TURBOMACHINE ASSEMBLY AND METHOD OF USING SAME

Abstract

A turbomachine assembly generally has a compressor section including a first end of a rotating member and a first cover configured to substantially enclose the first end therein. The compressor section includes a bypass valve coupled to the first cover portion and configured to control fluid flow within the compressor section to enable controlling at least one operating parameter of the compressor section. A turbine section is arranged in flow communication with the compressor section. The turbine section includes a second end of the rotating member and a second cover configured to substantially enclose the second end therein. At least one regulating valve that is in flow communication with the compressor section and the turbine section, wherein the regulating valve is configured to control fluid flow between the compressor and turbine sections to enable controlling at least one operating parameter of the turbine section.

Description

BACKGROUND

The field of the invention relates generally to power systems and, more particularly, to a turbomachine assembly that may be used in power systems.

At least some known power systems use at least one machine that is coupled to a load. The machine may be a turbomachine, such as a turbine engine, that generates mechanical torque. The load may be an electrical system, such as an electrical generator or inverter, which converts mechanical energy to electrical energy for a power output. The load may also be coupled to an energy storage device such that some of the power output may be stored for later use. For example, at least some known power systems provide bi-directional electrical energy or power flow, wherein the power output from the load may be transferred to the turbine engine to power the turbomachine or the power output may be delivered to, for example, the energy storage device for storage. At least some known turbomachines have allowable performance thresholds that may be attained by, for example, monitoring and/or controlling various operating parameters of the entire turbomachine. For example, a control system may be used to monitor and/or control the flow rate and/or the temperature within the entire turbomachine.

While monitoring and controlling operating parameters within the entire turbomachine does improve the potential to achieve performance thresholds for the entire turbomachine, desired thresholds may not be met because the individual components are not independently monitored and/or controlled. More specifically, at least some known turbomachines that are used to recover energy or are used to generate power include a turbine having a rotor that is coupled to either a compressor or a pump rotor. Turbines and compressors, as well as pumps, each have their own unique allowable performance thresholds or envelopes in which they each operate efficiently. As such, each individual component within the turbomachine may need to be monitored and/or controlled as well.

However, due to the configuration of many turbomachines, controlling operating parameters for each of the components independently may be difficult. More specifically, the turbine is coupled to either the compressor or to the rotor pump via a common shaft. Since there is a common shaft between such components, it can be difficult to vary the performance characteristics of each of the components. As such, the turbomachine may be unable to attain the performance threshold or envelopes for each of the components. Turbomachines performing outside the allowable performance thresholds or envelops may cause unstable operational parameters, such as an unstable flow rate, temperature, or pressure. Such unstable operational parameters may lead to a failure of at least one component of the turbomachine and/or the power system, prevent proper bi-directional power flow, and/or adversely affect the overall operation of the turbomachine and/or the power system.

BRIEF DESCRIPTION

In an exemplary embodiment, a turbomachine assembly is provided. The turbomachine assembly generally comprises a compressor section that includes a first end of a rotating member and a first cover portion that is configured to substantially enclose at least a portion of the first end of the rotating member therein. The compressor section also includes a bypass valve that is coupled to the first cover portion, wherein the bypass valve is configured to control fluid flow being channeled within the compressor section to enable controlling at least one operating parameter of the compressor section. A turbine section is arranged in flow communication with the compressor section, such as proximate to the compressor section. The turbine section includes a second end of the rotating member and a second cover portion that is configured to substantially enclose at least a portion of the second end of the rotating member therein. At least one regulating valve is in flow communication with the compressor section and the turbine section. The regulating valve is configured to control fluid flow being channeled between the compressor section and the turbine section to enable controlling at least one operating parameter of the turbine section. Controlling the operating parameter(s) of each of the compressor and turbine sections, at least partly independently, facilitates attaining a predefined performance threshold for each of the compressor and turbine sections.

In another embodiment, a power system is provided. The power system generally comprises a load apparatus that includes a load configured to convert mechanical rotational energy to electrical energy for a power output. The power system also includes a turbomachine assembly that is coupled to the load apparatus. The turbomachine assembly includes a compressor section that includes a first end of a rotating member and a first cover portion that is configured to substantially enclose at least a portion of the first end of the rotating member therein. The compressor section also includes a bypass valve that is coupled to the first cover portion, wherein the bypass valve is configured to control fluid flow being channeled within the compressor section to enable controlling at least one operating parameter of the compressor section. A turbine section is arranged in flow communication with the compressor section. The turbine section includes a second end of the rotating member and a second cover portion that is configured to substantially enclose at least a portion of the second end of the rotating member therein. Moreover, the turbomachine assembly includes at least one regulating valve that is in flow communication with the compressor section and the turbine section. The regulating valve is configured to control fluid flow being channeled between the compressor section and the turbine section to enable controlling at least one operating parameter of the turbine section. Controlling the operating parameter(s) of each of the compressor and turbine sections, at least partly independently, facilitates attaining a predefined performance threshold for each of the compressor and turbine sections.

