Patent Description:
Gas turbine engines are utilized globally for electric power generation or as mechanical drives for operating equipment under a variety of climatic conditions. Operation during cold ambient temperature and high humidity conditions can lead to icing problems in gas turbine systems in which gas turbine engines are utilized. For example, ice can plug the filtration system of an air intake system to a gas turbine engine causing a significant drop in pressure in the air intake system, which in turn, leads to performance loss (e.g., gas turbine power output deterioration). In extreme cases, there is even a possibility that ice pieces can get ingested into a first blade stage of a compressor in the gas turbine engine, which can cause damage and may lead to some blades becoming inoperable. Ice may also cause the disruption of compressor work because of excessive vibration, or surging by decreasing the inlet flow, all of which can reduce the operational efficiency of the gas turbine system. Consequently, gas turbine systems that are located in cold weather locations where icing conditions can exist are typically equipped with anti-icing systems that can heat the intake air before it enters the compressor of the gas turbine engine. These anti-icing systems, which can include inlet heating coils, can be costly to implement.

<CIT> discloses a gas turbine system comprising a gas turbine engine, an air intake system to intake air for supply to the gas turbine engine, the air intake system comprising an air filter inlet house to filter the intake air, wherein the air filter inlet house includes at least one filter stage having an array of pulse filters, with each of the pulse filters being hydrophobic, and a combustion inlet air path in fluid communication with the air intake system and the gas turbine engine, the combustion inlet air path receiving the filtered air from the air filter inlet house and supplying the filtered air as combustion inlet air to an inlet of the gas turbine engine.

<CIT> suggests to apply erosion resistant icephobic coatings on various gas turbine engine components, such as stators, inlets, nose cones, fan blades, leading edge structures, etc., to provide lower ice adhesion strengths and better erosion resistance, should the need arise.

<CIT> discloses a filter media comprising a hydrophobic media layer for use e.g. in a filtration system for a gas turbine engine.

<CIT> discloses a moisture removal system and method for a gas turbine system and suggests to provide a hydrophobic coating on weather hoods at the air inlet of the gas turbine system and use hydrophobic filter materials or fibers in primary filters in the air duct downstream of the air inlet.

The following presents a simplified summary of the disclosed subject matter in order to provide a basic understanding of some aspects of the various embodiments described herein. This summary is not an extensive overview of the various embodiments. It is not intended to exclusively identify key features or essential features of the claimed subject matter set forth in the Claims, nor is it intended as an aid in determining the scope of the claimed subject matter. Its sole purpose is to present some concepts of the disclosure in a streamlined form as a prelude to the more detailed description that is presented later.

The various embodiments of the present invention are directed to providing a novel and nonobvious anti-icing approach for use with a gas turbine system utilizing a gas turbine engine without having to rely on an anti-icing system to heat the intake air. The solution provided by the various embodiments includes utilizing an array of hydrophobic pulse filters in the air filter inlet house of an air intake system to a gas turbine engine, along with at least one component in the combustion inlet air path between the air filter inlet house and the inlet of the gas turbine engine that has a surface with an anti-icing coating to prevent ice from forming. With this configuration, a pulse filter controller can be programmed to pulse the pulse filters to dislodge ice from the filters as conditions dictate. Further, employing pulse filters that are hydrophobic blocks liquid water from passing through to the combustion inlet air path and into the inlet of the gas turbine engine. Blocking liquid water from passing through to the combustion inlet air path prevents ice accretion on the components in the path that can arise in cold weather conditions.

Even though the hydrophobic pulse filters block water that can lead to icing in the combustion inlet air path, icing conditions can still develop due to humidity that moves through the combustion inlet air path. Operation during cold ambient temperatures and high humidity are conditions that can lead to icing problems in gas turbine systems in which gas turbine engines are utilized. In general, icing conditions can develop on components in the combustion inlet air path when ambient operating conditions include at least <NUM>% humidity and a temperature that is below <NUM>,<NUM> (<NUM> degrees Fahrenheit (F)). Applying an anti-icing coating to at least one component in the combustion inlet air path prevents ice from forming when operating conditions include at least <NUM>% humidity and a temperature that is below <NUM>,<NUM> (<NUM> degrees F).

