A new approach for enhancing performance of a gas turbine (case study: Khangiran refinery)

There are various methods which are commercially available for turbine air inlet cooling aiming to improve gas turbine efficiency. In this study a new approach has been proposed to improve performance of a gas turbine. The approach has been applied to one of the Khangiran refinery gas turbines. The idea is to cool inlet air of the gas turbine by potential cooling capacity of the refinery natural-gas pressure drop station. The study is part of a comprehensive program aimed to enhance gas turbines performance of the Khangiran gas refinery. The results show that the gas turbine inlet air temperature could be reduced in range of 4–25 K and the performance could be improved in range of 1.5–5% for almost 10 months.     

Comparison of evaporative inlet air cooling systems to enhance the gas turbine generated power

The gas turbine performance is highly sensitive to the compressor inlet temperature. The output of gas turbine falls to a value that is less than the rated output under high temperature conditions. In fact increase in inlet air temperature by 1°C will decrease the output power by 0.7% approximately. The solution of this problem is very important because the peak demand season also happens in the summer. One of the convenient methods of inlet air cooling is evaporating cooling which is appropriate for warm and dry weather. As most of the gas turbines in Iran are installed in such ambient conditions regions, therefore this method can be used to enhance the performance of the gas turbines. In this paper, an overview of technical and economic comparison of media system and fog system is given. The performance test results show that the mean output power of Frame‐9 gas turbines is increased by 11 MW (14.5%) by the application of media cooling system in Fars power plant and 8.1 MW (8.9%) and 9.5 MW (11%) by the application of fog cooling system in Ghom and Shahid Rajaie power plants, respectively. The total enhanced power generation in the summer of 2004 was 2970, 1701 and 1340 MWh for the Fars, Ghom and Shahid Rajaie power plants, respectively. The economical studies show that the payback periods are estimated to be around 2 and 3 years for fog and media systems, respectively. This study has shown that both methods are suitable for the dry and hot areas for gas turbine power augmentation. Copyright © 2007 John Wiley & Sons, Ltd.     

Operation window and part-load performance study of a syngas fired gas turbine

Integrated coal gasification combined cycle (IGCC) provides a great opportunity for clean utilization of coal while maintaining the advantage of high energy efficiency brought by gas turbines. A challenging problem arising from the integration of an existing gas turbine to an IGCC system is the performance change of the gas turbine due to the shift of fuel from natural gas to synthesis gas, or syngas, mainly consisting of carbon monoxide and hydrogen. Besides the change of base-load performance, which has been extensively studied, the change of part-load performance is also of great significance for the operation of a gas turbine and an IGCC plant.In this paper, a detailed mathematical model of a syngas fired gas turbine is developed to study its part-load performance. A baseline is firstly established using the part-load performance of a natural gas fired gas turbine, then the part-load performance of the gas turbine running with different compositions of syngas is investigated and compared with the baseline. Particularly, the impacts of the variable inlet guide vane, the degree of fuel dilution, and the degree of air bleed are investigated. Results indicate that insufficient cooling of turbine blades and a reduced compressor surge margin are the major factors that constrain the part-load performance of a syngas fired gas turbine. Results also show that air bleed from the compressor can greatly improve the working condition of a syngas fired gas turbine, especially for those fired with low lower heating value syngas. The regulating strategy of a syngas fired gas turbine should also be adjusted in accordance to the changes of part-load performance, and a reduced scope of constant TAT (turbine exhaust temperature) control mode is required.     

透平冷却空气量计算方法综述

燃气轮机效率提高的主要途径是提高透平进口温度。随着透平进口温度的不断提高,对冷却空气量的需求也逐渐增多,为保证透平安全可靠运行,透平冷却空气量的计算就显得尤为重要。本文对比了国内几篇文献中针对V94.3燃气轮机透平冷却空气量的估算方法,同时介绍了国内外其他研究人员利用流体网络法的研究成果。通过对比分析可知,采用叶片冷却模型以及从燃气轮机功率角度估测冷却空气量的方法适用于工程应用。流体网络法有严谨的理论支持,可针对空气系统具体部件进行计算分析。     

