EP4735743A1 - Gas turbine engines and methods of heating compressor working fluid - Google Patents

Abstract

An integration system for use with a turbine, the integration system including an inlet bleed heat (IBH) system, an exhaust gas recirculation (EGR) system, and a controller.

Description

GAS TURBINE ENGINES AND METHODS OF HEATING COMPRESSOR WORKING FLUID

BACKGROUND

[1] The field of the disclosure relates generally to turbine engine assemblies and more particularly, to methods and systems for heating compressor inlet air to facilitate improved gas turbine engine efficiency.

[2] Gas turbines are widely used in a variety of commercial operations, such as power generation operations. Known gas turbines generally include a compressor, one or more combustors, and a turbine. Conventionally, the compressor compresses a working fluid, e.g., air, and discharges the compressed working fluid to the combustors. Fuel is injected into the flow of compressed working fluid and the mixture is ignited to produce combustion gases having a relatively high temperature, pressure, and velocity. The combustion gases exit the combustors and flow to the turbine where they expand to produce work which may be converted into electrical and/or mechanical power.

[3] Working fluid entering an inlet, e.g., an inlet transition duct or a filter housing, of a compressor may be heated to prevent icing when operating in lower temperature environments, for example. Inlet working fluid may also be heated to improve the part or partial load efficiency of the gas turbine. In some gas turbines, compressed working fluid may be extracted from an extraction location near an outlet of the compressor and recirculated to heat the inlet working fluid using a system that is conventionally referred to as an inlet bleed heat system. However, known inlet bleed heat systems reduce the overall operating efficiency of the associated gas turbine engine as at least some of the compressed working fluid that would otherwise be routed to doing work in the turbine is extracted and recirculated to the inlet.

[4] Accordingly, a need exists for systems and methods that more efficiently heat inlet working fluid prior to entering the compressor inlet in a manner that facilitates reducing the overall losses in turbine efficiency. SUMMARY

[5] In one aspect, an integration system for use with a turbine is provided. The integration system includes an exhaust gas recirculation (EGR) system including a EGR flow control device for channeling flow extracted from a turbine exhaust to an EGR return location upstream from a compressor inlet and an inlet bleed heat (IBH) system including a IBH flow control device for channeling flow extracted downstream from a compressor outlet to a IBH return location upstream from the compressor inlet. The system further includes a controller communicatively coupled to the EGR flow control device and to the IBH flow control device, wherein the controller variably adjusts a relative flow rates of the EGR system and the IBH system.

[6] In another aspect, a power generation system is provided. The power generation system includes a compressor for compressing working fluid, a combustor, and an integration system. The integration system includes an exhaust gas recirculation (EGR) system including a EGR flow control device for channeling flow extracted from a turbine exhaust to an EGR return location upstream from a compressor inlet and an inlet bleed heat (IBH) system including a IBH flow control device for channeling flow extracted downstream from a compressor outlet to a IBH return location upstream from the compressor inlet. The system further includes a controller communicatively coupled to the EGR flow control device and to the IBH flow control device, wherein the controller variably adjusts a relative flow rates of the EGR system and the IBH system.

[7] In yet another aspect, a method of using an integration system for a gas turbine engine is provided. The method includes receiving sensor data from a plurality of sensors coupled at various locations within the integration system, determining a current operating condition based on received sensor data, and adjusting at least one of a flow parameter of an EGR system, and a flow parameter of an IBH system to facilitate improving an operating efficiency of the gas turbine engine.

BRIEF DESCRIPTION OF THE DRAWINGS

[8] These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

[9] FIG. 1 is a schematic illustration of an exemplary power generation system including a gas turbine engine and an integrated efficiency (IE) system.

[10] FIG. 2 is a schematic illustration of an exemplary integrated efficiency system including an inlet bleed heat (IBH) system that may be used with the power generation system shown in FIG. 1, for example.

[11] FIG. 3 is a schematic illustration of another exemplary integrated efficiency system that may be used with the power generation system shown in FIG. 1, for example, and including the IBH system and an exhaust gas recirculation (EGR) system.

[12] FIG. 4 is a block diagram of an exemplary control system that may be used with the IE system shown in FIGS. 1-3.

[13] FIG. 5 is a first perspective view of an exemplary filter that may be used with the IE system shown in FIGS. 1-3, for example.

[14] FIG. 6 is a second perspective view of the filter shown in FIG. 5.

[15] FIG. 7 is a cross-sectional view of the filter shown in FIG. 5.

[16] FIG. 8 is a perspective view of an exemplary IBH manifold that may be used with the IE system shown in FIGS. 1-3.

[17] FIG. 9 is a detailed view of the IBH manifold shown in FIG. 8.

[18] FIG. 10 is a front perspective view of an exemplary EGR manifold that may be used with the IE system shown in FIGS. 1-3.

[19] FIG 11 is a rear perspective view of the exemplary EGR manifold shown in FIG. 10

[20] FIG. 12 is a rear view of the exemplary EGR manifold shown in FIG. 10 [21] FIG. 13 is a process flow diagram of an exemplary method of controlling the IE system shown in FIGS. 1-3, for example.

[22] Unless otherwise indicated, the drawings provided herein are meant to illustrate features of embodiments of the disclosure. These features are believed to be applicable in a wide variety of systems comprising one or more embodiments of the disclosure. As such, the drawings are not meant to include all conventional features known by those of ordinary skill in the art to be required for the practice of the embodiments disclosed herein.

DETAILED DESCRIPTION

[23] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. “Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not. Furthermore, references to “one embodiment” are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Moreover, unless explicitly stated to the contrary, embodiments “including” or “having” an element or a plurality of elements having a particular property may include additional such elements not having that property.

[24] As used herein, the term “real-time” refers to either the time of occurrence of the associated events, the time of measurement and collection of predetermined data, the time to process the data, or the time of a system response to the events and the environment. In the embodiments described herein, these activities and events occur substantially instantaneously.

