TURBINE COOLING SYSTEM

Abstract

A turbine cooling system is provided, having a compressor for supplying cooling air, a forward turbine rotor wheel space, a high-pressure packing seal (HPPS) bypass cavity, and a metering device. The forward turbine rotor wheel space is cooled by the cooling air supplied by the compressor. The HPPS bypass cavity is in fluid communication with and receives a portion of the cooling air from the compressor, and is in fluid communication with and supplies the cooling air to the forward turbine rotor wheel space. The metering device is in operable communication with the forward turbine rotor wheel space and the HPPS bypass cavity to modulate the cooling air supplied to the forward turbine rotor wheel space from the HPPS bypass cavity. The metering device modulates the cooling air based on at least one operating condition of the turbine.

Description

BACKGROUND OF THE INVENTION

The subject matter disclosed herein relates to a turbine cooling system system, and more specifically to a turbine cooling system having a metering device for modulating cooling air to a forward turbine rotor wheel space.

Gas turbines generally include a compressor, a combustor, one or more fuel nozzles, and a turbine. Air enters the gas turbine through an air intake and is pressurized by the compressor. The pressurized air is then mixed with fuel supplied by the fuel nozzles. The air-fuel mixture is supplied to the combustors at a specified ratio for combustion. The combustion generates pressurized exhaust gases, which drive blades of the turbine.

The turbine includes a rotor assembly having a plurality of turbine blades installed on a rotating disk. During operation the turbine blades, the rotating disk, and other components in the turbine are subjected to elevated temperatures. In an effort to maintain the temperature of the internal components of the turbine at acceptable levels, cooling air is introduced. For example, cooling air may be supplied from the combustor plenum and is used to cool a forward turbine rotor wheel space. The forward turbine rotor wheel space is located between a nozzle assembly and a compressor exit diffuser of the turbine, and may be subjected to some of the highest temperatures experienced by the turbine. Cooling air is supplied to the forward turbine rotor wheel space in order to operate in a temperature range, which is suitable for long term component durability. Under certain operating conditions, such as high ambient temperatures, the volume of cooling air may be insufficient to maintain the forward turbine rotor wheel space within the desired temperature range for long term component durability.

In one approach, the amount of cooling air supplied to the forward turbine rotor wheel space is increased by removing bore plugs from a compressor discharge casing. Removal of the bore plugs results in a portion of the high pressure air exiting the compressor to be diverted to the forward turbine rotor wheel space. However, this approach allows for cooling air to enter the forward turbine rotor wheel space at all operating conditions with no flow control. Therefore, removing the bore plugs results in a reduction in overall performance of the turbine, as more cooling air is supplied than needed during less demanding operating conditions. Moreover, this approach also requires the gas turbine to be shut down and the combustion system removed for access to the bore plugs, which can be troublesome and inconvenient. In another approach, an orifice may be provided to bypass some of the cooling air to the forward turbine rotor wheel space. However, the orifice is typically sized to provide adequate cooling to the forward turbine rotor wheel space during worst case conditions. Therefore, the orifice also results in a reduction in overall performance of the turbine, as more cooling air is supplied than needed during less demanding operating conditions.

BRIEF DESCRIPTION OF THE INVENTION

According to one aspect of the invention, a turbine cooling system is provided having a compressor for supplying cooling air, a forward turbine rotor wheel space, a high-pressure packing seal (HPPS) bypass cavity, and a metering device. The forward turbine rotor wheel space is cooled by the cooling air supplied by the compressor. The HPPS bypass cavity is in fluid communication with and receives a portion of the cooling air from the compressor, and is in fluid communication with and supplies the cooling air to the forward turbine rotor wheel space. The metering device is in operable communication with the forward turbine rotor wheel space and the HPPS bypass cavity to modulate the cooling air supplied to the forward turbine rotor wheel space from the HPPS bypass cavity. The metering device modulates the cooling air based on at least one operating condition of the turbine.

These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWING

The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

FIG. 1 is a schematic view of an exemplary gas turbine system; and

FIG. 2 is a cross-sectioned view of a portion of a compressor and a turbine section shown in FIG. 1.

The detailed description explains embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.

DETAILED DESCRIPTION OF THE INVENTION

As used herein the terms module and sub-module refer to an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that executes one or more software or firmware programs, a combinational logic circuit, and/or other suitable components that provide the described functionality.