In yet another embodiment, a method of using a turbomachine assembly is provided. The method includes providing a compressor section that includes a first end of a rotating member and a first cover portion that is configured to substantially enclose at least a portion of the first end of the rotating member therein. The compressor section also includes a bypass valve coupled to the first cover portion. Fluid flow being channeled within the compressor section is controlled via the bypass valve to enable controlling at least one operating parameter of the compressor section. A turbine section is arranged in flow communication with the compressor section, preferably proximate to the compressor section. The turbine section includes a second end of the rotating member and a second cover portion that is configured to substantially enclose at least a portion of the second end of the rotating member therein. Fluid flow being channeled between the compressor section and the turbine section is controlled, via at least one regulating valve in flow communication with the compressor section and the turbine section, to enable controlling at least one operating parameter of the turbine section. Controlling the operating parameter(s) of each of the compressor and turbine sections, at least partly independently, facilitates attaining a predefined performance threshold for each.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of an exemplary power system;

FIG. 2 is a perspective view of a portion of an exemplary turbomachine assembly that may be used with the power system shown in FIG. 1 and taken from area 2;

FIG. 3 is a perspective view of a portion of the turbomachine assembly shown in FIG. 2 and taken from area 3;

FIG. 4 is a side view of a portion of the turbomachine assembly shown in FIG. 2 and taken from area 4; and

FIG. 5 is a cross-sectional view of a portion of the turbomachine assembly shown in FIG. 2 and taken along line 5-5.

DETAILED DESCRIPTION

The exemplary systems and methods described herein provide a turbomachine assembly for use in a power system, wherein the turbomachine assembly is configured to enable the operational parameters for each of the components therein to be controlled independently such that desired performance thresholds or envelopes for each of the components may be attained. The turbomachine assembly includes a compressor section and a turbine section in flow communication with the compressor section. The compressor section includes a bypass valve configured to control fluid flow being channeled within the compressor section to enable controlling at least one operating parameter of the compressor section. At least one regulating valve is in flow communication with the compressor section and the turbine section. The regulating valve is configured to control fluid flow being channeled between the compressor section and the turbine section to enable controlling at least one operating parameter of the turbine section. Accordingly, the turbomachine assembly is configured such that the operational parameters for each of the compressor and turbine sections can be separately controlled. Being able to independently control the operating parameter(s) of each of the compressor and turbine sections facilitates attaining a predefined performance threshold for each section.

FIG. 1 illustrates an exemplary power system 100. Although the exemplary embodiment illustrates a power system, the present disclosure is not limited to power systems, and one of ordinary skill in the art will appreciate that the current disclosure may be used in connection with other types of system. In the exemplary embodiment, power system 100 includes a turbomachine assembly 102 that is coupled to a load apparatus 104 via a drive shaft 106. It should be noted that, as used herein, the term “couple” is not limited to a direct mechanical, thermal, flow communication, and/or an electrical connection between components, but may also include an indirect mechanical, thermal, flow communication and/or electrical connection between multiple components.

In the exemplary embodiment, turbomachine assembly 102 includes a compressor section (not shown in FIG. 1), a turbine section (not shown in FIG. 1) coupled downstream from the compressor section via a rotor shaft (not shown in FIG. 1), and a center section positioned between the compressor and turbine sections (not shown in FIG. 1). In one embodiment, turbomachine assembly 102 may include an energy source (not shown) and an energy injection system, such as a combustible fuel source and a fuel injection assembly, to facilitate powering turbomachine assembly 102. For example, a burner (not shown in FIG. 1) may be positioned proximate to the turbine section and/or a combustor (not shown) may be positioned in the center section. The fuel source may then channel fuel, via the fuel injection assembly, to the burner and/or to the combustor such that the energy can be used to facilitate generating combustion gases that can be used by the turbine section.

Load apparatus 104, in the exemplary embodiment, includes a load (not shown) such as an electrical system, in particular a high speed electrical generator or inverter. More specifically, in the exemplary embodiment, load apparatus 104 can comprise the load apparatus described in co-pending U.S. patent application Ser. No. 13/682,313 entitled LOAD APPARATUS AND METHOD OF USING SAME (attorney docket no. 31938-6) filed Jan. 29, 2013, which is incorporated herein by reference in its entirety. Load apparatus 104 can be coupled to an energy storage device 110, such as a battery.

Power system 100 also includes a control system 114 that is coupled to each of load apparatus 104 and turbomachine assembly 102. Control system 114, in the exemplary embodiment, is configured to control the power output produced by load apparatus 104 and to control fluid flow within turbomachine assembly 102. In the exemplary embodiment, control system 114 includes a controller 120 that is operatively coupled to vary the operation of load apparatus 104 and turbomachine assembly 102, as a function of values determined from sensors (not shown) responsive to parameters such as flow rates, rotational speed, local pressures, torque, temperatures and the like, as well as rates of change of such parameters, according to a programmed control scheme or algorithm. More specifically, controller 120 may be coupled to, for example, at least one valve (not shown) in load apparatus 104 and at least one valve (not shown in FIG. 1) in turbomachine assembly 102. Controller 120 is enabled to facilitate operative features of the valves, via features that include, without limitation, receiving permissive inputs, transmitting permissive outputs, and transmitting opening and closing commands.

In the exemplary embodiment, controller 120 may be a real-time controller and may include any suitable processor-based or microprocessor-based system, such as a computer system, that includes microcontrollers, reduced instruction set circuits (RISC), application-specific integrated circuits (ASICs), logic circuits, and/or any other circuit or processor that is capable of executing the functions described herein. In one embodiment, controller 120 may be a microprocessor that includes read-only memory (ROM) and/or random access memory (RAM), such as, for example, a 32 bit microcomputer with 2 Mbit ROM and 64 Kbit RAM. As used herein, the term “real-time” refers to outcomes occurring in a substantially short period of time after a change in the inputs affect the outcome, with the time period being a design parameter that may be selected based on the importance of the outcome and/or the capability of the system processing the inputs to generate the outcome.