燃气轮机进气喷雾蒸发式冷却与Li-Br吸收式制冷冷却增能对比分析

燃气轮机进气冷却技术是一种能够有效提高高温环境下燃气轮机发电机组输出功率的重要手段。介绍了几种主要的进气冷却技术方法,并分析了进气冷却技术的作用机理。着重对比分析了华菱涟钢能源中心所采用的两种进气冷却技术对燃气轮机输出功率的影响规律,并阐明了两种进气冷却技术各自的优缺点。根据运行参数以及相关数据分析的对比研究结果,为燃气轮机进气冷却技术在实际工程上的应用提供一定的参考。     

大型燃气轮机透平冷却空气量估算

大型燃气轮机透平冷却空气量一般难以直接获得。本文从燃机总体物质与能量平衡的角度,结合透平一级静叶的冷却模型,给出了一种估算大型燃气轮机冷却空气量的方法,并对GE公司系列燃气轮机和西门子公司V94．3燃气轮机冷却空气量进行了估算。结果表明采用本文的方法估算的燃气轮机透平冷却空气量是合理的。     

燃气轮机进气雾化式蒸发冷却控制技术研究

大气环境温度对燃气轮机性能的影响很大,加装燃气轮机进气雾化冷却系统对改善燃气轮机性能具有很高的实用价值.通过对燃气轮机进气雾化冷却工作原理的分析,提出了一种基于PLC的燃气轮机进气雾化冷却控制系统的设计方案以及功能实现.运行结果表明,该控制系统自动化程度高,工作稳定性好,性能可靠.配置控制系统的燃气轮机进气雾化式冷却撬体投运后,PG6551(B)型燃气轮机功率相对增加8.35%,效率相对提高3.24%.     

AE94.3A型燃气轮机进气冷却的应用可行性研究

对AE94.3A型燃气轮机燃气-蒸汽联合循环热力系统平衡进行研究进而发现,与同类型、同等级不同型号机组相比,AE94.3A型联合循环机组余热锅炉的排烟温度较高,排烟余热仍有进一步利用的空间。通过设计优化,扩大省煤器受热面,回收烟气余热加热给水,驱动热水型溴化锂制冷机制冷,用于机组满负荷调峰时的压气机进气冷却或厂房及办公区域空调供冷,对改善燃气轮机联合循环的运行性能,实现能源梯级利用,提高能源利用率和机组经济性运行起到了很大作用。     

回热燃气轮机余热利用进气冷却的研究

本文研究了利用余热制冷进气冷却的回热燃气轮机系统,并对该系统性能进行了模拟计算,得到了压比、流量比等参数对系统性能的影响规律。并通过与常规回热循环比较,指出利用余热制冷来进气冷却的方式能使系统效率提高11%,是提高燃气轮机系统性能的有效途径之一。     

小型燃气轮机CCHP系统变工况性能入口加热调控研究

提出了一种利用冷热电联产系统(CCHP)低温烟气与环境空气混和加热控制压气机入口温度,提升燃气轮机冷热电系统变工况性能的方法,并以1.9 MW小型燃气轮机OPRA16为例,建立了CCHP系统模型,分析了调控方法的效果、机理。结果表明,入口混和加热可以有效改善冷热电联产系统变工况下系统性能,并扩展系统节能运行范围。与传统燃料流量调控方法相比,新型调控手段下夏季制冷与冬季供热模式下系统节能率分别提升5.7%和21.6%。     

Effects of evaporative inlet and aftercooling on the recuperated gas turbine cycle

Inlet air cooling and cooling of the compressor discharge using water injection boost both efficiency and power of gas turbine cycles. Four different layouts of the recuperated gas turbine cycle are presented. Those layouts include the effect of evaporative inlet and aftercooling (evaporative cooling of the compressor discharge). A parametric study of the effect of turbine inlet temperature (TIT), ambient temperature, and relative humidity on the performance of all four layouts is investigated. The results indicate that as TIT increases the optimum pressure ratio increases by 0.45 per 100 K for the regular recuperated cycle and by 1.4 per 100 K for the recuperated cycle with evaporative aftercooling. The cycles with evaporative aftercooling have distinctive pattern of performance curves and higher values of optimum pressure ratios. The results also showed that evaporative cooling of the inlet air could boost the efficiency by up to 3.2% and that evaporative aftercooling could increase the power by up to about 110% and cycle efficiency by up to 16%.     