FIG. 1 illustrates a schematic diagram of an exemplary power generation system indicated by reference number 10. The power generation system 10 is a gas turbine system having a compressor 20, a combustor 22, and a turbine 24. Air enters the power generation system 10 though an air intake 30 located in the compressor 20, and is compressed by the compressor 20. The compressed air is then mixed with fuel by a fuel nozzle 34 located in an end cover (not shown) of the combustor 22. The fuel nozzle 34 injects an air-fuel mixture into the combustor 22 in a specific ratio for combustion. The combustion generates hot pressurized exhaust gases that drives blades (not shown) that are located within the turbine 24. In one exemplary embodiment, the turbine 24 is configured into three stages having six rows of airfoils (not shown) disposed axially for channeling the hot pressurized exhaust gases. In one embodiment, the turbine 24 includes a first stage stator vane (not shown) that defines a nozzle assembly (not shown).

FIG. 2 is an enlarged view of a portion of the compressor 20 and the turbine 24 illustrating one exemplary embodiment of a metering device 46. High pressure compressor discharge air or cooling air is supplied from the compressor 20, and is located within and flows through a plenum 48. A forward turbine rotor wheel space 50 is located between the nozzle assembly (not shown) and a compressor exit diffuser (not shown). The temperature of the cooling air in the plenum 48 is lower than the temperature of the air located in the forward turbine rotor wheel space 50. Specifically, the forward turbine rotor wheel space 50 tends to experience some of the highest temperatures of the turbine 24 due to the specific location of the forward turbine rotor wheel space 50 in relation to some of the other components of the power generation system 10, such as the combustor 22. Therefore, the cooling air located in the plenum 48 is used to provide cooling to the forward turbine rotor wheel space 50. The metering device 46 is used to modulate the amount of cooling air supplied to the forward turbine rotor wheel space 50.

Continuing to refer to FIG. 2, the cooling air from the plenum 48 flows through a cooling channel 52. A portion of the cooling air from the cooling channel 52 leaks past a pressure packing seal (HPPS) 56 to create a HPPS leakage flow 58. The HPPS leakage flow 58 flows to the forward turbine rotor wheel space 50, and is employed to provide cooling to the forward turbine rotor wheel space 50. The remaining cooling air that does not leak past the HPPS 56 flows into a HPPS bypass cavity 60. The metering device 46 is employed to modulate the amount of cooling air supplied to the forward turbine rotor wheel space 50 from the HPPS bypass cavity 60.

The metering device 46 is typically any type of variable orifice that is able to modulate the amount of cooling air that is supplied to the forward turbine rotor wheel space such as, for example, a valve or a solenoid. In the exemplary embodiment as shown in FIG. 2, the metering device 46 is a pintle-type valve 62, however it is understood that other metering devices may be used as well. The valve 62 includes a needle or pintle 64 that is an elongated member that cooperates with an orifice 66 located in a wall 68 of the HPPS bypass cavity 60 to modulate the amount of cooling air supplied to the forward turbine rotor wheel space 50. Specifically, in the exemplary embodiment as shown, the pintle 62 includes an angular outer surface 70, and the orifice 66 also includes a corresponding angular surface 72. The pintle 62 is selectively actuated by a valve portion 74 of the pintle-type valve 62 in the directions D1 and D2. In one embodiment, the valve portion 74 is a piezoelectric device that actuates the pintle 62 based on electrical current, however it is understood that other approaches may be used as well.

The angular outer surface 70 of the pintle 62 cooperates with the corresponding angular surface 72 of the orifice 66 to modulate the amount of cooling air supplied to the forward turbine rotor wheel space 50. That is, when the pintle 62 is actuated in the first direction D1, the pintle 62 is actuated towards the orifice 66, and decreases the amount of cooling air supplied to the forward turbine rotor wheel space 50. When the pintle 62 is actuated in the second direction D2, the pintle 62 is actuated away from the orifice 66 and the amount of cooling air supplied to the forward turbine rotor wheel space 50 increases.

The modulation of the metering device 46 is controlled by a control module 80 that is in communication with the metering device 46 through a data link 82. The data link 82 could be a hard-wired or a wireless radio frequency (RF) data link used to communicate control signals to the metering device 46. The control module 80 includes control logic for sending a control signal to the metering device 46 to either increase or decrease the amount of cooling air supplied to the forward turbine rotor wheel space 50 based on specific operating conditions. For example, in the exemplary embodiment as shown in FIG. 2, the control module 80 includes control logic for sending a control signal to the metering device 46 to actuate the pintle 62 in the directions D1 and D2. Specifically, the control module 80 either increases or decreases the amount of cooling air based on at least one of the following operating conditions which include but are not limited to ambient temperature, overall back flow margin of the turbine 24, bulk metal temperature of the turbine blades, forward turbine rotor wheel space temperature, turbine emissions requirements, and compressor discharge pressure.

In one embodiment, the control module 80 is connected to and receives temperature data from an ambient sensor (not shown). As the ambient temperature changes, the control module 80 includes control logic for sending a control signal to the metering device 46 to either increase or decrease the amount of cooling air to the forward turbine rotor wheel space 50. For example, as the ambient temperature increases, the control module 80 includes control logic for sending a control signal to the metering device 46 to increase the amount of cooling air supplied to the forward turbine rotor wheel space 50.