A foreign object damage (FOD) screen is one component in the combustion inlet air path between the air filter inlet house and the inlet of the gas turbine engine that has an anti-icing coating. A FOD screen, which collectively includes one or more screens and an air sock, is used to protect the gas turbine engine from debris (e.g., weld slag) that could lead to damage (e.g., blade damage) if allowed to pass through into the gas turbine engine. The FOD screen, which is placed upstream of the inlet of the gas turbine engine, provides "last chance" protection against foreign object damage to the gas turbine engine. Icing conditions (i.e., at least <NUM>% humidity and a temperature that is below <NUM>,<NUM> (<NUM> degrees F)) can lead to ice formation on the FOD screen. Ice on the FOD screen can lead to a differential pressure across the FOD screen. As differential pressure increases across the FOD screen, it reduces the air flow going through the gas turbine engine. This can affect turbine operation due to icing build up in the FOD screen. This icing build up in the FOD screen can eventually cause the turbine to shut down. Applying the anti-icing coating to the FOD screen transforms the screen to an icephobic FOD screen that inhibits the formation of ice that can lead to damage of the gas turbine engine and possible shut down of the turbine.

Other components in or upstream of the combustion inlet air path between the air filter inlet house and the inlet of the gas turbine engine can also have an anti-icing coating applied to a surface to prevent the formation of ice. These other components can include, but are not limited to, weather hoods mounted on the air filter inlet house that permit passage of a stream of inlet air and prevent weather elements from entering, the silencer that is used to reduce the "noise" associated with the stream of the combustion inlet air transmitted to the inlet of the gas turbine engine, the inlet plenum and inlet volute that supply the combustion inlet air to the inlet of the gas turbine engine, the inlet guide vanes that direct the combustion inlet air to the inlet of the gas turbine engine, and the inlet struts that support the combustion inlet air duct that supplies the combustion inlet air towards the inlet of the gas turbine engine. Applying an anti-icing coating to one or more of these components can complement the anti-icing coating applied to the FOD screen.

The configuration of the array of hydrophobic pulse filters along with at least one component in the combustion inlet air path between the air filter inlet house and the inlet of the gas turbine engine that has a surface with an anti-icing coating, allows the various embodiments of the present invention to eliminate the possibility of ice accretion in the combustion inlet duct. This allows the gas turbine engine to operate continuously during icing conditions. In addition, the configuration of the various embodiments obviates the need to utilize an anti-icing system to heat the intake air, thereby maximizing efficiency and cost effectiveness of the gas turbine system. Further, the configuration of the various embodiments is suitable for use with gas turbine systems that are already implemented with an anti-icing system. To this extent, the configuration of the various embodiments can be utilized to avoid parasitic loads that are associated with the use of these anti-icing systems.

In accordance with one aspect of the invention, a gas turbine system is provided. The gas turbine system comprises: a gas turbine engine; an air intake system to intake air for supply to the gas turbine engine, the air intake system comprising an air filter inlet house to filter the intake air, wherein the air filter inlet house includes at least one filter stage having an array of pulse filters, with each of the pulse filters being hydrophobic, a combustion inlet air path in fluid communication with the air intake system and the gas turbine engine, the combustion inlet air path receiving the filtered air from the air filter inlet house and supplying the filtered air as combustion inlet air to an inlet of the gas turbine engine; and a foreign object damage (FOD) screen in the combustion inlet air path between the air filter inlet house and the inlet of the gas turbine engine to prevent debris from entering the inlet of the gas turbine engine, wherein the FOD screen includes one or more mesh screens and an air sock placed over the one or more mesh screens, the one or more mesh screens enclosed in a frame structure having horizontally and vertically extending rails defining individual segments of sub-frame structures formed by intersections of the horizontally extending rails with the vertically extending rails, each individual segment of sub-frame structures enclosing portions of the one or more mesh screens, wherein a surface of each of the one or more mesh screens (<NUM>) in the individual segments of sub-frame structures and the air sock placed over the one or more screens comprises an anti-icing coating to prevent ice formation thereon, the anti-icing coating applied to each of the one or more mesh screens in the individual segments of sub-frame structures and the air sock in locations where there is direct particle impact with particles flowing through the combustion inlet air path and locations without direct particle impact with the particles flowing through the combustion inlet air path.