Maisotsenko循环在燃气轮机进气冷却中的应用研究

采用基于Maisotsenko循环的露点间接蒸发式冷却作为进气冷却的手段,研究了不同环境条件下其对燃气轮机性能的提升效果。建立了针对某9E级燃气轮机的热力循环过程的计算模型,并利用该热力模型分析了进气温度变化对燃机出力的影响。基于Maisotsenko循环的原理,以温降为指标对露点间接蒸发冷却器的性能进行了分析。以功率和效率作为指标,对燃气轮机性能随环境条件的变化情况做了数值模拟,对露点蒸发式冷却与无进气冷却、直接喷雾式冷却对燃机性能的影响进行了计算分析。结果表明,在高温低湿度的条件下,露点间接蒸发式冷却能有效提升燃机性能。     

Analysis of gas turbine operating parameters with inlet fogging and wet compression processes

Inlet fogging has been widely noticed in recent years as a method of gas turbine air inlet cooling for increasing the power output in gas turbines and combined cycle power plants. The effects of evaporative cooling on gas turbine performance were studied in this paper. Evaporative cooling process occurs in both compressor inlet duct (inlet fogging) and inside the compressor (wet compression). By predicting the reduction in compressor discharge air temperature, the modeling results were compared with the corresponding results reported in literature and an acceptable difference percent point was found in this comparison. Then, the effects of both evaporative cooling in inlet duct, and wet compression in compressor, on the power output, turbine exhaust temperature, and cycle efficiency of 16 models of gas turbines categorized in four A–D classes of power output, were investigated. The results of this analysis for saturated inlet fogging as well as 1% and 2% overspray are reported and the prediction equations for the amount of actual increased net power output of various gas turbine nominal power output are proposed. Furthermore the change in values of physical parameters and moving the compressor operating point towards the surge line in compressor map was investigated in inlet fogging and wet compression processes.     

应用溴化锂吸收式制冷技术提高燃气轮机电站发电效率的研究

对燃气轮机进口的空气进行预冷,能够提高发电机组的输出功率。与蓄冷方法相比,使用燃气轮机－蒸汽联合循环电站余热锅炉低压蒸发器的一部分蒸汽为热源,利用溴化锂吸收式制冷机制取冷源,冷却燃气轮机进口处的空气,以提高发电机组的输出功率,该方法技术可行,经济效益显著。     

Performance enhancement of gas turbines by inlet air‐cooling in hot and humid climates

In this paper, a model to study the effect of inlet air‐cooling on gas turbines power and efficiency is developed for two different cooling techniques, direct mechanical refrigeration and an evaporative water spray cooler. Energy analysis is used to present the performance improvement in terms of power gain ratio and thermal efficiency change factors. Relationships are derived for an open gas turbine cycle with irreversible compression and expansion processes coupled to air‐cooling systems. The obtained results show that the power and efficiency improvements are functions of the ambient conditions and the gas turbine pressure ratio. The performance improvement is calculated for, ambient temperatures from 30 to 50°C, the whole range of humidity ratio (10–100%) and pressure ratio from 8 to 12. For direct mechanical refrigeration air‐cooling, the power improvement is associated with appreciable drop in the thermal efficiency. The maximum power gain can be obtained if the air temperature is reduced to its lowest limit that is the refrigerant evaporation temperature plus the evaporator design temperature difference. Water spray cooling process is sensitive to the ambient relative humidity and is suitable for dry air conditions. The power gain and efficiency enhancement are limited by the wet bulb temperature. The performance of spray evaporative cooler is presented in a dimensionless working graph. The daily performance of the cooling methods is examined for an ABB‐11D5 gas turbine operating under the hot humid conditions of Jeddah, Saudi Arabia. The results indicate that the direct mechanical refrigeration increased the daily power output by 6.77% versus 2.57% for the spray air‐cooling. Copyright © 2005 John Wiley & Sons, Ltd.     

Thermoeconomic optimization of an ice thermal storage system for gas turbine inlet cooling

The gas turbine power output and efficiency decrease with increasing ambient temperature. With compressor inlet air cooling, the air density and mass flow rate as well as the gas turbine net power output increase. The inlet cooling techniques include vapor or absorption refrigeration systems, evaporative cooling systems and thermal energy storage (TES) systems. In this paper the thermoeconomic analysis of ice (latent) thermal energy storage system for gas turbine inlet cooling application was performed. The optimum values of system design parameters were obtained using genetic algorithm optimization technique. The objective function included the capital and operational costs of the gas turbine, vapor compression refrigeration system, without (objective function I) and with (objective function II) corresponding cost due to the system exergy destruction. For gas turbines with net power output in the range of 25-100 MW, the inlet air cooling using a TES system increased the power output in the range of 3.9-25.7%, increased the efficiency in the range 2.1-5.2%, while increased the payback period from about 4 to 7.7 years.     