Controller 120, in the exemplary embodiment, includes a memory device 130 that stores executable instructions and/or one or more operating parameters representing and/or indicating an operating condition of load apparatus 104 and of turbomachine assembly 102. Controller 120 also includes a processor 132 that is coupled to the memory device 130 via a system bus 134. In one embodiment, processor 132 may include a processing unit, such as, without limitation, an integrated circuit (IC), an application specific integrated circuit (ASIC), a microcomputer, a programmable logic controller (PLC), and/or any other programmable circuit. Alternatively, processor 132 may include multiple processing units (e.g., in a multi-core configuration). The above examples are exemplary only, and thus are not intended to limit in any way the definition and/or meaning of the term “processor.”

Moreover, in the exemplary embodiment, controller 120 includes a control interface 136 that is coupled to turbomachine assembly 102 and to load apparatus 104. More specifically, control interface 136 is coupled to the valves within turbomachine assembly 102 and within load apparatus 104, and control interface 136 is configured to control an operation of the valves. For example, processor 132 may be programmed to generate one or more control parameters that are transmitted to control interface 136. Control interface 136 may then transmit a control parameter to modulate, open, or close the valves.

Various connections are available between control interface 136 and turbomachine assembly 102 and load apparatus 104. Such connections may include, without limitation, an electrical conductor, a low-level serial data connection, such as Recommended Standard (RS) 232 or RS-485, a high-level serial data connection, such as USB, a field bus, a PROFIBUS®, or Institute of Electrical and Electronics Engineers (IEEE) 1394 (a/k/a FIREWIRE), a parallel data connection, such as IEEE 1284 or IEEE 488, a short-range wireless communication channel such as BLUETOOTH, and/or a private (e.g., inaccessible outside power system 100) network connection, whether wired or wireless. PROFIBUS is a registered trademark of Profibus Trade Organization of Scottsdale, Ariz. IEEE is a registered trademark of the Institute of Electrical and Electronics Engineers, Inc., of New York, N.Y. BLUETOOTH is a registered trademark of Bluetooth SIG, Inc. of Kirkland, Wash.

In the exemplary embodiment, control system 114 also includes at least one sensor 137 that is coupled to load apparatus 104 and to controller 120. More specifically, in the exemplary embodiment, controller 120 includes a sensor interface 140 that is coupled to sensor 137. In the exemplary embodiment, sensor 137 is positioned in close proximity to, and coupled to at least a portion of load apparatus 104. Alternatively, sensor 137 may be coupled to various other components within power system 100. In the exemplary embodiment, sensor 137 is configured to detect the level of the power output being produced by load apparatus 104. Alternatively, sensor 137 may detect various other operating parameters that enable load apparatus 134 and/or power system 100 to function as described herein.

Control system 114 also includes at least two sensors 142 and 143 that are each coupled to turbomachine assembly 102 and to controller 120. In the exemplary embodiment, sensors 142 and 143 are each positioned in close proximity to, and coupled to at least a portion of turbomachine assembly 102 and to sensor interface 140. More specifically, sensor 142 is coupled to the compressor section and sensor 143 is coupled to the turbine section of turbomachine assembly 102. In the exemplary embodiment, sensors 142 and 143 are each configured to detect various operating parameters, such as temperature and/or flow rate, within the compressor section and the turbine section, respectively.

Sensors 137, 142, and 143 each transmit a signal corresponding to their respective detected parameters to controller 120. Sensors 137, 142, and 143 may each transmit a signal continuously, periodically, or only once, for example. Other signal timings may also be contemplated. Furthermore, sensors 137, 142, and 143 may each transmit a signal either in an analog form or in a digital form. Various connections are available between sensor interface 140 and sensors 137, 142, and 143. Such connections may include, without limitation, an electrical conductor, a low-level serial data connection, such as RS 232 or RS-485, a high-level serial data connection, such as USB or IEEE® 1394, a parallel data connection, such as IEEE® 1284 or IEEE® 488, a short-range wireless communication channel such as BLUETOOTH®, and/or a private (e.g., inaccessible outside power system 100) network connection, whether wired or wireless.

Control system 114 may also include a user computing device 150 that is coupled to controller 120 via a network 149. More specifically, computing device 150 includes a communication interface 151 that is coupled to a communication interface 153 contained within controller 120. User computing device 150 includes a processor 152 for executing instructions. In some embodiments, executable instructions are stored in a memory device 154. Processor 152 may include one or more processing units (e.g., in a multi-core configuration). Memory device 154 is any device allowing information, such as executable instructions and/or other data, to be stored and retrieved.

User computing device 150 also includes at least one media output component 156 for use in presenting information to a user. Media output component 156 is any component capable of conveying information to the user. Media output component 156 may include, without limitation, a display device (not shown) (e.g., a liquid crystal display (LCD), an organic light emitting diode (OLED) display, or an audio output device (e.g., a speaker or headphones)).

Moreover, in the exemplary embodiment, user computing device 150 includes an input interface 160 for receiving input from a user. Input interface 160 may include, for example, a keyboard, a pointing device, a mouse, a stylus, a touch sensitive panel (e.g., a touch pad or a touch screen), a gyroscope, an accelerometer, a position detector, and/or an audio input device. A single component, such as a touch screen, may function as both an output device of media output component 156 and input interface 160.