[25] In the exemplary embodiments described herein, a power generation system includes an integrated efficiency (IE) system used with a gas turbine engine. In some embodiments, the IE system includes an inlet bleed heat (IBH) system and an exhaust gas recirculation (EGR) system. In at least some of the embodiments described herein, the IE system returns working fluid and/or exhaust gases to one or more locations upstream from a compressor section, e.g., such as an inlet transition duct that channels working fluid into the compressor. In the exemplary embodiment, the IBH system draws working fluid from the extraction location near the compressor outlet and returns the compressed working fluid to a location upstream from the compressor inlet and the EGR system draws exhaust gases exiting a turbine outlet and returns the exhaust gases to a location upstream from the compressor inlet. In the embodiments described herein, the IE system heats the inlet working fluid prior to the fluid entering the compressor inlet, thus improving the part load efficiency of a gas turbine, or the efficiency of the turbine at operating conditions other than its full load design point, while also preventing icing and/or compressor surge. The power generation system may include a gas turbine simple cycle, cogeneration, or a combined cycle.

[26] In some embodiments, the IE system includes a controller that adjusts a flow parameter, such as a mass flow rate, a relative mass flow rate, and/or an amount of fluid, e.g, exhaust gas or compressed air, respectively, of the EGR and the IBH systems enabling a desired operating condition of the gas turbine engine to be achieved. In some embodiments, the controller is communicatively coupled to one or more sensors, and may selectively adjust the flow parameter in real-time or periodically, based on received sensor data and based on the targeted operating conditions. In some embodiments, the controller may determine one or more parameters, e.g., temperature, and selectively adjust the flow parameter based on the determined parameter. As the EGR and the IBH systems may be used in combination, the IBH system may be more compact, having a smaller physical footprint, and draw a smaller amount of compressed fluid, thus facilitating improving the efficiency of the power generation system 100. In some embodiments, the IBH system may be used to only prevent compressor surge, supplement the EGR system, and/or act as a backup as heating of the inlet air is achieved primarily by the EGR system. In some embodiments, the controller may selectively turn on/off the IBH system to prevent compressor surge, while the EGR is operated continuously to heat the inlet air.

[27] In some embodiments, the IE system prevents icing by heating one or more components of the gas turbine system and/or by heating inlet working fluid prior to the heated working fluid entering the compressor. The IE system may return compressed working fluid by the IBH system and/or return exhaust gases by the EGR system to heat the inlet transition duct and/or the inlet working fluid upstream from the compressor. In particular, the exhaust gases and/or the bleed compressed air may have a higher temperature than the temperature of the drawn inlet air.

[28] In some embodiments, the IE system facilitates reducing emissions from the gas turbine engine. More specifically, in some embodiments, the EGR system draws exhaust air from the turbine outlet to be returned to a location upstream from the compressor inlet, thus controlling the release of emissions of the gas turbine engine.

[29] In some embodiments, the IE system also facilitates reducing the likelihood of compressor surge. Compressor surge may refer to operating conditions wherein airflow within the compressor becomes unstable and/or the airflow is disrupted, causing unwanted vibration and noise. In some embodiments, the IE system includes a IBH system which draws compressed working fluid exiting the compressor extraction location and returns the compressed working fluid upstream from the compressor inlet. Because the compressed working fluid is drawn from the compressor extraction location, a front-end load on the compressor is reduced and as such the likelihood of compressor surge is substantially reduced.

[30] In some embodiments, the IE system improves part load efficiency, an efficiency of the compressor and/or an efficiency of the turbine, by preheating inlet working fluid. Heating of the working fluid enables the gas turbine to remain in a premix operating condition, wherein fuel is mixed with compressed working fluid prior to combustion, over a larger load range, while maintaining higher firing temperatures, compressor and combustor stability, and emissions compliance and while reducing the current IBH extraction flow requirements. Reduction in IBH extraction facilitates reducing fuel consumption for the same work/power output of the gas turbine engine, thus improving part load efficiency. Furthermore, inlet heating increases the compressor discharge temperature and the gas turbine exhaust temperature and thus increases the efficiency of the bottoming cycle, and as follows, the combined cycle output and efficiency.

[31] In some embodiments, the IE system facilitates reducing acoustic noise levels and thus enables plant acoustic requirements to be satisfied. In some embodiments, the IE system reduces an amount of noise by a silencer and/or acoustic nozzles of a IBH manifold. [32] Tn some embodiments, the TE system includes one or more sensors that detect one or more operating conditions of the gas turbine engine, the IBH system, and/or the EGR system. The sensors may include, but are not limited to only including, temperature sensors, pressure sensors, flow sensors, and/or emission sensors. In some embodiments, the IE system may use data obtained from the sensors to detect a surge event, a potential surge event, and/or a surge event in its early stages. For example, sensors may detect in airflow and/or pressure at and/or near the compressor, e.g., the compressor outlet, wherein the detected changes may be indicative of a surge event. In some embodiments, the controller may determine a surge condition using any suitable method, e.g., using a compressor map including a surge line. In some embodiments, the IE system may use the data provided by such sensors to detect an icing event. For example, in some embodiments, one or more sensors may be positioned to detect inlet temperature, working fluid temperature, and/or ambient temperature, humiditv or relative humidity e.g, outside of the gas turbine engine, and/or any other temperature(s) reading(s) upstream from the compressor inlet. In some embodiments, the IE system may utilize data obtained from the sensors to detect the emissions from the power generation system.

[33] In some embodiments, the IE system may determine, e.g., using a controller, one or more operating conditions of the gas turbine engine, the IBH system, and/or the EGR system, e.g., without utilizing a sensor for direct measurement. For example, the controller may calculate or look-up one or more values for pressure, temperature, flow rate and/or emissions at one or more locations of the IE system and/or the gas turbine engine.