冷却空气量对涡轮冷却性能影响综述

涡轮冷却技术被广泛应用于航空发动机及燃气轮机涡轮研发中,冷却空气的引气量成为影响整机效率的重要因素之一。本文基于现代燃气轮机及航空发动机涡轮叶片采用外部冷却与内部冷却结合的复合冷却的技术发展背景,综述了国内外在冷却空气量对涡轮叶片冷却性能影响方面的研究进展,分析并总结了冷却空气量对气膜冷却、交错肋冷却以及对综合冷却效率的影响规律,并对未来的研究方向给出了一定的建议。分析表明：对气膜孔形状的探索是未来气膜冷却技术研究的重点;交错肋研究主要处于定性研究阶段,对定量研究方法的探索是目前的发展趋势;对综合冷却效率的研究还处于起步阶段,未来可以从外部冷却和内部冷却之间的相互作用关系方面对综合冷却效率开展进一步的研究。     

冷却空气对燃气轮机性能影响的计算分析

冷却空气量是影响燃气轮机性能的关键因素,透平冷却技术研究的重点方向是以最少的冷却空气量来达到最好的冷却效果,才能使燃气轮机性能达到先进水平.对市场上具有代表性的某些型号的燃气轮机冷却空气量进行了推算,并对300 MW等级燃气轮机在不同透平初温、不同冷却空气量下的性能进行了计算,对透平初温、冷却空气量对机组循环性能的影响进行了定性分析.     

Brayton refrigeration cycle for gas turbine inlet air cooling

In this paper, a new approach to enhance the performance of gas turbines operating in hot climates is investigated. Cooling the intake air at the compressor bell mouth is achieved by an air Brayton refrigerator (reverse Joule Brayton cycle) driven by the gas turbine and uses air as the working fluid. Fraction of the air is extracted from the compressor at an intermediate pressure, cooled and then expands to obtain a cold air stream, which mixes with the ambient intake. Mass and energy balance analysis of the gas turbine and the coupled Brayton refrigerator are performed. Relationships are derived for a simple open gas turbine coupled to Brayton refrigeration cycle, the heat rejected from the cooling cycle can be utilized by an industrial process such as a desalination plant. The performance improvement in terms of power gain ratio (PGR) and thermal efficiency change (TEC) factor is calculated. The results show that for fixed pressure ratio and ambient conditions, power and efficiency improvements are functions of the extraction pressure ratio and the fraction of mass extracted from the air compressor. The performance improvement is calculated for ambient temperature of 45°C and 43.4% relative humidity. The results indicated that the intake temperature could be lowered below the ISO standard with power increase up to 19.58% and appreciable decrease in the thermal efficiency (5.76% of the site value). Additionally, the present approach improved both power gain and thermal efficiency factors if air is extracted at 2 bar which is unlike all other mechanical chilling methods. Copyright © 2007 John Wiley & Sons, Ltd.     

燃气轮机陆基试验台进气系统阻力模拟装置气动性能数值分析

为某型燃气轮机陆基试验台进气系统设计了一种由5个节流板组成的进气阻力模拟装置,用于模拟燃气轮机实船状态下的进气阻力。采用CFD数值模拟方法,分析该装置阻力模拟装置节流板不同偏转角度对燃气轮机进口空气流场及总压损失的影响,通过试验验证了数值模拟结果的准确性。数值结果表明：节流板顺时针持续偏转,下流底部回流区域逐渐扩大,下游主流流速分布较均匀,有利于燃气轮机运行;同时节流板偏转使得燃气轮机进口截面顶部区域低速区扩大,截面高速分布区域更加均匀。节流板逆时针偏转会增大燃气轮机进口截面不均匀度,且引起的总压损失要大于顺时针偏转,不利于燃气轮机运行。同时还通过试验验证了数值计算模型和相关分析的可靠性,为节流板的设计、安装提供了重要的理论依据。