During operation of power system 100, air is channeled to the compressor section, wherein the air is compressed to a higher pressure and temperature prior to being discharged towards the center section. The compressed air may then be mixed with fuel and other fluids and ignited to generate combustion gases that are channeled towards the turbine section. More specifically, fuel, such as natural gas and/or fuel oil, air, diluents, and/or Nitrogen gas (N₂), may be channeled into, for example, the combustor section, via the fuel injection assembly, and into the air flow. The blended mixtures are ignited within the combustor section to generate high temperature combustion gases that are channeled towards the turbine section. The turbine section converts the thermal energy from the gas stream to mechanical rotational energy, as the combustion gases impart rotational energy to the turbine section and to the rotational components contained therein.

The mechanical rotational energy is converted to electrical energy via load apparatus 104 for a power output. Load apparatus 104 facilitates bi-directional power flow within power system 100 such that the power output from load apparatus 104 may be transferred to turbomachine assembly 102 to power the turbomachine assembly 102 or the power output may be delivered to, for example, energy storage device 110. For example, a user may initially input a predefined threshold value for a power output from load apparatus 104 via input interface 160. The predefined threshold value may be programmed with user computing device 150 and/or controller 120. As such, when the mechanical rotational energy is converted to electrical energy via load apparatus 104 for a power output, the output is detected by sensor 137. Sensor 137 then transmits a signal representative of the power output to controller 120.

Depending on whether the power output is less than, greater than, or equal to the predefined threshold, controller 120 will transmit a control parameter to the valve within load apparatus 104. For example, in the exemplary embodiment, if the power output exceeds the predefined threshold, controller 120 will transmit a control parameter to the valve such that electrical energy (i.e. power output) is channeled in a first direction 184 towards energy storage device 110 such that the power output may be stored for later use by power system 100. If the power output is below the predefined threshold, controller 120 may transmit a control parameter to the valve such that electrical energy is channeled in a second direction 186 towards turbomachine assembly 102 such that the power output may be used by turbomachine assembly 102 to generate additional power.

Moreover, during operation of power system 100, the rotor shaft within turbomachine assembly 102 rotates. As explained in more detail below with respect to FIGS. 2-5, the rotor shaft extends from the compressor section to the turbine section. Despite having a common shaft between each of the components within turbomachine assembly 102, the operational parameters for each of the components therein may be independently controlled by control system 114. As explained in more detail below with respect to FIGS. 2-5, turbomachine assembly 102 is configured such that control system 114 can independently control the operational parameters for each of the components therein such that performance thresholds and envelopes for each of the components of turbomachine assembly 102 may be attained.

FIG. 2 is a perspective view of a portion of turbomachine assembly 102 taken from area 2 (shown in FIG. 1). FIG. 3 is a perspective view of a portion of turbomachine assembly 102 taken from area 3 (shown in FIG. 2). FIG. 4 is a side view of a portion of turbomachine assembly 102 taken from area 4 (shown in FIG. 2). FIG. 5 is a cross-sectional view of a portion of turbomachine assembly 102 taken along line 5-5 (shown in FIG. 2).

Referring to FIGS. 2 and 5, turbomachine assembly 102 includes a compressor section 202 and a turbine section 204 coupled to compressor section 202 via a rotor shaft 206 such that turbine section 204 is positioned downstream from compressor section 202 and such that turbine section 204 is in flow communication with compressor section 202. In the exemplary embodiment, rotor shaft 206 includes a first end portion 208, a second end portion 210, and a middle portion 211 therebetween. Rotor shaft 206 extends from compressor section 202 to turbine section 204 such that first end portion 208 of rotor shaft 206 is positioned within compressor section 202 and second end portion 210 of rotor shaft 206 is positioned within turbine section 204. A compressor rotor 212 substantially circumscribes at least a portion of first end portion 208 and a turbine rotor 214 substantially circumscribes at least a portion of second end portion 210.

In the exemplary embodiment, referring to FIGS. 4 and 5, compressor rotor 212 includes an annular base portion 201 having an exterior surface 203 and an opposing interior surface 205, wherein interior surface 205 substantially circumscribes at least a portion of first end portion 208 of rotor shaft 206 and a plurality of rotor blades 207 extend radially outwardly from base portion exterior surface 203 such that each blade 207 is substantially perpendicular with respect to exterior surface 203. Similarly, referring to FIGS. 3 and 5, turbine rotor 214 includes an annular base portion 217 having an exterior surface 209 and an opposing interior surface 213, wherein interior surface 213 substantially circumscribes at least a portion of second end portion 210 of rotor shaft 206 and a plurality of rotor blades 219 extend radially outwardly from exterior surface 209 such that each blade 219 is substantially perpendicular with respect to exterior surface 209. Turbomachine assembly 102 also includes at least two shaft bearings 216 such that one bearing 216 is adjacent to at least a portion of first end portion 208 of rotor shaft 206 and one bearing 216 is adjacent to at least a portion of second end portion 210 of rotor shaft 206.