In accordance with another aspect of the invention, a method for preventing icing in the combustion inlet air path of a gas turbine system having a gas turbine engine, an air intake system to intake air for supply to the gas turbine engine, and a combustion inlet air path to supply combustion inlet air to an inlet of the gas turbine engine is provided. The method comprises: filtering the intake air in the air intake system with an air filter inlet house including at least one filter stage having an array of hydrophobic pulse filters; supplying the filtered air as combustion inlet air to the inlet of the gas turbine engine; and applying an anti-icing coating to a surface of at least one component in a path of the combustion inlet air between the air filter inlet house and the inlet of the gas turbine engine to prevent ice from forming on the at least component. The at least one component comprises a foreign object damage (FOD) screen, wherein the FOD screen includes one or more mesh screens and an air sock placed over the one or more mesh screens. The one or more mesh screens are enclosed in a frame structure having horizontally and vertically extending rails defining individual segments of sub-frame structures formed by intersections of the horizontally extending rails with the vertically extending rails, each individual segment of sub-frame structures enclosing portions of the one or more mesh screens, wherein a surface of each of the one or more mesh screens in the individual segments of sub-frame structures and the air sock placed over the one or more screens comprises the anti-icing coating to prevent ice formation thereon. The anti-icing coating is applied to each of the one or more mesh screens in the individual segments of sub-frame structures and the air sock in locations where there is direct particle impact with particles flowing through the combustion inlet air path and locations without direct particle impact with the particles flowing through the combustion inlet air path.

Example embodiments of the present invention will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments are shown. Indeed, the present invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. For like numbers may refer to like elements throughout.

This disclosure relates generally to gas turbine systems, and more specifically, to a system and method for preventing icing in the combustion inlet air path of a gas turbine system. As used herein, the combustion inlet air path of a gas turbine system extends from the ambient air at the air intake system of the gas turbine system to the first stage of the gas turbine compressor.

The various embodiments of the present invention prevent the formation of ice in the combustion inlet air path of a gas turbine system through the use of an array of hydrophobic pulse filters in the air filter inlet house of an air intake system to a gas turbine engine, along with at least one component in the combustion inlet air path between the air filter inlet house and the inlet of the gas turbine engine that has a surface with an anti-icing or icephobic coating to prevent ice from forming on the at least one component. The prevention of the formation of ice in the combustion inlet air path of a gas turbine system as described in the various embodiments is suitable for use with all types of gas turbine systems and gas turbine combustion systems utilizing turbomachinery regardless of their application (e.g., land-based, marine-based, and aviation based applications). Gas turbine systems and gas turbine combustion systems using turbomachines that include, but are not limited to, heavy frame industrial gas turbines, aeroderivative gas turbines, marine gas turbines, ammonia-fueled gas turbines, hydrogen-fueled gas turbines, aviation gas turbines, and general combustion turbines are non-limiting examples of systems that can have a need to prevent ice formation in the combustion inlet air path if deployed in cold weather locations, and thus, are applicable for use with the various embodiments.

Turning now to the figures, <FIG> shows a schematic block diagram of a gas turbine system <NUM> in which a system for preventing icing in the combustion inlet air path of the gas turbine system can be implemented according to an embodiment of the invention. As shown in <FIG>, the gas turbine system <NUM> includes a gas turbine engine <NUM>, a gas turbine enclosure <NUM> that houses the gas turbine engine <NUM>, an air intake system <NUM> that provides filtered air to the gas turbine engine <NUM> for combustion, a gas turbine combustion exhaust <NUM> for releasing exhaust gases from the gas turbine engine <NUM>, and a gas turbine enclosure ventilation exhaust system <NUM> to purge and ventilate heat and exhaust products from the gas turbine engine <NUM>.

The gas turbine engine <NUM> can include a compressor, a combustor, and a turbine. In general, the compressor can compress an incoming flow of air. The compressor can deliver the compressed flow of air to the combustor, where the compressed flow of air mixes with a compressed flow of fuel. The combustor can ignite the air/fuel mixture to create a flow of combustion gases. The flow of combustion gases can be delivered to the turbine to drive the turbine to produce mechanical work. The mechanical work produced in the turbine can drive the compressor and an external load, such as an electrical generator or the like. The flow of combustion gases may be exhausted or otherwise disposed by the gas turbine combustion exhaust <NUM>.

The gas turbine engine <NUM> can use natural gas, various types of syngas, and/or other types of fuels. In addition, the gas turbine engine <NUM> may be any one of a number of different gas turbine engines such as those offered by the General Electric Company.

The gas turbine enclosure <NUM>, which encloses the gas turbine engine <NUM>, can isolate the gas turbine engine. In addition, the gas turbine enclosure <NUM> can include a number of different components that operate in conjunction with the gas turbine engine <NUM>. For example, the gas turbine enclosure <NUM> can include piping for lube oil, NOx emissions, power augmentation, and the like. Other components can include, but are not limited to, a gas detection system and a fire detection and suppression system. Also, the gas turbine enclosure <NUM> can perform a number of different functions that contribute to the operation of the gas turbine engine <NUM>. For example, the gas turbine enclosure <NUM> can serve as a sump for oil leaks from the gas turbine engine <NUM>.