[34] In the exemplary embodiment, the controller is coupled to the IBH system and to the EGR system enabling selective control of the operation, or relative operation, of the IBH system and/or the EGR sy stem. The controller may also be coupled to the one or more sensors. In some embodiments, the controller may selectively control a flow parameter, such as a flow rate of a working fluid (e.g., by controlling the control valve positions) channeled through IBH system and/or the flow parameter of exhaust gases channeled through the EGR system to enable desired operating conditions to be achieved while improving the operating efficiency. In some embodiments, the controller may use data received from the sensors, and/or data determined by the controller, to selectively adjust one or more parameters of the IE system, e.g., a parameter of the IBH system and/or a parameter of the EGR system. For example, in some embodiments, the controller may predict an amount of time until a probable surge event, an icing event, and/or until an emission level exceeds a predefined operating threshold.

[35] Referring now to the drawings, FIG. 1 is a schematic of an exemplary power generation or mechanical drive system 100 including a turbine engine 110 and an integrated efficiency (IE) system 200 including an exhaust gas recovery (EGR) system 202 and an inlet bleed heat system (IBH) system 204. While the exemplary embodiment is illustrated in association with a gas turbine engine, the present invention is not limited to any particular engine, and one of ordinary skill in the art will appreciate that the current invention may be used in connection with other turbine engines. As used herein, the terms “turbine,” “turbine assembly,” and “turbine engine” shall be used interchangeably.

[36] The IE system 200 may include a controller 206 that is coupled to the EGR system 202 and the IBH system 204. The controller 206 may control a flow of working fluid traveling through the IBH system 204 and/or a flow of exhaust gases traveling through the EGR system 202, as will be described in detail herein. The IE system 200 may further include at least one sensor 208 that detects one or more parameters or operating conditions of the IE system 200 and/or the gas turbine engine 110. The controller 206 may be incorporated with a controller associated with the gas turbine engine 110. Additionally, and/or alternatively the controller 206 may be separate from a controller associated with the gas turbine engine 110.

[37] In the exemplary embodiment, turbine engine 110 includes an intake section 112, a compressor section 114 coupled downstream from intake section 112, a combustor section 116 coupled downstream from compressor section 114, a turbine section 118 coupled downstream from combustor section 116, and an exhaust section 120. Turbine section 118 is coupled to compressor section 114 via a rotor shaft 122. The combustor section 116 may include a plurality of combustors (not shown ). Combustor section 116 is coupled in flow communication with compressor section 114.

[38] A fuel injector 124 is coupled to the combustor section 116. In some embodiments, the turbine engine 110 includes a manifold or manifolds 126 including a plurality of the fuel injectors 124. Turbine section 118 is coupled to compressor section 114 and to a load 128 such as, but not limited to, an electrical generator and/or a mechanical drive application. In the exemplary embodiment, each of the compressor sections 114 and turbine section 118 includes at least one rotor disk assembly 130 that is coupled to a rotor shaft 122 to form a rotor assembly 132.

[39] During operation, intake section 112 channels air towards a compressor inlet 134 of the compressor section 114 wherein the air is compressed to a higher pressure and temperature prior to the pressurized air being mixed with fuel and the resulting mixture discharged towards combustor section 116. More specifically, the compressed air is mixed with a fuel mixture and ignited to generate combustion gases that are channeled towards turbine section 118. Turbine section 118 converts thermal energy from the gas stream to mechanical rotational energy, as the combustion gases impart rotational energy to turbine section 118 and to rotor assembly 132.

[40] In some embodiments, the fuel source 150 may be a variable fuel source that delivers various types and/or mixtures of fuel. Fuel source 150 may store and/or supply natural gas, liquified petroleum gases (LPG) blends, methane, hydrogen, hydrogen/natural gas blends, fuel oils, coke oven gas, refinery gases and any suitable gas fuel or gas fuel mixture, for example. The fuel supplied and/or stored by the fuel source, may be variably selected based on the operating conditions and/or availability of one or more fuel sources.

[41 ] The turbine engine 110 may include one or more conduits, pipes, ducts, and/or tubes, generally referred to herein as conduits 140, used to transfer fuel between components. Fuel may be motivated to move through conduits 140 from upstream components to downstream components using gravitational forces. Alternatively, and/or additionally, fuel may be pressurized through conduits 140 using compressors or pumps or blowers 142, for example.

[42] In some embodiments, the gas turbine engine 110 includes a variable inlet guide vane assembly 148 positioned upstream from the compressor inlet 134. In such embodiments, the controller 206 may selectively adjust an angle of one or more vanes of the variable inlet guide vane assembly 148 to adjust a mass flow rate and/or to vary an amount of working fluid entering the compressor section 114. For example, the gas turbine engine 110 may adjust inlet guide vane 148 to facilitate reducing an amount of working fluid delivered to the compressor section 1 14 such that a desired ratio of working fluid to fuel ratio is maintained, e.g., during parts loading operating conditions. In some embodiments, the controller 206 may selectively adjust both the inlet guide vane assembly 148 and the temperature of the working fluid delivered to the compressor section 114, by selectively controlling the IBH and EGR systems, to control an amount of working fluid delivered to the compressor section 114.

[43] As mentioned above, the IE system 200 controls the temperature of working fluid upstream from the compressor section 114. An increase in the inlet working temperature decreases the density of the working fluid and thereby decreases the mass of working fluid entering the compressor section 114. The controller 206 may determine an amount of heat, e.g., thermal energy', which will need to be supplied to upstream working fluid, to ensure correct heating of the working fluid, and the necessary decrease in the density of the working fluid, in order to adjust the amount of working fluid delivered to the compressor section 114. The controller 206 may adjust both the variable inlet guide vane 148 and the IE system 200 to control a mass flow rate of working fluid entering the compressor section 114. For example, the controller 206 may position the variable inlet guide vane assembly 148 in a fully opened, or a maximum opened position, and the controller may utilize the IE system 200 to adjust the amount of working fluid delivered to the compressor section 114. For example, the controller 206 may increase the amount of exhaust gas delivered upstream from the compressor inlet 136 using the EGR system 202, heating the inlet working fluid and decreasing the density of the working fluid, and therefore decreasing an amount of working fluid that is delivered to the compressor section 114.