In the exemplary embodiment, first end portion 208, middle portion 211, and second end portion 210 of rotor shaft 206 are formed integrally together such that rotor shaft 206 is a single unitary component. Alternatively, one or more of the components of rotor shaft 206 may be formed separate and removably or permanently coupled together. Each of the first end portion 208, middle portion 211, and second end portion 210 of rotor shaft 206 may be formed via a variety of manufacturing processes known in the art, such as, but not limited to, molding processes, drawing processes, or machining processes. One or more types of materials may be used to fabricate rotor shaft 206 with the materials selected based on suitability for one or more manufacturing techniques, dimensional stability, cost, moldability, workability, rigidity, and/or other characteristic of the material(s). For example, rotor shaft 206 may be at least partially formed from lightweight and rigid materials, such as an alumina material, a ceramic material, and/or a metal matrix composite material. The metal matrix composite material may include a first metal material and at least one other material, such as a second metal material and/or a ceramic compound. Alternatively, rotor shaft 206 may be formed of any suitable material that enables the turbomachine assembly 102 and/or power system 100 (shown in FIG. 1) to function as described herein.

In the exemplary embodiment, compressor section 202 is coupled to load apparatus 114 (shown in FIG. 1) such that compressor section 202 is directly adjacent to load apparatus 114. More specifically, first end portion 208 of rotor shaft 206 is coupled to drive shaft 106 (shown in FIG. 1). Referring to FIGS. 2, 4, and 5, compressor section 202 includes a cover portion 218 that is configured to substantially enclose at least a portion of first end portion 208 of rotor shaft 206 and at least a portion of compressor rotor 212 therein. Cover portion 218 may be formed via a variety of manufacturing processes known in the art, such as, but not limited to, molding processes, drawing processes, or machining processes. One or more types of materials may be used to fabricate cover portion 218 with the materials selected based on suitability for one or more manufacturing techniques, dimensional stability, cost, moldability, workability, rigidity, and/or other characteristic of the material(s). For example, cover portion 218 may be at least partially formed from a metal material.

Referring to FIG. 5, compressor section 202 includes a bypass valve 223 coupled to cover portion 218. More specifically, in the exemplary embodiment, cover portion 218 includes a channel 230 that defines a flow path 232 therein, and bypass valve 223 is positioned within flow path 232. Channel 230 is in flow communication with a compressor inlet opening 240 and a compressor bypass circuit inlet opening 242. In the exemplary embodiment, bypass valve 223 is configured to be modulated such that flow path 232 may be opened, closed, or partially opened such that fluid flow may be controlled within flow path 232. More specifically, bypass valve 223 is configured to be modulated such that fluid flow may be directed in a first direction 234 through bypass circuit inlet opening 242 and towards load apparatus 114 or in a second direction 236 through compressor inlet opening 240 and towards other components within turbomachine assembly 102.

Referring to FIGS. 2, 3, and 5, turbine section 204 includes a turbine cover portion 250 that is configured to substantially enclose at least portion of second end portion 210 of rotor shaft 206 and at least a portion of turbine rotor 214 therein. Turbine cover portion 250 may be formed via a variety of manufacturing processes known in the art, such as, but not limited to, molding processes, drawing processes, or machining processes. One or more types of materials may be used to fabricate turbine cover portion 250 with the materials selected based on suitability for one or more manufacturing techniques, dimensional stability, cost, moldability, workability, rigidity, and/or other characteristic of the material(s). For example, turbine cover portion 250 may be at least partially formed from a metal material.

In the exemplary embodiment, referring to FIG. 5, turbine cover portion 250 includes a channel 252 that defines a flow path 254 therein such that fluids, including but not limited to exhausts being emitted from turbomachine assembly 102, may be channeled through flow path 254. In some embodiments, cover portion 250 may include an opening (not shown) such that channel 252 may be in flow communication with a conduit (not shown) that couples turbomachine assembly 102 to at least one other machine (not shown). For example, the machine may generate and/or emit fluids, such as exhaust gases, and the conduit may channel such fluids from the machine to turbine section 204 of turbomachine assembly 102. A burner 258 may be included within turbine section 204.

Moreover, in the exemplary embodiment, at least one heat exchanger 259 is positioned within turbine section 204, wherein heat exchanger 259 is configured to receive waste heat, such as exhaust gases, from the machine and/or from turbomachine assembly 102. For example, heat exchanger 259 may be positioned adjacent to the cover portion opening such that exhaust gases being channeled to turbine section 204 from the machine may be recovered by heat exchanger 259. Exhaust gases being generated by turbine section 204 may also be recovered by heat exchanger 259. In the exemplary embodiment, heat exchanger 259 may be any suitable type of heat exchanger known in the art, such as a compact heat exchanger that is configured to be received and positioned within turbine section 204.

Referring to FIGS. 3 and 5, turbine section 204, in the exemplary embodiment, also includes an annular nozzle ring 290 that is positioned adjacent to bearing 216. Nozzle ring 290, in the exemplary embodiment, may be a stationary nozzle ring that is configured to facilitate the optimization of work energy utilization for turbine rotor 214. Nozzle ring 290 includes a surface 291 and a plurality of nozzle vanes 292 that extend outwardly from surface 291. In the exemplary embodiment, nozzle ring 290, along with surface 291 and vanes 292, are integrally formed together. Alternatively, nozzle ring 290, along with surface 291 and vanes 292, may be formed separate and removably or permanently coupled together.