The air intake system <NUM> can include an inlet screen or an air filter inlet house that includes one or more filter assemblies having a number of inlet air filters that remove moisture and/or particulate matter (such as dust, dirt, contaminants and/or debris) from intake air channeled for supply to the gas turbine engine <NUM>. A clean air duct can receive the filtered air from the air filter inlet house. The air in the clean air duct can be divided into combustion inlet air that goes to the compressor of the gas turbine engine <NUM>, and ventilation inlet air that is supplied to the gas turbine enclosure <NUM>. In particular, a combustion inlet air duct can provide the combustion inlet air to the compressor, while a ventilation inlet air bypass conduit can supply the ventilation inlet air to the gas turbine enclosure <NUM>.

The gas turbine enclosure ventilation exhaust system <NUM> can include one or more ventilation fans that operate to generate an air flow to purge the gas turbine enclosure <NUM> of heat and exhaust products from the gas turbine engine <NUM>. In addition, the gas turbine enclosure ventilation exhaust system <NUM> can include a damper that controls the flow of air containing the heat and exhaust products from the gas turbine engine <NUM> and the gas turbine enclosure <NUM>.

It is understood that the gas turbine system <NUM> can include a number of other components not depicted in <FIG>. For example, the gas turbine system <NUM> can include a shaft operatively coupled to the compressor and turbine of the gas turbine engine <NUM>. To this extent, the shaft may be connected to an electrical generator for power generation applications.

In one embodiment, the gas turbine system <NUM> depicted in <FIG> can take the form of an aeroderivative gas turbine system. <FIG> shows a schematic example of an aeroderivative gas turbine system <NUM>, of which the system for preventing icing in the combustion inlet air path described herein can be implemented according to an embodiment of the invention. As used herein, "downstream" and "upstream" are terms that indicate a direction relative to the flow of a fluid, such as the working fluid through the gas turbine system, for example, the flow of air through the air intake system or through one of the components of a gas turbine engine. The term "downstream" corresponds to the direction of flow of the fluid, and the term "upstream" refers to the direction opposite to the flow.

As shown in <FIG>, The aeroderivative gas turbine system <NUM> of <FIG> shows the air intake system <NUM> having an air filter inlet house <NUM>. The air intake system <NUM> can further include a weather hood <NUM> mounted on the air filter inlet house <NUM> that permits passage of a stream of inlet air <NUM> and prevents weather elements such as rain, snow, and the like from entering therein. The weather hood <NUM> may be largely of conventional design, and can include a plurality of inlet vane type separators and moisture separators to prevent heavy rain or heavy fog mist from entering the air filter inlet house <NUM>. For example, the inlet vane type separators can remove water droplet particles larger than a specified size (e.g., <NUM> microns in size) to prevent liquid droplets from carrying any absorbed salt downstream into the gas turbine engine <NUM>. The moisture separators can remove water droplets particles that are smaller than the specified size. In particular, the moisture separators can collect smaller aerosol droplets and coalesce them into large droplets which can be easily removed with the help of the inertia of the larger droplets.

The air filter inlet house <NUM> can include a filter module <NUM> that can further remove moisture as well as particulate matter (such as dust, sand, dirt, salt, water droplets, contaminants, and/or debris) from the stream of inlet air <NUM> channeled to the gas turbine engine <NUM>. In one embodiment, the filter module <NUM> can include a multiple of filter stages to filter the stream of inlet air <NUM> provided to the gas turbine engine <NUM>. Note that for clarity, the filter module <NUM> of <FIG> only shows one filter stage.

Each of the filter stages in the filter module <NUM> can include any suitable filtering component that may be configured to remove and/or filter out large and small particles and/or debris that may be found in the stream of inlet air <NUM>, such as, sand grains, dirt, dust, salt, rain drops, snow, and other undesirable debris and contaminants. In one embodiment, each of the filter stages in the filter module <NUM> can include an array of fabric filters such as hydrophobic pulse filters that can filter finer and/or smaller particulates from the stream of inlet air <NUM> flowing therethrough.

After passing through the air filter inlet house <NUM>, the stream of inlet air <NUM> can then flow through a transition piece <NUM> that connects the air filter inlet house <NUM> to a silencer section <NUM> that can reduce the "noise" associated with the stream of inlet air <NUM> transmitted through the air intake system <NUM>. The stream of inlet air <NUM> flows from the silencer section <NUM> to a foreign object damage (FOD) screen <NUM> via an inlet duct <NUM>. The FOD screen <NUM>, which collectively can include more than one screen, may be used to deflect contaminants or debris. The stream of inlet air <NUM> then may pass through an inlet plenum/volute <NUM> (a combustion inlet air duct) and into the gas turbine engine <NUM> as combustion inlet air for compression and combustion.