[44] In the exemplary embodiment, the IBH system 204 draws compressed working fluid downstream from the compressor outlet 136 and reintroduces the compressed fluid at a location upstream from the compressor inlet 134. The drawn compressed working fluid may be motivated to travel through the IBH system 204 via a pressure differential of the drawn working fluid. For example, the working fluid of the IBH system 204, extracted from the compressor 114, may have a higher pressure as compared to working fluid and/or air that is upstream from the compressor inlet 134. In some alternative embodiments, the drawn compressed working fluid may be motivated via flow motive devices. In some embodiments, the IBH system 204 includes one or more flow control devices 144, e.g., valves, which control the flow of compressed working fluid. The TBH system 204 may also include conduits that direct compressed air from the compressor outlet 136 to a location upstream from the compressor inlet 134. The IBH system 204 is shown and described in more detail with respect to FIGS. 2 and 3.

[45] In the exemplary embodiment, the EGR system 202 draws exhaust gases exiting the turbine section 118 and reintroduces the exhaust gases upstream from the compressor inlet 134. In some embodiments, the EGR system 202 may include one or more flow motive devices 146 for motivating the flow of exhaust gas through the EGR system 202 from the combustor outlet to the upstream reintroduction location. In some embodiments, the pressure of the drawn exhaust gas may be less than the pressure of working fluid upstream from the compressor inlet 134. In some embodiments, the temperature of the drawn exhaust gas has a higher temperature than that of the working fluid, and/or of that of the air upstream from the compressor inlet 134. The EGR system 202 may include one or more conduits that direct exhaust flow from the combustor outlet towards a location upstream from the compressor inlet 134. The EGR system 202 is shown and described in greater detail with respect to FIGS. 2 and 3.

[46] In the exemplary embodiment, the IE system 200 may be operated in any of a plurality of operation modes, enabling the IE system 200 to achieve one or more desired operating conditions including, for example, and without limitation, anti-icing, surge protection, and/or emission compliance, while improving the efficiency of the power generation system 100 or the gas turbine engine 110. The controller 206 may variably select an operation mode based on a targeted operating condition. At least one operating mode is an EGR mode in which the controller 206 causes the IE system 200 to utilize the EGR system 202 and during which time, the IBH system 204 is deenergized and/or placed in a standby mode. At least one other operating mode includes an EGR dominate mode, in which the IE system 200 supplies a higher amount or a higher mass flow of exhaust gases through the EGR system 202 as compared to the amount or mass flow of compressed working fluid drawn at an extraction location downstream from the compressor outlet 136 through the IBH system 204. [47] As used herein, the terms “processor” and “computer” and related terms, e.g., “processing device,” “computing device,” and “controller” are not limited to just those integrated circuits referred to in the art as a computer, but instead refer broadly to a microcontroller, a microcomputer, a programmable logic controller (PLC), an application specific integrated circuit, and/or other programmable circuits, and such terms are used interchangeably herein. In the embodiments described herein, memory may include, but is not limited to, a computer-readable medium, such as a random-access memory (RAM), and a computer-readable non-volatile medium, such as flash memory. Alternatively, a floppy disk, a compact disc-read only memory (CD-ROM), a magneto-optical disk (MOD), and/or a digital versatile disc (DVD) may also be used. Also, in the embodiments described herein, additional input channels may be, but are not limited to only being, computer peripherals associated with an operator interface such as a mouse and a keyboard. Alternatively, other computer peripherals may also be used such as, but not limited to, a scanner or a touchscreen. Furthermore, in the embodiments described herein, additional output channels may include, but are not limited to only being, an operator interface monitor.

[48] FIG. 2 is a schematic view of an exemplary embodiment of the IBH system 204 that may be used with the IE system 200, shown in FIG. 1. FIG. 3 is a schematic view of the IE system 200 and includes both the IBH system 204 and the EGR system 202. In the exemplary embodiment, the IE system 200 may include a filter 210, a silencer 212, and/or an IBH manifold 214. The filter 210, the silencer 212, and/or the IBH manifold 214 may be within an inner passage 216 defined by an inlet transition duct 218. The inlet transition duct 218 may be coupled in flow communication with the compressor inlet 134, such that the inlet transition duct 218 directs inlet working fluid, air, and/or exhaust gases, etc., towards the compressor inlet 134. In some embodiments, the inlet transition duct 218 may be incorporated with at least a portion of the intake section 112 that draws inlet fluid 220 into the compressor 114. The duct 218 may have any suitable shape or size that enables IE system to function as described herein. In some embodiments, the IBH manifold 214 may extend across, e.g., completely across, the inner passage 216 defined by the duct 218. The inlet transition duct 218 may include a transaction duct including a duct which couples the inlet filter house ducting to inlet compressor, e.g., the transition duct may couple two duct portions together that each have different cross-sectional area. The filter 210 may include one or more filter elements 222. The filter 210, the silencer 212, and/or the IBH manifold 214 may be upstream from the compressor inlet 134. In some embodiments, the silencer 212 is downstream from the filter 210 and upstream from the compressor inlet 134. The IBH manifold 214 distributes fluid used with the IBH system 204. In some embodiments, the IE system 200 include a EGR manifold 224 for distributing exhaust gas upstream from the compressor inlet 134.

[49] The sensors 208 of the IE system 200 may include, but are not limited to only including, for example, a temperature sensor, a pressure sensor, a flow sensor, relative humidity sensor, and/or an emission sensor. The sensors 208 may be positioned at various suitable locations within or in proximity to the IE system 200 and/or the power generation system 100. In some embodiments, the IE system 200 may use data supplied from at least one of the sensors 208, or determined by the controller 206, to detect a surge event, a potential surge event, and/or a surge event in its early stages. For example, IE system 200 may detect a surge event by detecting, or determined, changes in airflow and/or pressure at and/or near the compressor and/or near the compressor outlet 136. In some embodiments, the controller 206 may determine a surge condition using any suitable method, e.g, using a compressor map including a surge line. In some embodiments, the IE system 200 may use the one or more sensors 208 to detect a current emission level or to determine emission performance or compliance.