Nozzle ring 290, along with surface 292 and vanes 292, may be formed via a variety of manufacturing processes known in the art, such as, but not limited to, molding processes, drawing processes, or machining processes. One or more types of materials may be used to fabricate nozzle ring 290, along with surface 292 and vanes 292, with the materials selected based on suitability for one or more manufacturing techniques, dimensional stability, cost, moldability, workability, rigidity, and/or other characteristic of the material(s). For example, nozzle ring 290, along with surface 291 and vanes 292, may be at least partially formed from a metal material. Nozzle ring 290, along with surface 291 and vanes 292, can be a part of or an extension of turbine cover portion 250, in which case, nozzle ring 290 may be fabricated of the same material as turbine cover portion 250. Alternatively, nozzle ring 290, along with surface 291 and vanes 292, can be a separate component from turbine cover portion 250. Moreover, turbine section 204 may also include heat isolating shield 300 that substantially circumscribes at least a portion of second end portion 210 of rotor shaft 206. In the exemplary embodiment, heat isolating shield 300 is positioned between nozzle ring 290 and turbine rotor 214. Heat isolating shield 300 may be fabricated from any suitable type of material, such as a sheet metal.

Turbomachine assembly 102 also includes a center section 260 positioned between compressor section 202 and turbine section 204. A housing assembly 262 substantially encloses at least a portion of center section 260 and is also positioned between compressor section 202 and turbine section 204. Housing assembly 262, in the exemplary embodiment, substantially circumscribes at least a portion of middle portion 211 of rotor shaft 206 and encloses components of center section 260 therein. For example, as discussed above, a combustor section (not shown) and/or energy sources (not shown) may be positioned within center section 260 and enclosed by housing assembly 262.

Housing assembly 262 may be formed via a variety of manufacturing processes known in the art, such as, but not limited to, molding processes, drawing processes, or machining processes. One or more types of materials may be used to fabricate housing assembly 262 with the materials selected based on suitability for one or more manufacturing techniques, dimensional stability, cost, moldability, workability, rigidity, and/or other characteristic of the material(s). For example, housing assembly 262 may be at least partially formed from a metal material.

In the exemplary embodiment, housing assembly 262 includes two conduits 270 extending from compressor section 202 to turbine section 204 such that fluid can flow through each of the conduits 270 and be channeled between compressor section 202 and turbine section 204. Housing assembly 262 also includes at least one regulating valve 272 that are each in flow communication with compressor section 202 and turbine section 204. More specifically, in the exemplary embodiment, housing assembly 262 includes two regulating valves 272 such that each regulating valve 272 is positioned within a separate conduit 270. Each regulating valve 272 is configured to be modulated such the respective conduit 270 may be opened, closed, or partially opened such that fluid flow may be controlled within each conduit. More specifically, each regulating valve 272 is configured to be modulated such that fluid flow may be directed in a first direction 280 towards compressor section 202 or in a second direction 282 towards turbine section 204.

While two regulating valves 272 are included within the exemplary embodiment, housing assembly 262 may have any number of regulating valves 272 that enables turbomachine assembly 102 and/or power system 100 to function as described herein. Moreover, the location of regulating valves 272 are not limited to center section 260. For example, regulating valve 272 may be positioned within compressor section 202. More specifically, in some embodiments turbomachine assembly 102 may not have center section 260 included therein. As such, turbomachine assembly 102 would include compressor section 202 and turbine section 204 positioned adjacent to compressor section 202, and at least one regulating valve 272 would be positioned within compressor section 202.

Moreover, as discussed above, turbomachine assembly 102 also includes two shaft bearings 216 such that one bearing 216 is adjacent to at least a portion of first end portion 208 of rotor shaft 206 and one bearing 216 is adjacent to at least a portion of second end portion 210 of rotor shaft 206. More specifically, each bearing 216 is positioned within center section 260 such that one bearing 216 is adjacent to at least a portion of first end portion 208 of rotor shaft 206 and one bearing 216 is adjacent to at least a portion of second end portion 210 of rotor shaft 206. While bearings 216 are positioned within center section 260, bearings are not limited to being positioned within center section 260. For example, as discussed above, in some embodiments turbomachine assembly 102 may not have center section 260 included therein. As such, turbomachine assembly 102 would include compressor section 202 and turbine section 204 positioned adjacent to compressor section 202, and one bearing 216 would be positioned within compressor section 202 and another bearing 216 would be positioned within turbine section 204.

During operation of power system 100, a user may initially input predefined threshold values for various operating parameters, such as flow rate and temperature, for each of the compressor section 202 and turbine section 204. The control point or threshold also can be variable in order to respond to an external input value. Assuming a given control point, the threshold values may be different for each section to facilitate an efficient operation of turbomachine assembly 102 and/or power system 100. The predefined threshold values may be programmed with user computing device 150 (shown in FIG. 1) and/or controller 120 (shown in FIG. 1).

As operation continues, air is channeled to compressor section 202 via inlet opening 240, wherein the air is compressed to a higher pressure and temperature. The air flows through channel 230 within flow path 232. At this time, bypass valve 223 is not obstructing flow path 232 such that the air can be channeled in second direction 236 towards center section 260. The compressed air may then be mixed with fuel and other fluids and ignited to generate combustion gases that are channeled towards turbine section 204. The flow rate within compressor section 202 and/or temperature within compressor section 202 can be detected by sensor 142 (shown in FIG. 1). Sensor 142 transmits a signal representative of the detected parameter(s) to controller 120.