It is understood that the air intake system <NUM> can be configured to include other components, and thus, the description of the air intake system as depicted <FIG> as well as the other figures described herein is not meant to be limiting. For example, the air filter inlet house <NUM> can be configured with heating or de-icing components (e.g., heating coils) to warm the stream of inlet air <NUM> and/or components of the air filter inlet house <NUM> such as for example, the filter module <NUM>. Sensors (e.g., temperature sensors, pressure sensors, humidity sensors, flow sensors, etc.) can measure various conditions associated with the air filter inlet house <NUM> and its components, as well as conditions associated with the stream of inlet air <NUM>. Other components can include, but are not limited, to a by-pass duct that can divert clean, filtered inlet air from the inlet plenum <NUM> and supplies it as ventilation inlet air to a gas turbine enclosure <NUM> that encloses the gas turbine engine <NUM>.

Further, it is understood that the air intake system <NUM> depicted in <FIG>, as well as <FIG> represent only one example of an air intake system that can be implemented with an aeroderivative gas turbine system, and is not meant to limit the various embodiments described herein. Those skilled in the art will appreciate that aeroderivative gas turbine systems can be implemented with an air intake system that takes on a different configuration than that depicted in <FIG> and <FIG>. For example, instead of having a single inlet for receiving the stream of inlet air <NUM> as depicted in <FIG> and <FIG>, there can be dual inlets that receive the inlet air, as well as multiple inlets to receive the stream of inlet air <NUM>.

Although not explicitly shown in <FIG>, the gas turbine engine <NUM> may generally include a compressor, a combustor and a turbine that can operate in the manner previously discussed. That is, the compressor delivers a compressed flow of air to the combustor. The combustor mixes the compressed flow of air with a compressed flow of fuel and ignites the mixture in a chamber to create a flow of combustion gases. The flow of combustion gases is in turn delivered to a turbine to drive the turbine blades to rotate about a shaft along an axis of the gas turbine engine. In this manner, the mechanical work in the turbine can drive a load such as an electrical generator <NUM> to produce power.

The aeroderivative gas turbine system <NUM> of <FIG> also can include a gas turbine enclosure ventilation exhaust system <NUM> that can generate an air flow to purge the gas turbine enclosure <NUM> of heat and exhaust products from the gas turbine engine <NUM>. It is understood that the aeroderivative gas turbine system <NUM> depicted in <FIG>, as well as the other figures disclosed herein that illustrate gas turbine systems of other embodiments, can include a number of other components not specifically referenced or shown in the figures. For example, the aeroderivative gas turbine system <NUM> in <FIG> and <FIG> can include, but is not limited to, a number of skids (e.g., a water injection skid, a liquid fuel boost skid, a compressor discharge pressure (CDP) skid, and a CDP cooler skid) and struts to support the gas turbine engine.

Further, it is understood that the aeroderivative gas turbine system <NUM> of <FIG>, as well as other figures (<FIG>) disclosed herein represent only one example of an aeroderivative gas turbine system and those skilled in the art will appreciate that aeroderivative gas turbine systems can be configured according to any of a number of possibilities. For example, an aeroderivative gas turbine system can be configured as a multi shaft design that can include a low-pressure compressor, a highpressure compressor, and a power turbine in a multi shaft design. Thus, the system described herein for preventing icing in the combustion inlet air path of the gas turbine system should not be limited to the aeroderivative gas turbine system <NUM> depicted in <FIG> and <FIG>.

The various embodiments of the present invention are directed to preventing icing in the combustion inlet air path of a gas turbine system, such as for example, an aeroderivative gas turbine system. <FIG> shows a schematic diagram of a system <NUM> for preventing icing in the combustion inlet air path of a gas turbine system <NUM> according to an embodiment of the invention. As discussed above with respect to <FIG> and <FIG>, the gas turbine system <NUM> includes a gas turbine engine <NUM> disposed in a gas turbine enclosure <NUM>, an air intake system <NUM> that receives a stream of inlet air <NUM> and provides filtered air to the gas turbine engine <NUM> for combustion. A gas turbine combustion exhaust <NUM> releases exhaust gases from the gas turbine engine <NUM>, and a gas turbine enclosure ventilation exhaust system <NUM> purges and ventilates heat and exhaust products from the gas turbine engine <NUM>.