[50] In some embodiments, at least one sensor 208 may be positioned to detect ambient temperature or humidity, e.g., a temperature outside of the gas turbine engine 110, and/or a temperature upstream from the compressor inlet 134. In some embodiments, the sensors 208 and/or the controller 206 may detect an icing condition. For example, an icing condition may be sensed based on a temperature sensor 208 detecting a predefined temperature upstream from the compressor inlet 134 and the controller 206 may receive the temperature data for processing. In such an example, the controller 206 may compare the temperature data to one or more temperature thresholds to determine if an icing event will occur or is occurring.

[51] In further reference to FIGS. 2 and 3, the IBH system 204 draws compressed working fluid from an extraction location that is near the compressor outlet 136 or downstream from the compressor outlet 136 and returns the drawn compressed fluid to a location upstream from the compressor inlet 134. The IBH system 204 includes a location 250 where the compressed working fluid is extracted from the gas turbine engine 110. Tn some embodiments, the extraction location 250 is downstream from the compressor outlet 136 and is upstream from the combustor section 116. In some embodiments, the extraction location 250 is at, or is in proximity to, the compressor outlet 136. The drawn working fluid extracted from the compressor section 114 may have a pressure that is higher than inlet fluid 220 upstream from the compressor inlet 134. In some embodiments, the drawn working fluid is extracted from any suitable extraction location near or directly from the compressor section 114.

[52] The IBH system 204 includes conduits 252, e.g., ducts, pipes, etc., used to transfer the extracted compressed working fluid to a return location 254. The IBH system 204 may include one or more flow control devices 144 to provide enhanced control of the flow of working fluid through the IBH system 204. In the exemplary embodiment, the IBH system 204 includes a first flow control device 258 and a second flow control device 260. More specifically, in the exemplary embodiment, the first flow control device 258 is a manual valve that may be selectively adjusted to prevent or control the flow of the drawn working fluid traveling through the IBH system 204, and the second flow control device 260 may be an automatic control valve that is selectively adjusted by the controller 206.

[53] The IBH system 204 illustrated in FIG. 2 includes three different potential return locations 254 that may be used with the IBH system 204 and/or the IE system 200. More specifically, in the exemplary embodiment, IBH system 204 includes a first return location 262 and/or a second return location 264. The first return location 262 is downstream from the silencer 212. The second return location 264 is upstream from the silencer 212 and downstream from the filter 210. Alternatively, the return location 254 may be any other suitable location upstream from the compressor inlet 134 that enables IBH system 204 to function as described herein.

[54] The IBH system 204 may return the compressed working fluid into the duct via the IBH manifold 214 such that the returned working fluid is combined with existing working fluid contained within the duct, such that the pressure and temperature of the existing working fluid are each increased. In particular, the drawn compressed working fluid, extracted from location 250, has a pressure and a temperature that are each higher than the pressure and temperature of working fluid contained within the inner passage 216, and/or the inlet fluid 220.

[55] The EGR system 202 extracts exhaust gases downstream from the turbine outlet 138. The EGR system 202 includes a return location 280 that is upstream from the compressor inlet 134. The EGR system 202 includes conduits 282, e.g., ducts, pipes, etc., which transfer the extracted exhaust gases to the return location 280, and also includes one or more flow control devices, e.g., the flow control device 146, including for example, and without limitation blower(s), ejector(s), compressor(s) coupled in parallel or series (variable or fixed speed controlled). In alternative embodiments, the EGR system 202 may include one or more flow control devices such as valves or regulators, not show n.

[56] The IE system 200 shown in FIG. 3, illustrates the IBH system 204 w ith the return location upstream from the silencer 212, and the return location of the IBH system 204 is downstream from the return location used with the EGR system 202. In other embodiments, the relative return locations of the IBH and EGR system 202 may be in any suitable location and orientation with respect to each other that enables the IE system 200 to function as described herein. For example, the IBH system 204 may include any of the return locations 264 or 262 illustrated in FIG. 2. Additionally, and/or alternatively, the IBH and/or the EGR systems 202 and 204, respectively, may include one or more return locations arranged in any other suitable location that enables the IE system 200 to function as described herein.

[57] In some embodiments, the EGR system 202 includes a flow control damper 270, e.g., positioned upstream from flow control device 146, to enhance control of the flow of exhaust gas through the conduits 282. In some embodiments, the EGR system 202 may include a variable speed drive or any other suitable flow control device. The EGR system 202 may include a shut off valve 272 for closing off or stopping the flow of exhaust gases through conduits 282. The EGR system 200 may also include an EGR injection manifold 224. See Figs. 10-12. In some embodiments, the EGR manifold 224 used with the EGR system and the IBH manifold 214 used with the IBH system 204 have two different configurations, suitable for the respective pressure and temperature of the IBH and EGR systems, 202 and 204. [58] Tn some embodiments, supplemental working fluid 274, e.g, air, also may be selectively added to the EGR system 202 to control the temperature or pressure of the exhaust gas that is returned into the inlet duct 218. For example, in some embodiments, the IE system 200 includes one or more flow control devices 276 for controlling the introduction of supplemental working fluid 274 into exhaust gas entrained within the EGR system 202, e.g., within conduit 282. The supplemental working fluid 274 may be introduced into the EGR system 202 downstream from flow control device 146 and/or valve 272 and upstream from the return location 280. The controller 206 is communicatively connected to the flow control device 276 and may selectively control the amount of supplemental working fluid 274 that is added to the EGR system 202. The controller 206 may selectively adjust the amount of supplemental working fluid 274 that is added to the EGR system 202 to selectively control the temperature of the exhaust gas introduced at location 280, thereby controlling the amount of thermal energy supplied to the inlet working fluid entering the compressor section 114.

[59] FIG. 4 is a block diagram of an exemplar}' controller 206 that may be used with system 200. The controller 206 includes a processor 402 and a memory 404. The controller 206 is communicatively coupled to the sensors 208 to receive data from the sensors 208 in real-time or at predefined time periods. In some embodiments, the controller 206 may determine data, e.g., pressure, temperature, and/or a flow rate. The controller 206 may utilize the received sensor data to determine a condition of the power generation system 100. For example, the controller 206 may determine if an icing condition, a surge condition, and/or an emission condition exists or is probable to exist. In some embodiments, the controller 206 may determine a temperature condition, such as a threshold temperature necessary for the maintenance of the temperature of the inlet, e.g., an operating temperature necessary to prevent icing or to improve the part load efficiency.

