The disclosure relates generally to gas turbines, and more specifically, to an auto-thermal valve for passively controlling fuel flow to an axial fuel stage (e.g., late lean injection) of a gas turbine.
Gas turbines typically include a compressor, a combustor section including one or more combustors, and at least one turbine section. Compressor discharge air is channeled into each combustor where fuel is injected, mixed, and burned. The combustion gases are then channeled to the turbine section which extracts energy from the combustion gases.
Gas turbine manufacturers are currently involved in research and engineering programs to produce gas turbines that will operate at high efficiency without producing undesirable air polluting emissions. The primary air polluting emissions usually produced by gas turbines burning conventional hydrocarbon fuels include oxides of nitrogen (NOx), carbon monoxide (CO), and unburned hydrocarbons.
Lean premixed combustion of fuel and air in a primary reaction zone of a combustor is widely used throughout the gas turbine industry as a method of reducing air pollutant levels, in particular thermal NOx emissions levels. Lean direct injection of hydrocarbon fuel and air via an axial fuel stage into a secondary reaction zone of a combustor, downstream from the primary reaction zone, has also been shown to be an effective method for reducing NOx emission levels for gas turbines.
A first aspect of the disclosure provides a combustor for a gas turbine, including: an axial fuel stage fuel injector; and a passively-actuated valve for selectively directing a supply of fuel to the axial fuel stage fuel injector based on a characteristic of the fuel.
A second aspect of the disclosure provides a turbine system, including: a compressor; a combustor; and a turbine, the combustor comprising: an axial fuel stage fuel injector; and a passively-actuated valve for selectively directing a supply of fuel to the axial fuel stage fuel injector based on a characteristic of the fuel.
A third aspect of the disclosure provides a method, including: controlling a temperature of fuel in a combustor of a gas turbine; and selectively actuating a passive, thermally-actuated valve in the combustor, based on the temperature of the fuel, to inject fuel into an axial fuel stage of the combustor.
The illustrative aspects of the present disclosure are designed to solve the problems herein described and/or other problems not discussed.
These and other features of this disclosure will be more readily understood from the following detailed description of the various aspects of the disclosure taken in conjunction with the accompanying drawings that depicts various embodiments of the disclosure. In the drawings, like numerals refer to like elements.
It is noted that the drawings of the disclosure are not necessarily to scale. The drawings are intended to depict only typical aspects of the disclosure, and therefore should not be considered as limiting the scope of the disclosure. In the drawings, like numbering represents like elements between the drawings.
The disclosure relates generally to gas turbines, and more specifically, to an auto-thermal valve for passively controlling fuel flow to an axial fuel stage (e.g., late lean injection) of a gas turbine.
In the Figures, for example as shown in
Turning to
The gas turbine system 4 includes a compressor system 16 and a combustor system 18. The gas turbine system 4 also includes a gas turbine 20 coupled to the shaft 12. In operation, air 22 enters an inlet of the compressor system 16, is compressed, and then discharged to the combustor system 18 where a supply of fuel 24 is burned to provide hot, high energy combustion gases 26, which drive the gas turbine 20. Typically, the combustor system 18 includes a circular array of circumferentially spaced combustors 11 (
According to embodiments, at least one passive, auto-thermal valve sensitive to fuel temperature is provided for selectively directing fuel to a set of axial fuel stage (AFS) fuel injectors (e.g., late lean fuel injectors) of a combustor of a gas turbine system. An auto-thermal valve may be located, for example, within a fuel passage in an end cover of the combustor. The fuel may include, for example, premixed fuels (e.g., PM2, PM3) used in a DLN2.6+ combustor (General Electric).
The auto-thermal valve is configured to be closed at fuel temperatures below a temperature set point and open at fuel temperatures above the temperature set point. When the auto-thermal valve is closed, fuel is prevented from flowing to the AFS fuel injectors. When the auto-thermal valve is open, fuel is allowed to flow to the set of the AFS fuel injectors.
The auto-thermal valve is responsive to fuel temperature, which may be controlled, for example, by the above-described fuel control system 36. In embodiments, the fuel control system 36 controls the fuel temperature between an ambient fuel temperature and a target fuel temperature. An intermediate fuel temperature is set between the ambient fuel temperature and the target fuel temperature. The auto-thermal valve is configured such that its temperature set point is equal to the intermediate fuel temperature.