<FIG> shows that the air intake system <NUM> can include an air filter inlet house <NUM> that removes moisture and/or particulate matter (such as dust and/or debris) from the intake air <NUM> channeled to the gas turbine engine <NUM>. In one embodiment, the air filter inlet house <NUM> can include a multiple of filter stages (e.g., Filter Stage <NUM>, Filter Stage <NUM>, Filter Stage <NUM>) to filter the intake air <NUM> provided to the gas turbine engine <NUM>. As shown in <FIG>, the filter stages can be disposed in series in the air filter inlet house <NUM> such that Filter Stage <NUM> applies a first filter to the intake air <NUM>, while Filter Stage <NUM>, which is downstream of Filter Stage <NUM>, and Filter Stage <NUM>, which is downstream of Filter Stage <NUM>, each applies an additional filtering of the intake air <NUM> to further remove any moisture and/or particulate matter that may remain after filtering in the filter stage upstream therefrom.

It is understood that the number of filter stages (Filter Stage <NUM>, Filter Stage <NUM>, Filter Stage <NUM>) depicted in <FIG> are illustrative of a number of filter stages that may be deployed in the air filter inlet house <NUM>, and is not meant to be limiting. Those skilled in the art will appreciate that the air filter inlet house <NUM> can have more or less filter stages than that what is depicted in <FIG>.

Each of the filter stages in the air filter inlet house <NUM> can include any suitable filtering component that may be configured to remove and/or filter out large and small particles and/or debris that may be found in the intake air <NUM>, such as, sand grains, dirt, rain drops, snow, and other undesirable debris. In one embodiment, each of the filter stages in the air filter inlet house <NUM> can include an array of hydrophobic pulse filters <NUM>.

It is understood that the air filter inlet house <NUM> can be configured to include other filtering components. For example, the air filter inlet house <NUM> can include vane filters (e.g., weather hoods and/or screens) to remove and/or filter out large particles and/or debris that may be found in the intake air <NUM>. For example, in one embodiment, the air filter inlet house <NUM> can be configured with vane filters formed at an inlet that receives the intake air <NUM> to remove and/or filter out large particles and/or debris, while the Filter Stages <NUM>, <NUM> and <NUM> can filter out the smaller or finer particles that remain in the intake air <NUM>.

The air intake system <NUM> further includes a clear air duct <NUM> in fluid communication with the air filter inlet house <NUM>. As used herein, "in fluid communication with" means that there is a passage that allows a fluid to flow. In one embodiment, the clean air duct <NUM> can receive the filtered air from the air filter inlet house <NUM>. The air in the clean air duct <NUM> can then be divided into combustion inlet air that goes to the compressor <NUM> of the gas turbine engine <NUM>, and ventilation inlet air that is supplied to the gas turbine enclosure <NUM>. In one embodiment, the inlet plenum/volute <NUM> (a combustion inlet air duct), that is in fluid communication with the clean air duct <NUM>, provides the combustion inlet air to a compressor <NUM> of the gas turbine engine <NUM>, while a ventilation inlet air bypass conduit <NUM>, that is in fluid communication with the clean air duct <NUM>, supplies the ventilation inlet air to the gas turbine enclosure <NUM>. To this extent, the clean air duct <NUM> receives the filtered intake air <NUM> from the last filter stage (e.g., Filter Stage <NUM>) of the air filter inlet house <NUM>, which the inlet plenum/volute <NUM> provides as combustion inlet air to the compressor <NUM>, and the ventilation inlet air bypass conduit <NUM> supplies as ventilation inlet air into the gas turbine enclosure <NUM>.

A silencer <NUM> and a FOD screen <NUM> are other components that form part of the air-intake system <NUM> as depicted in <FIG>. The silencer <NUM> can be an assembly formed from a plurality of silencer panels that is located downstream of the air filter inlet house <NUM>, about the clear air duct <NUM>, to reduce the "noise" associated with the intake air <NUM> transmitted through the air intake system <NUM>. The FOD screen <NUM> is used to deflect contaminants or debris (e.g., weld slag). The stream of inlet air <NUM> then may pass through the inlet plenum/volute <NUM> and into the gas turbine engine <NUM> as combustion inlet air for compression and combustion.