[60] The controller 206 is communicatively coupled to the EGR system 202 and IBH system 204 to control an amount of fluid traveling through each system. The controller 206 may transmit one or more signals to the flow control device 146 to control the flow of exhaust gases through the EGR system 202. The controller 206 may transmit one or more signals to the flow control devices 260 to control the flow of compressed fluid through the IBH system 204. [61] FIGS. 5-8, illustrates a filter 210 that may be used with the IE system 200 shown in FIGS. 1-3, for example. The filter 210 may be upstream from the compressor 114, and may include one or more filter elements 222, or not show n used to treat the air or w orking fluid, before the working fluid is introduced to the compressor inlet 134. For example, the filter 210 may remove contaminants entrained in the working fluid. Moreover, the filter 210 may include one or more weather hoods 502, and/or a filter compartment 504 including an outlet 508 for discharging filtered working fluid into the duct 218.

[62] FIG. 9 illustrates an exemplary IBH manifold 214 that may be used with the system 200. In the exemplary embodiment, the IBH manifold 214 may introduce or return the recirculated compressed working fluid of the IBH system 204 into the inlet transition duct 218. The IBH manifold 214 may include a horizontal member 602 and a plurality of vertical members 604 that extend generally perpendicularly from the horizontal member 602 and that are fluidically coupled to the horizontal members 602. The plurality of vertical members 604 may be equi-spaced along a length L214 of the horizontal member 602. The IBH manifold 214 includes a plurality of exit members 606 that are fluidically coupled to the vertical members 604. The horizontal member 602, the vertical members 604, and the exit members 606 may be hollow, e.g., hallow pipes or tubes, to enable recirculated compressed working fluid to travel through the horizontal member 602 and into the vertical members 604 prior to the compressed working fluid being discharged through the array of exit member 606.

[63] The recirculated compressed working fluid may be motivated to move through the IBH manifold 214 via a pressure differential. For example, the compressed working fluid extracted from the compressor outlet 136 has a higher pressure as compared to an operating pressure downstream from the compressor outlet 136 within the IBH system 204, thus motivating the flow' through the IBH manifold 214. The array of exit members 606 distribute the compressed air across the duct 218.

[64] In reference to FIGS. 10 - 12, in some embodiments, the IE system includes the EGR manifold 224 for introducing exhaust flow into the duct 218. The EGR manifold 224 may include a housing 702 having an inlet 704 and an outlet 706. The housing 702 may be a portion of duct 218. The EGR manifold 224 may include one or more pipes 708, extending from, and fluidically coupled to the conduits 282. The pipes 708 may be equally spaced along a vertical length L282 of the conduits 282. The pipes 708 may extend, e.g., horizontally, across the duct 218, such that the exhaust gas is distributed equally across the duct 218. The pipes 708 may include a plurality of openings 710 spaced across a length L706 of the pipes 706. The exhaust gas travels through conduits 282 through the pipes 708 and exits the pipe 708 through the openings 710 to distribute the exhaust gas to the inlet duct 218 without introducing turbulence. The exhaust gas may be motivated or regulated to move through the EGR manifold 224 by the flow control device 146 and/or the damper 270.

[65] FIG. 13 is a process flow of an exemplary method of operating the integrated efficiency system 200 (IE system 200), including the EGR system 202 and the IBH system 204, for use with a power generating system such as the power generation system 100. Any or all of process 800 may be performed by controller 206, for example.

[66] In some embodiments, process 800 may include selecting an operating condition or an operating mode. In some embodiments, the controller 206 may select an operating mode based on a targeted or desired operating condition. In some embodiments, the operating mode may be selected by an operator, for example, using a user interface. In some embodiments, the controller 206 may select an operating mode based on received sensor data. Operating modes may include an EGR mode in which the controller 206 causes the IE system 200 to utilize the EGR system 202 and during which time, the IBH system 204 is deenergized and/or placed in a standby mode. At least one other operating mode includes an EGR dominate mode, in which the IE system 200 supplies a higher mass flow, or mass flow rate, of exhaust gases through the EGR system 202 as compared to the compressed working fluid drawn downstream from the compressor outlet 136 through the IBH system 204. An operating condition may include ice prevention, compressor surge prevention, an efficiency target, for example. In the embodiments described herein, the IE system 200 may be operated in one or more of a plurality of operating modes, including an EGR mode, wherein the controller 206 causes the IE system 200 to operate the EGR system 202 and the IBH system 204 is deenergized and/or is placed in a standby mode. Alternatively, the controller 206 may cause the IE system 200 to be operated in an EGR dominate mode, wherein both the EGR system 202 and the IBH system 204 are operated, while the IBH system 204 is supplying a minimal amount of compressed working fluid to the inlet. [67] The process 800 may include detecting 802 one or more parameters of the power generation system 100 and/or the IE system 200. Detecting 802 a parameter may include a temperature detected using a temperature sensor at one or more locations upstream from the compressor inlet 134. Detecting 802 a parameter may include a pressure detected using a pressure sensor at one or more locations downstream from the compressor inlet 134. In some embodiments, process 800 includes determining, e.g., using controller 206, one or more parameters of the power generation system 100 and/or the IE system 200.

[68] The process 800 may include determining a condition, based on the detected 802 parameter or the determined parameter. In some embodiments, the process 800 includes determining 806 a surge condition. In some embodiments, a surge condition may be determined 806 using the controller 206. The controller 206 may determine a surge condition using any suitable method, e.g., using a compressor map including a surge line. In some embodiments, the controller 206 may determine a surge condition based on a detected 802 parameter and/or a determined parameter. In some embodiments, the process 800 includes determining 806 an icing condition based on a detected 802 parameter and/or a determined parameter.