At and below the intermediate fuel temperature, the auto-thermal valve is closed, and no fuel flows to AFS fuel injectors. When the gas turbine reaches a desired level of output, the fuel control system 36 increases the fuel temperature towards the target temperature. The auto-thermal valve begins to open at a fuel temperature above the intermediate fuel temperature. When the target temperature is reached, the auto-thermal valve is fully open, and a full flow of fuel is supplied to the AFS fuel injectors.
The combustor 11 of the gas turbine system 2 includes a combustor chamber 40 enclosed within a compressor discharge casing 42. Generally described, the volume 44 located between the combustor chamber 40 and the compressor discharge casing 42 receives a flow of compressed air 8 discharged from the compressor section 4. The flow of compressed air 8 passes through the volume 44 toward a head end 46 of the combustor 11, which is closed by an end cover assembly 48.
The combustor chamber 40 further includes a primary reaction zone 50 in which fuel introduced by a set of fuel injectors 68 is mixed with the compressed air 8. The fuel/air mixture is ignited and burned within the primary reaction zone 50 to generate a flow of hot combustion gases 26. The hot combustion gases 26 pass into and through a secondary reaction zone 52 and a transition duct 54 to the turbine section 16. In the turbine section 16, the hot combustion gases 26 may be used, for example, to drive a rotor shaft (e.g., shaft 12,
During some operating stages of the combustor 11 of the gas turbine system 4, additional fuel may be injected into the secondary reaction zone 52, which is located downstream of the primary reaction zone 50. In general, in axial staging, the primary reaction zone is designed for optimum performance (and low emissions) at low power. When more power is required, fuel may be injected into one or more reaction zones downstream of the primary reaction zone.
According to embodiments, an injector assembly 60 including a set of AFS fuel injectors 62 may be provided for injecting a supply of fuel 64 (with or without a carrier fluid such as air) into the secondary reaction zone 52. The fuel 64 is ignited by the hot gases 26 exiting the primary reaction zone 50, and the resulting combustion goes to completion in the transition duct 54. As detailed below with regard to
The end cover assembly 48 may include various supply passages, manifolds, and associated valving (not shown in
A partial enlarged cross-sectional view of the head end 46 of the combustor 11 of
The fuel passages 72 fluidly couple the fuel passage 70 to the fuel injectors 62 of the injector assembly 60 through the auto-thermal valve 66. In the configuration shown in
The auto-thermal valve 66 includes a temperature set point, such that the auto-thermal valve 66 is closed at fuel temperatures below the temperature set point and open at fuel temperatures above the temperature set point. To this extent, the operation of the auto-thermal valve 66 is controlled by the temperature of the fuel 64 passing through the fuel passage 70 and past the auto-thermal valve 66. The temperature of the fuel 64, as detailed above, is controlled by the fuel control system 36. Thus, the fuel control system 36 indirectly controls the operation of the auto-thermal valve 66 through regulation of the temperature of the fuel 64.
As shown in
As the operational load of the combustor 11 increases, the fuel control system 36 increases the temperature of the fuel 64 passing into and through the fuel passage 70 and over the auto-thermal valve 66. When the temperature of the fuel 64 increases above the temperature set point of the auto-thermal valve 66, the auto-thermal valve 66 begins to enter an open state in which at least some fuel 64 is allowed to flow through the fuel passages 72 to the fuel injectors 62 of the injector assembly 60. The auto-thermal valve 66 opens further as the temperature of the fuel 64 increases under control of the fuel control system 36 towards the target temperature set by the fuel control system 36. At the target temperature, the auto-thermal valve 66 is fully open, and a maximum flow of fuel 64 is supplied to the fuel injectors 62 of the injector assembly 60. Regardless of the state of the auto-thermal valve 66, however, the flow of fuel 64 through the fuel passages 74 to the set of fuel nozzles 68 is not interrupted.
It should be noted that the ‘target’ temperature at which the auto-thermal valve 66 is fully open may not necessarily correspond to the fuel temperature at base load operation. For example, according to embodiments, the auto-thermal valve 66 may be fully open at a fuel temperature below the fuel temperature at base load operation, so that all auto-thermal valves 66 in the system will be fully open after accounting for minor variations in valve manufacture.