It is understood that the FOD screen can be implemented in a number of different locations depending on the aeroderivative gas engine package, and thus, the placement of the FOD screen <NUM> is not meant to be limiting. For example, the FOD screen <NUM> can be placed in a number locations before the compressor <NUM>, but downstream of the filters. In one embodiment, the FOD screen <NUM> can be coupled to a wall (e.g., annular wall) of the housing of the silencer <NUM>. In certain embodiments, the FOD screen <NUM> can be coupled to other walls in the combustion inlet air path that are not part of the housing of the silencer <NUM>. In other embodiments, the FOD screen <NUM> can be coupled to an upstream end of an engine bell mouth defining the inlet of the gas turbine engine <NUM>.

<FIG> shows the gas turbine engine <NUM> with the compressor <NUM>, a combustor <NUM>, and a turbine <NUM> that can operate in the manner previously discussed. That is, the compressor <NUM> delivers a compressed flow of air to the combustor <NUM>. The combustor <NUM> mixes the compressed flow of air with a compressed flow of fuel and ignites the mixture in a chamber to create a flow of combustion gases. The flow of combustion gases is in turn delivered to the turbine <NUM> to drive the turbine blades to rotate about a shaft along an axis of the gas turbine engine <NUM>. In this manner, the mechanical work in the turbine can drive a load such as an electrical generator to produce power.

As shown in <FIG>, the gas turbine system <NUM> can further include a gas turbine enclosure ventilation exhaust system <NUM> to generate an air flow to purge the gas turbine enclosure <NUM> of heat and exhaust products from the gas turbine engine <NUM>. In one embodiment, the gas turbine enclosure ventilation exhaust system <NUM> can include one or more ventilation fans <NUM> to generate the air flow that purges the gas turbine enclosure <NUM> of heat and exhaust products from the gas turbine engine <NUM>. Ventilation silencers and ducts <NUM>, in fluid communication with each fan <NUM>, can draw the air flow from the gas turbine enclosure <NUM> and direct it to ambient as ventilation outlet air.

Although not illustrated in <FIG>, the gas turbine enclosure ventilation exhaust system <NUM> can include a ventilation air control damper that can be used to aid in directing the ventilation outlet air to ambient. In one embodiment, the ventilation air control damper, which can be an electronically controlled device, can be configured to also direct the ventilation outlet air from the gas turbine enclosure <NUM> to one or more air inlet heating ducts that are in fluid communication with a corresponding ventilation conduit <NUM>. In this manner, the ventilation outlet air can be directed back to the air intake system <NUM> and used to heat the stream of inlet air <NUM> supplied to the air filter inlet house <NUM>.

The gas turbine system <NUM> of <FIG> can further include a controller <NUM> that is operatively coupled to the air intake system <NUM>, the gas turbine engine <NUM>, the gas turbine combustion exhaust <NUM>, and the gas turbine enclosure ventilation exhaust system <NUM>. In this manner, the controller <NUM> can control the operation of various components associated with each of these parts of the gas turbine system <NUM>. For example, one or more sensors may be disposed about the gas turbine engine <NUM>, the air intake system <NUM>, the gas turbine combustion exhaust <NUM>, and the gas turbine enclosure ventilation exhaust system <NUM> to detect any of a number of conditions. The sensors can be in communication with the controller <NUM> to provide measurements representative of any number of parameters that the sensors are configured to detect. A non-limiting list of sensors that are suitable for use include temperature sensors, pressure sensors, flow sensors, and humidity sensors.

In one embodiment, one or more temperature sensors can be disposed about the air intake system <NUM> to obtain temperature measurements about the air intake system. For example, an ambient temperature sensor can be disposed about the inlet of the air intake system <NUM>, while an air intake system temperature sensor can be disposed within the air intake system. To this extent, the ambient temperature sensor can obtain ambient temperature measurements about the inlet of the air intake system <NUM>, while the air intake system temperature sensor can obtain temperature measurements within the air intake system. In one scenario, the controller <NUM> can use these temperature measurements, along with humidity measurements obtained from humidity sensors located about the air intake system <NUM> to determine the presence of icing conditions.

As noted above, the various embodiments of the present invention are directed to preventing icing in the combustion inlet air path of a gas turbine system. The system <NUM> depicted in <FIG> prevents icing in the combustion inlet air path of the gas turbine system <NUM> without the use of an anti-icing heating system (e.g., heater coils and the use of the ventilation outlet air to heat the intake air) to heat the stream of inlet air <NUM>. In particular, the system <NUM> can prevent the formation of ice in the combustion inlet air path of the gas turbine system <NUM> through the use of the array of hydrophobic pulse filters <NUM> in the air filter inlet house <NUM>, along with at least one component in the combustion inlet air path between the air filter inlet house <NUM> and the inlet of the gas turbine engine <NUM> that has a surface with an anti-icing or icephobic coating to prevent ice from forming on the at least one component. More specifically, the controller <NUM> can direct the array of hydrophobic pulse filters <NUM> to be pulsed in response to determining the presence of ice on the filters or that icing conditions exist. Pulsing the filters <NUM> will dislodge any ice from the filters, preventing it from being ingested and traveling to the inlet of the gas turbine engine <NUM>.