Depending for example on whether the detected flow rate and/or the detected temperature is less than, greater than, or equal to the respective predefined threshold value, controller 120 will transmit a control signal to compressor bypass valve 223. For example, in the exemplary embodiment, if the detected flow rate is higher than the predefined threshold value, controller 120 may transmit a control to modulate bypass valve 223 toward a closed or partially closed position such that flow path 232 is obstructed or partially obstructed. For example, when flow path 232 is obstructed by bypass valve 223, the airflow will then be channeled in first direction 234 towards bypass circuit inlet opening 242 and towards load apparatus 104. As such, the flow rate within compressor section 202 may be substantially reduced.

Moreover, when compressed air is being channeled to center section 260, fuel, such as natural gas and/or fuel oil, air, diluents, and/or Nitrogen gas (N₂), may be channeled into center section 260 via a fuel source (not shown). A combustor (not shown) within center section 260 or burner 258 may ignite the fuel mixture to generate expanding high temperature combustion gases that are channeled towards turbine section 204 such that turbine section 204 can convert the thermal energy from the combustion gas stream to mechanical rotational energy. The flow rate within turbine section 204 and/or temperature within turbine section 204 can be detected by sensor 143 (shown in FIG. 1). Sensor 143 transmits a signal representative of the detected parameter(s) to controller 120.

Depending on whether the detected flow rate and/or the detected temperature is less than, greater than, or equal to the respective predefined threshold value, controller 120 will transmit a control parameter to at least one of the regulating valves 272. For example, in the exemplary embodiment, if the detected flow rate is higher than the predefined threshold value, controller 120 may transmit a control parameter to modulate at least one of the regulating valves 272 to a closed or partially closed position such that respective channels 270 are obstructed or partially obstructed. For example, when one channel 270 is obstructed by respective regulating valve 272, the fluid flow will then be prevented from entering turbine section 204. As such, the flow rate within turbine section 204 may be substantially reduced. Moreover, as fluid flow is channeled to turbine section 204, nozzle ring 290 channels the fluid flow over turbine rotor 214. In the exemplary embodiment, the shape and configuration of nozzle ring 290 can change the direction of the fluid flow as well accelerate the fluid flow. For example, vanes 292 may direct the fluid flow and facilitate accelerating the fluid flow that is channeled to turbine section 204.

Accordingly, control system 114 (shown in FIG. 1) is able to control certain of the various operating parameters of compressor section 202 and turbine section 204 separately and independently. Because the parameters of compressor section 202 and turbine section 204 are being controlled and varied independently, a predefined performance threshold or envelop for each of the compressor section 202 and turbine section 204 may be attained. When such performance thresholds are obtained for each section 202 and 204, turbomachine assembly 102 as a whole may be operated efficiently and operational failure of turbomachine assembly 102 or components therein and/or of power system 100 is inhibited.

There may be additional components included within turbomachine assembly 102 and/or turbomachine assembly 102 may have various other functions. For example, turbomachine assembly 102 can comprise the turbomachine assembly and components therein described in co-pending U.S. patent application No. ______ entitled TURBOMACHINE ASSEMBLY FOR RECOVERING WASTE HEAT AND METHOD OF USING SAME (attorney docket no. F9941-00009) filed May, 2013, which is incorporated herein by reference in its entirety.

As compared to known power systems that use turbomachines having various components, the embodiments described herein provide a turbomachine assembly that is configured to enable the operational parameters for each of the components therein to be controlled independently such that the performance thresholds or envelops for each of the components may be attained. The turbomachine assembly includes a compressor section and a turbine section in flow communication with the compressor section. The compressor section includes a bypass valve configured to control fluid flow being channeled within the compressor section to enable controlling at least one operating parameter of the compressor section. At least one regulating valve is in flow communication with the compressor section and the turbine section. The regulating valve is configured to control fluid flow being channeled between the compressor section and the turbine section to enable controlling at least one operating parameter of the turbine section. Accordingly, the turbomachine assembly is configured such that the operational parameters for each of the compressor and turbine sections can be separately controlled. Being able to independently control the operating parameter(s) of each of the compressor and turbine sections facilitates attaining a predefined performance threshold for each section.

Exemplary embodiments of systems, apparatus, and methods are described above in detail. The systems, apparatus, and methods are not limited to the specific embodiments described herein, but rather, components of each system, apparatus, and/or method may be utilized independently and separately from other components described herein. For example, each system may also be used in combination with other systems and is not limited to practice with only systems as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other applications.

Although specific features of various embodiments of the invention may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the invention, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Claims

1. A turbomachine assembly comprising:

a compressor section comprising a first end of a rotating member and a first cover portion that is configured to substantially enclose at least a portion of said first end of said rotating member therein, said compressor section further comprises a bypass valve coupled to said first cover portion, wherein said bypass valve is configured to control fluid flow being channeled within said compressor section to enable controlling at least one operating parameter of said compressor section;

a turbine section in flow communication with said compressor section, wherein said turbine section comprises a second end of said rotating member and a second cover portion that is configured to substantially enclose at least a portion of said second end of said second rotating member therein; and

at least one regulating valve in flow communication with said compressor section and said turbine section, wherein said at least one regulating valve is configured to control fluid flow being channeled between said compressor section and said turbine section to enable controlling at least one operating parameter of said turbine section, wherein controlling the at least one operating parameter of each of said compressor section and said turbine section, at least partly independently, facilitates attaining a predefined performance threshold for each of said compressor section and said turbine section.