A chart of the behavior of the auto-thermal valve 66 is depicted in
A door 96 in the end cover assembly 48 provides access to the auto-thermal valve 66 (e.g., for installation, repair, and/or replacement of the auto-thermal valve 66). Although only one auto-thermal valve 66 is depicted, a plurality of auto-thermal valves 66 may be utilized. Each of the plurality of auto-thermal valve 66 may have the same or different temperature set points and target temperatures.
The fuel control system 36 (
The auto-thermal valve 66 is sensitive to the temperature of the fuel 64, and is passively actuated. In other words, no control connections and no sensor signals are required. For example, the auto-thermal valve 66 may be passively actuated via the expansion of a temperature-sensitive fluid coupled to a movable piston.
An auto-thermal valve 66 according to embodiments is depicted in
The auto-thermal valve 66 is shown in a closed configuration in
An increase in the temperature of the fuel 64 causes an expansion of the thermally expandable material 112 within the expandable element 110. The enlargement of the expandable element 110 within the housing 108 (e.g., as indicated by arrow 122) forces the rod 114 and valve disc 116 away from the valve seat 120 and the fuel outlet port 106.
Above the temperature set point of the auto-thermal valve 66, the surface 118 of the valve disc 116 no longer forms a seal against the valve seat 120. This allows fuel 64 to flow from the fuel inlet ports 104 through the gas flow outlet port 106 (as indicated by the dashed arrows) into a downstream location. When the temperature of the fuel 64 reaches the target temperature, as shown in
The auto-thermal valve 66 is configured to open over a range of fuel temperatures. In this case, the auto-thermal valve 66 may begin to open at a first temperature and be fully open at a second, higher temperature.
Various thermally expandable materials 112 may be used in different auto-thermal valves 66 to provide different coefficients of thermal expansion. This provides, for example, different opening/closing temperature set points for different auto-thermal valves 66. Further, in general, any number of auto-thermal valves 66 may be used. In addition, although the auto-thermal valves 66 are shown as disposed in particular locations in the figures, these locations are for descriptive purposes only; other suitable locations may be available in a gas turbine system.
In other embodiments, a pressure-sensitive valve may be used in lieu of or in addition to one or more of the auto-thermal valves 66. In this case, when the fuel temperature is high enough to push the pressure drop across a fuel nozzle to a high enough level, the pressure-sensitive valve will open. Of course, actively controlled valves may also be used in lieu of or in addition to one or more of the auto-thermal valves 66.
Use of an auto-thermal valve enables the addition (e.g., retrofitting) of AFS fuel staging to a existing combustor without requiring a complete and expensive fuel circuit, including fuel manifold and control valve. The flow of fuel to the AFS fuel injectors is indirectly controlled, with a control ‘signal’ being passed to the auto-thermal valve via fuel temperature. The piping and/or tubing required to route fuel to the AFS fuel injectors, typically located on or near the transition duct, does not require much space and is limited to tubing between the AFS fuel injectors and the end cover assembly. This enables a manufacturer to offer an upgrade package with AFS with a very low cost, compared to today's technology. AFS using auto-thermal valve(s) will enable a significant improvement in gas turbine turndown (minimum load in emissions compliance). One reason for this is because the AFS air flow bypasses the combustor head end, but the auto-thermal valve enables all of the fuel to be routed to the head-end at low power conditions, increasing head-end temperature and enabling CO to be fully reacted before the flow leaves the combustor.
In various embodiments, components described as being “coupled” to one another can be joined along one or more interfaces. In some embodiments, these interfaces can include junctions between distinct components, and in other cases, these interfaces can include a solidly and/or integrally formed interconnection. That is, in some cases, components that are “coupled” to one another can be simultaneously formed to define a single continuous member. However, in other embodiments, these coupled components can be formed as separate members and be subsequently joined through known processes (e.g., fastening, ultrasonic welding, bonding).
When an element or layer is referred to as being “on”, “engaged to”, “connected to” or “coupled to” another element, it may be directly on, engaged, connected or coupled to the other element, or intervening elements may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to”, “directly connected to” or “directly coupled to” another element, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
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 languages of the claims.
This application is related to co-pending U.S. application Ser. No. 15/059,721 filed Mar. 3, 2016, and GE docket number 313900-1 filed on Nov. 15, 2016.