[69] Process 800 may include determining 806 a target flow parameter of the IBH system 204 and a target flow parameter of the EGR system 202. In some embodiments, the flow parameter may be a mass flow rate. In some embodiments, process 800 may include determining a mass parameter of the IBH and/or the EGR system 202. For example, the controller 206 may determine a IBH mass parameter and/or an EGR mass parameter. The IBH mass parameter is indicative of an amount of compressed working fluid being delivered upstream from the compressor using the IBH system 204, and a EGR mass parameter is indicative of an amount of exhaust gases delivered upstream from the compressor using the EGR system 202.

[70] In some embodiments, process 800 includes determining, using controller 206, a target temperature of the returned exhaust gas, within the EGR system 202, that is introduced at location 280. The process 800 may include the controller 206 selectively adjusting the amount of supplemental working fluid 274 added to the exhaust gas in order to achieve the determined target temperature. The controller 206 may selectively adjust the amount of added supplemental working fluid 274 by transmitting one or more signals to the flow control device 276.

[71] In some embodiments, process 800 includes determining, e.g, using controller 206, a target amount of working fluid to be delivered to the compressor section 114. The process 800 may include the controller 206 transmitting one or more signals to the inlet guide vane 148, the IBH system 204, and the EGR system 202, to control the amount of working fluid that is delivered to the compressor section 114. In some embodiments, the process 800 may include determining, e.g., using controller 206, an amount of working fluid to be delivered to the compressor section 114 based on a temperature of the working fluid upstream from the compressor section 114.

[72] The controller 206 may determine the flow parameter based on one or more conditions detected by the sensors 208 or conditions determined by the controller 206. In some embodiments, the controller 206 may determine the flow parameter based on a selected condition. In some embodiments, the controller 206 may determine the flow parameter based on the selected operating mode, e.g., a mode selected by an operator.

[73] Process 800 includes simultaneous controlling 808 the EGR system 202 and the IBH system 204, by the controller 206, based on the determined 806 flow parameters.

[74] In some embodiments, process 800 includes iteratively detecting, e.g., in realtime or periodically, operating conditions such as the flow parameters, and simultaneously controlling the EGR system 202 and the IBH system 204 based on the detected conditions to facilitate optimizing, the power generation system 100 by preventing icing, and/or preventing a surge event, using a combination of the EGR system 202 and the IBH system 204. Moreover process 800 can be used to facilitate improving the overall efficiency of the power generation system 100.

[75] Further aspects of the present disclosure are provided by the subject matter of the following clauses:

[76] 1. An integration system for use with a turbine, the integration system comprising: an exhaust gas recirculation (EGR) system including a EGR flow control device for channeling flow extracted from a turbine exhaust to an EGR return location upstream from a compressor inlet; an inlet bleed heat (IBH) system including a TBH flow control device for channeling flow extracted downstream from a compressor outlet to a IBH return location upstream from the compressor inlet; and a controller communicatively coupled to the EGR flow control device and to the IBH flow control device, wherein the controller variably adjusts a relative flow rates of the EGR system and the IBH system.

[77] 2. The integrated efficiency system according to any preceding clause, wherein the EGR flow control device is at least one of a pump, blower, or ejector.

[78] 3. The integrated efficiency system according to any preceding clause, wherein the IBH flow control device is a control valve.

[79] 4. The integrated efficiency system according to any preceding clause, wherein the IBH is reintroduced at the IBH return location through an IBH manifold.

[80] 5. The integrated efficiency system according to any preceding clause, wherein the integration system further comprises a temperature sensor configured to detect a temperature upstream from the compressor inlet.

[81] 6. The integrated efficiency system according to any preceding clause, wherein the controller is configured to determine an icing event using data received from at least a temperature sensor.

[82] 7. The integrated efficiency system according to any preceding clause, wherein the integration system further includes a pressure sensor configured to detect operating pressure dow nstream from the compressor outlet.

[83] 8. The integrated efficiency system according to any preceding clause, wherein the controller is configured to determine a potential compressor surge event based on data received from a pressure sensor.

[84] 9. A power generation system comprising: a compressor for compressing a working fluid; a combustor; and an integration system for use with a turbine, the integration system comprising: an exhaust gas recirculation (EGR) system including an EGR flow control device for use in channeling flow extracted from an exhaust of the combustor to an EGR return location upstream from an inlet of the compressor; an inlet bleed heat (TBH) system including a TBH flow control device for use in channeling flow extracted downstream from an outlet of the compressor to a IBH return location upstream from the inlet of the compressor; and a controller communicatively coupled to the EGR flow control device and the IBH flow control device, wherein the controller selectively adjusts a relative flow rates of the EGR system and the IBH system.

[85] 10. The power generation system according to any preceding clause, wherein the EGR flow control device is at least one of a pump, blower, or ejector.

[86] 11. The power generation system according to any preceding clause, wherein the IBH flow control device is a control valve.

[87] 12. The power generation system according to any preceding clause, wherein the IBH is reintroduced at the IBH return location through an IBH manifold.

[88] 13. The power generation system according to any preceding clause, wherein the integration system further comprises a temperature sensor configured to detect a temperature upstream from the compressor inlet.

[89] 14. The power generation system according to any preceding clause, wherein the integration system further includes a pressure sensor configured to detect operating pressure downstream from the compressor outlet.

[90] 15. The power generation system according to any preceding clause, wherein the controller is configured to determine a potential compressor surge event based on data received from a pressure sensor.

[91] 16. A method of using an integration system for a gas turbine engine, the method comprising: receiving sensor data from a plurality of sensors coupled at various locations within the integration system; determining a current operating condition based on received sensor data; and adjusting at least one of a flow parameter of an EGR system, and a flow parameter of an IBH system to facilitate improving an operating efficiency of the gas turbine engine. [92] 17. The method according to any preceding clause, wherein adjusting at least one of a flow parameter of an EGR system further comprises transmitting a signal to a EGR flow control device indicative of a flow rate.

[93] 18. The method according to any preceding clause, wherein receiving sensor data further comprising receiving temperature data from a temperature sensor located upstream from a compressor.