The control module 80 may also include control logic for modulating the amount of cooling air supplied to the forward turbine rotor wheel space 50 based on the overall back flow margin of the turbine 24. The overall back flow margin is the difference between the cooling air pressure and the gas flow pressure of the turbine 24, where a positive overall back flow margin is typically maintained. The back flow margin may be a calculated or measured value. In one example, if the back flow margin is not sufficient, then the control module 80 includes control logic for sending a control signal to the metering device 46 to increase the amount of cooling air supplied to the forward turbine rotor wheel space 50.

The control module 80 may include control logic for modulating the cooling air to the forward turbine rotor wheel space 50 based on the bulk metal temperature of the turbine blades (not shown). Specifically, in one embodiment if the bulk metal temperature of the turbine blades exceeds a pre-defined temperature limit, then the control module 80 includes control logic for sending a control signal to the metering device 46 to increase the amount of cooling air supplied to the forward turbine rotor wheel space 50.

The control module 80 may include control logic for modulating the cooling air to the forward turbine rotor wheel space 50 based on the air temperature of the forward turbine rotor wheel space 50. For example, in one embodiment, if the temperature of the forward turbine rotor wheel space 50 exceeds a pre-defined temperature limit, then the control module 80 includes control logic for increasing the amount of cooling air to the forward turbine rotor wheel space 50.

The control module 80 may also include control logic for modulating the amount of cooling air to the forward turbine rotor wheel space 50 based on emissions requirements. For example, in one embodiment, during a turndown mode of the power generation system 10, increased airflow extraction out the plenum 48 is utilized to by-pass the primary combustion zone during load rejection resulting in a reduction in the mass flow rate of air entering the combustor 22 (shown in FIG. 1); which in turn results in a lower combustion temperature resulting in reduced emissions. Thus the metering device 46 is modulated to increase the amount of cooling air supplied to the forward turbine rotor wheel space 50.

The control module 80 may also include control logic for modulating the amount of cooling air to the forward turbine rotor wheel space 50 to provide compressor surge protection. Specially, as the power generation system 10 operates at relatively high compressor pressure ratios, the pressure ratio of the compressor 20 may eventually exceed a critical value, which results in a rapid reduction of compressor discharge pressure. The decrease in compressor discharge pressure results in flow separation, which is known as compressor surge. Thus, the amount of cooling air to the forward turbine rotor wheel space 50 is modulated to provide a compressor discharge ratio that is a specified margin away from a surge boundary of the compressor 20. Modulating the amount of cooling air supplied to the forward turbine rotor wheel space 50 reduces or substantially reduces or eliminates the need to recirculate a portion of the compressor discharge air back to the compressor inlet by an inlet bleed valve. Recirculating a portion of the compressor discharge air back to the compressor inlet is referred to as inlet bleed heat.

The amount of cooling air is modulated to the forward turbine rotor wheel space 50 in an effort to manage turbine rotor cooling and enhance the part-life of the internal turbine components. Actively modulating the amount of cooling air to the forward turbine rotor wheel space 50 also increases the overall performance of the power generation system 10 when compared to some of the other approaches that are currently being used to increase cooling air to the forward turbine rotor wheel space 50. For example, one approach for increasing cooling air involves removing the bore plugs from the compressor discharge casing. However, this results in cooling air entering the forward turbine rotor wheel space at all operating conditions with no flow control, and reduces the overall performance of the turbine. In contrast, actively modulating the amount of cooling air to the forward turbine rotor wheel space 50 allows for the amount of cooling air to be adjusted depending on specific operating conditions, which in turn increases overall performance of the power generation system 10.

While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.

Claims

1. A turbine cooling system for a turbine, comprising:

a compressor supplying a cooling air;

a forward turbine rotor wheel space cooled by the cooling air supplied by the compressor;

a high-pressure packing seal (HPPS) bypass cavity in fluid communication with and receiving a portion of the cooling air from the compressor, the HPPS bypass cavity in fluid communication with and supplying the cooling air to the forward turbine rotor wheel space; and

a metering device in operable communication with the forward turbine rotor wheel space and the HPPS bypass cavity to modulate the cooling air supplied to the forward turbine rotor wheel space from the HPPS bypass cavity, the metering device modulating the cooling air based on at least one operating condition of the turbine.

2. The turbine cooling system of claim 1, wherein the at least one operating condition is at least one of ambient temperature, an overall back flow margin of the turbine, a bulk metal temperature of a plurality of turbine blades, a forward turbine rotor wheel space temperature, a turbine emissions requirement, and a compressor discharge pressure.