2. A turbomachine assembly in accordance with claim 1, wherein said first cover portion comprises a first flow path defined therein, said bypass valve is configured to control fluid flow being channeled within said compressor section by controlling fluid flow being channeled within said first flow path.

3. A turbomachine assembly in accordance with claim 2, wherein said bypass valve controls fluid flow being channeled within said first flow path by channeling fluid flow within said first flow path in one of a first direction and a second direction, wherein the first direction is different from the second direction.

4. A turbomachine assembly in accordance with claim 2, wherein said bypass valve controls fluid flow being channeled within said first flow path by channeling fluid flow within said first flow path towards one of a load and said housing assembly.

5. A turbomachine assembly in accordance with claim 1, wherein said second cover portion comprises a second flow path defined therein.

6. A turbomachine assembly in accordance with claim 1, further comprising a housing assembly positioned between said compressor section and said turbine section, said housing assembly comprises a plurality of conduits extending from said compressor section to said turbine section.

7. A turbomachine assembly in accordance with claim 6, wherein said at least one regulating valve comprises a plurality of regulating valves such that each of said plurality of regulating valves is positioned in a separate conduit of said plurality of conduits.

8. A power system comprising:

a load apparatus comprising a load configured to convert mechanical rotational energy to electrical energy for a power output; and

a turbomachine assembly coupled to said load apparatus, said turbomachine assembly comprises: a compressor section comprising a first end of a rotating member and a first cover portion that is configured to substantially enclose at least a portion of said first end of said rotating member therein, said compressor section further comprises a bypass valve coupled to said first cover portion, wherein said bypass valve is configured to control fluid flow being channeled within said compressor section to enable controlling at least one operating parameter of said compressor section; a turbine section positioned in flow communication with said compressor section, wherein said turbine section comprises a second end of said rotating member and a second cover portion that is configured to substantially enclose at least a portion of said second end of said rotating member therein; and at least one regulating valve that is in flow communication with said compressor section and said turbine section, wherein said at least one regulating valve is configured to control fluid flow being channeled between said compressor section and said turbine section to enable controlling at least one operating parameter of said turbine section, wherein controlling the at least one operating parameter of each of said compressor section and said turbine section, at least partly independently, facilitates attaining a predefined performance threshold for each of said compressor section and said turbine section.

9. A power system in accordance with claim 8, wherein said first cover portion comprises a first flow path defined therein, said bypass valve is configured to control fluid flow being channeled within said compressor section by controlling fluid flow being channeled within said first flow path.

10. A power system in accordance with claim 9, wherein said bypass valve controls fluid flow being channeled within said first flow path by channeling fluid flow within said first flow path in one of a first direction or a second direction, wherein the first direction is different from the second direction.

11. A power system in accordance with claim 9, wherein said bypass valve controls fluid flow being channeled within said first flow path by channeling fluid flow within said first flow path towards one of said load apparatus or towards said housing assembly.

12. A power system in accordance with claim 8, wherein said second cover portion comprises a second flow path defined therein.

13. A power system in accordance with claim 8, wherein said turbomachine assembly further comprises a housing assembly positioned between said compressor section and said turbine section, said housing assembly comprising a plurality of conduits extending from said compressor section to said turbine section.

14. A power system in accordance with claim 13, wherein said at least one regulating valve comprises a plurality of regulating valves such that each of said plurality of regulating valves is positioned in a separate conduit of said plurality of conduits.

15. A method of using a turbomachine assembly, said method comprising:

providing a compressor section that includes a first end of a rotating member and a first cover portion that is configured to substantially enclose at least a portion of the first end of the rotating member therein, the compressor section also includes a bypass valve coupled to the first cover portion;

controlling fluid flow being channeled within the compressor section, via the bypass valve, to enable controlling at least one operating parameter of the compressor section;

positioning a turbine section in relation to the compressor section such that the turbine section is in flow communication with the compressor section, wherein the turbine section includes a second end of the rotating member and a second cover portion that is configured to substantially enclose at least a portion of the second end of the rotating member therein;

controlling fluid flow being channeled between the compressor section and the turbine section, via at least one regulating valve that is in flow communication with the compressor section and the turbine section, to enable controlling at least one operating parameter of the turbine section, wherein controlling the at least one operating parameter of each of the compressor section and the turbine section, at least partly independently, facilitates attaining a predefined performance threshold for each of the compressor section and the turbine section.

16. A method in accordance with claim 15, wherein controlling fluid flow being channeled within the compressor section further comprises controlling fluid flow being channeled within a first flow path that is defined within the first cover portion.

17. A method in accordance with claim 16, wherein controlling fluid flow being channeled within a first flow path further comprises controlling fluid flow being channeled within the first flow path in one of a first direction or a second direction, wherein the first direction is different from the second direction.

18. A method in accordance with claim 16, wherein controlling fluid flow being channeled within a first flow path further comprises controlling fluid flow being channeled within the first flow path towards one of a load or towards the housing assembly.

19. A method in accordance with claim 15, further comprising positioning a housing assembly between the compressor section and the turbine section, wherein the housing assembly includes a plurality of conduits extending from the compressor section to the turbine section.

20. A method in accordance with claim 19, wherein controlling fluid flow being channeled between the compressor section and the turbine section further comprises controlling fluid flow being channeled within the plurality of conduits to one of the compressor section and the turbine section.