[94] 19. The method according to any preceding clause, wherein receiving sensor data further comprising receiving pressure data from a pressure sensor located downstream from a compressor.

[95] 20. The method according to any preceding clause, wherein adjusting at least one of a flow parameter of an EGR system further comprises: heating working fluid upstream from a compressor; and adjusting a flow parameter of the IBH system to prevent compressor surge.

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

[97] In the exemplary embodiments described herein, an integrated efficiency (IE) system is provided for use with a gas turbine engine. The IE system includes an inlet bleed heat (IBH) system and an exhaust gas recirculation (EGR) system that may each be selectively used in combination, and/or isolation, to facilitate improving the efficiency of the power generation system, improving part load efficiency, improving the control of the release of emissions, and/or preventing icing and compressor surge. The combination of the EGR system and the IBH system, enables the controller to selectively control the use of the systems, thus enabling the IBH system to be significantly reduced in size and complexity, as the EGR system supplements the use of the IBH system. In some embodiments, the controller may selectively use the EGR system in isolation, such that the IBH system is in a standby mode and as such, the IBH does not need to draw compressed working fluid, resulting in an increase in the efficiency of the power generation system. [98] Tn the embodiments described herein, the TE system heats the inlet working fluid prior to entering the compressor inlet, thus improving the part load efficiency of a gas turbine, and/or the efficiency of the turbine at operating conditions other than its full load design point, while also preventing icing and/or compressor surge. In some embodiments, the IE system includes a controller that variably adjusts a mass flow rate, or a relative mass flow rate, of the EGR and the IBH systems to achieve a desired operating condition of the gas turbine engine. In some embodiments, the controller is communicatively coupled to one or more sensors, and may adjust the mass flow rates, in real-time or periodically, based on received sensor data and the targeted operating conditions. In some embodiments, the IBH system may be used to only prevent compressor surge, and heating of the inlet air is achieved primarily by the EGR system. In some embodiments, the controller may selectively turn on/off the IBH system to prevent compressor surge, while the EGR is operated continuously to heat the inlet air.

[99] This written description uses examples to disclose the embodiments of systems and methods, including the best mode, and also to enable any person skilled in the art to practice the systems and methods, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the systems and methods 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.

Claims

WHAT TS CLAIMED IS:

1. An integration system for use with a turbine, the integration system comprising: an exhaust gas recirculation (EGR) system including a EGR flow control device for channeling flow extracted from a turbine exhaust to an EGR return location upstream from a compressor inlet; an inlet bleed heat (IBH) system including a IBH flow control device for channeling flow extracted downstream from a compressor outlet to a IBH return location upstream from the compressor inlet; and a controller communicatively coupled to the EGR flow control device and to the IBH flow control device, wherein the controller variably adjusts a relative flow rates of the EGR system and the IBH system.

2. The integration system in accordance with Claim 1, wherein the EGR flow control device is at least one of a pump, blower, or ejector.

3. The integration system in accordance with Claim 1, wherein the IBH flow control device is a control valve.

4. The integration system in accordance with Claim 1 , wherein the IBH is reintroduced at the IBH return location through an IBH manifold.

5. The integration system in accordance with Claim 1, wherein the integration system further comprises a temperature sensor configured to detect a temperature upstream from the compressor inlet.

6. The integration system in accordance with Claim 1, wherein the controller is configured to determine an icing event using data received from at least a temperature sensor.

7. The integration system in accordance with Claim 1, wherein the integration system further includes a pressure sensor configured to detect operating pressure downstream from the compressor outlet.

8. The integration system in accordance with Claim 1 , wherein the controller is configured to determine a potential compressor surge event based on data received from a pressure sensor.

9. A power generation system comprising: a compressor for compressing a working fluid; a combustor; and an integration system for use with a turbine, the integration system comprising: an exhaust gas recirculation (EGR) sy stem including an EGR flow control device for use in channeling flow extracted from an exhaust of the combustor to an EGR return location upstream from an inlet of the compressor; an inlet bleed heat (IBH) system including a IBH flow control device for use in channeling flow extracted downstream from an outlet of the compressor to a IBH return location upstream from the inlet of the compressor; and a controller communicatively coupled to the EGR flow control device and the IBH flow control device, wherein the controller selectively adjusts a relative flow rates of the EGR system and the IBH system.

10. The power generation system in accordance with Claim 9, wherein the EGR flow control device is at least one of a pump, a blower, or an ejector.

1 1 . The power generation system in accordance with Claim 9, wherein the IBH flow control device is a control valve.

12. The power generation system in accordance with Claim 9, wherein the IBH is reintroduced at the IBH return location through an IBH manifold.

13. The power generation system in accordance with Claim 9, wherein the integration system further comprises a temperature sensor configured to detect a temperature upstream from the compressor inlet.

14. The power generation system in accordance with Claim 9, wherein the integration system further includes a pressure sensor configured to detect operating pressure downstream from the compressor outlet.

15. The power generation system in accordance with Claim 9, wherein the controller is configured to determine a potential compressor surge event based on data received from a pressure sensor.

16. A method of using an integration system for a gas turbine engine, the method comprising: receiving sensor data from a plurality of sensors coupled at various locations within the integration system; determining a current operating condition based on received sensor data; and adjusting at least one of a flow parameter of an EGR system, and a flow parameter of an IBH system to facilitate improving an operating efficiency of the gas turbine engine.

17. The method in accordance with Claim 16, wherein adjusting at least one of a flow parameter of an EGR system further comprises transmitting a signal to a EGR flow control device indicative of a flow rate.

18. The method in accordance with Claim 16, wherein receiving sensor data further comprising receiving temperature data from a temperature sensor located upstream from a compressor.

19. The method in accordance with Claim 16, wherein receiving sensor data further comprising receiving pressure data from a pressure sensor located downstream from a compressor.

20. The method in accordance with Claim 16, wherein adjusting at least one of a flow parameter of an EGR system further comprises: heating working fluid upstream from a compressor; and adjusting a flow parameter of the IBH system to prevent compressor surge.