3. The turbine cooling system of claim 1, wherein modulation of the metering device is controlled by a control module in communication with the metering device.

4. The turbine cooling system of claim 3, wherein the control module includes a control logic for sending a control signal to the metering device to modulate the cooling air supplied to the forward turbine rotor wheel space depending on an ambient temperature.

5. The turbine cooling system of claim 3, wherein the control module includes a control logic for modulating the cooling air to the forward turbine rotor wheel space based on a bulk metal temperature of a plurality of turbine blades.

6. The turbine cooling system of claim 3, wherein the control module includes a control logic for modulating the cooling air to the forward turbine rotor wheel space based on an air temperature of the forward turbine rotor wheel space.

7. The turbine cooling system of claim 3, wherein the control module includes a control logic for modulating the amount of cooling air to the forward turbine rotor wheel space based on emissions requirements

8. The turbine cooling system of claim 3, wherein the control module includes a control logic for modulating the amount of cooling air to the forward turbine rotor wheel space to provide compressor surge protection for the compressor.

9. The turbine cooling system of claim 1, further comprising a high-pressure packing seal (HPPS), wherein a portion of the cooling air from the forward turbine rotor wheel space leaks past the HPPS to create a HPPS leakage flow that flows to the forward turbine rotor wheel space.

10. The turbine cooling system of claim 1, wherein the metering device is one of a valve, a solenoid, and a pintle-type valve.

11. A turbine cooling system for a turbine, comprising:

a compressor supplying a cooling air;

a forward turbine rotor wheel space cooled by the cooling air supplied by the compressor;

a high-pressure packing seal (HPPS) bypass cavity in fluid communication with and receiving a portion of the cooling air from the compressor, the HPPS bypass cavity in fluid communication with and supplying the cooling air to the forward turbine rotor wheel space;

a metering device in operable communication with the forward turbine rotor wheel space and the HPPS bypass cavity to modulate the cooling air supplied to the forward turbine rotor wheel space from the HPPS bypass cavity, the metering device modulating the cooling air based on at least one operating condition of the turbine; and

a control module in communication with the metering device, the control module including control logic for sending a control signal to the metering device to modulate the cooling air based on the at least one operating condition of the turbine.

12. The turbine cooling system of claim 11, wherein the control module includes a control logic for sending a control signal to the metering device to modulate the cooling air supplied to the forward turbine rotor wheel space depending on an ambient temperature.

13. The turbine cooling system of claim 11, wherein the control module includes a control logic for modulating the cooling air to the forward turbine rotor wheel space based on a bulk metal temperature of a plurality of turbine blades.

14. The turbine cooling system of claim 11, wherein the control module includes a control logic for modulating the cooling air to the forward turbine rotor wheel space based on an air temperature of the forward turbine rotor wheel space.

15. The turbine cooling system of claim 11, wherein the control module includes a control logic for modulating the amount of cooling air to the forward turbine rotor wheel space based on emissions requirements.

16. The turbine cooling system of claim 11, wherein the control module includes a control logic for modulating the amount of cooling air to the forward turbine rotor wheel space to provide compressor surge protection for the compressor.

17. The turbine cooling system of claim 11, further comprising a high-pressure packing seal (HPPS), wherein a portion of the cooling air from the forward turbine rotor wheel space leaks past the HPPS to create a HPPS leakage flow that flows to the forward turbine rotor wheel space.

18. The turbine cooling system of claim 11, wherein the metering device is one of a valve, a solenoid, and a pintle-type valve.

19. A turbine having a turbine cooling system, comprising:

a compressor supplying a cooling air;

a forward turbine rotor wheel space cooled by the cooling air supplied by the compressor;

a high-pressure packing seal (HPPS) bypass cavity in fluid communication with and receiving a portion of the cooling air from the compressor, the HPPS bypass cavity in fluid communication with and supplying the cooling air to the forward turbine rotor wheel space;

a metering device in operable communication with the forward turbine rotor wheel space and the HPPS bypass cavity to modulate the cooling air supplied to the forward turbine rotor wheel space from the HPPS bypass cavity, the metering device modulating the cooling air based on at least one operating condition of the turbine; and

a control module in communication with the metering device, the control module including control logic for sending a control signal to the metering device to modulate the cooling air based on the at least one operating condition of the turbine cooling system, and the control module including a control logic for sending a control signal to the metering device to increase the amount of cooling air to the forward turbine rotor wheel space.

20. The turbine of claim 19, wherein the at least one operating condition is at least one of an overall back flow margin of the turbine, a bulk metal temperature of a plurality of turbine blades, a forward turbine rotor wheel space temperature, a turbine emissions requirement, and a compressor discharge pressure.