the apparatus comprises means for providing a working fluid acquired by the compressor which comprises essentially at least about three-quarters of one weight percent liquid water in admixture with fully humidified air.

38. The apparatus of claim 37, wherein the apparatus comprises means for providing a working fluid to the compressor which comprises from at least about 2 to about 8 weight percent of liquid water in admixture with fully humidified air.