One aspect of the anti-icing properties that is provided by the system <NUM> are attained due to the pulse filters <NUM> being hydrophobic. In particular, the hydrophobic pulse filters <NUM> block liquid water from passing through the air filter inlet house <NUM> into the combustion inlet air path and onto the inlet of the gas turbine engine. This blocking of liquid water from passing into the combustion inlet air path prevents ice accretion that can lead to icing in parts or components of the combustion inlet air path.

Even though the hydrophobic pulse filters <NUM> block water that can lead to icing in the combustion inlet air path, icing conditions can still develop when the humidity and temperature reach certain levels. As noted above, icing conditions can develop on components in the combustion inlet air path when ambient operating conditions include at least <NUM>% humidity and a temperature that is below <NUM>,<NUM> (<NUM> degrees Fahrenheit (F)). The system <NUM> addresses this icing concern that can arise when conditions include at least <NUM>% humidity and a temperature that is below <NUM> degrees F by applying the anti-icing or icephobic coating to at least one component in the combustion inlet air path. To this extent, the anti-icing coating applied to at least one component in the combustion inlet air path prevents ice from forming when operating conditions include at least <NUM>% humidity and a temperature that is below <NUM>,<NUM> (<NUM> degrees F).

In general, the anti-icing coating applied to the at least one component in the combustion inlet air path can prevent the formation of ice due to the coating having one or more properties that can include, but are not limited to, preventing ice nucleation (the way water vapor is triggered into freezing), lowering the freezing temperature for water that touches a surface containing the coating, making it difficult for ice to grab onto the surface containing the coating (low ice adhesion), and super-hydrophobicity in cold and humid climates.

The anti-icing coating can comprise any of a number of commercially available anti-icing or icephobic coatings including, but not limited to icephobic/super hydrophobic and nano-textured super hydrophobic coatings that can inhibit the accretion of ice. A non-exhaustive list of anti-icing or icephobic coatings that are suitable for use in the various embodiments include, but are not limited to, AEROKRET <NUM>, NEINCE, ADAPTIVE SURFACE TECHNOLOGIES' SLIP FOUL PROJECT, LUNA INNOVATIONS' GENTOO, BATTEL HEATCOAT, ECOLOGICAL COATINGS' <NUM> Series icephobic coatings, KISS POLYMERS' KISS-COTE, NEI'S NANOMYTE coating, NBD NANO's REPELSHELL, and OPUS MATERIALS TECHNOLOGIES' ICEMART. Other commercially available anti-icing or icephobic coatings are available from KYNAR, HYGRATEK LLC, FRAUNHOFER IGB, and EQUINOR ASA. In addition to being effective anti-icing coatings, these coatings exhibit strong durability properties that make them suitable for use in gas turbine applications in which it is desirable to have coatings that can withstand the impact of debris that may arise during the usual operation of a gas turbine system.

The FOD screen <NUM> is a particular component in the combustion inlet air path between the air filter inlet house <NUM> and the inlet of the gas turbine engine <NUM> that has an anti-icing coating. In general, the FOD screen <NUM>, which can collectively include one or more screen, including an air sock placed over the screen(s) can be formed from any of a number of materials. A non-limiting list of materials that are suitable for use in the screen(s) and the air sock of the FOD screen <NUM> can include, but is not limited to, a woven mesh of a flexible, non-metal material (e.g., mesh wires), a metal material, nylon, para-aramid synthetic fibers (e.g., Kevlar®, Twaron®, etc.) and combinations thereof. To this extent, these materials can enable each screen in the FOD screen <NUM> including the sock to block debris or foreign objects from entering the inlet of the gas turbine engine <NUM>.

<FIG> show various views of an example of the FOD screen <NUM> in which an anti-icing coating can be applied according to an embodiment of the invention. As shown in in <FIG>, the FOD screen <NUM> comprises a frame structure <NUM> with a screen <NUM> enclosed by the frame structure. The frame structure <NUM> is formed from rails, support rods, or the like. As shown in <FIG>, the rails extend horizontally and vertically across to define individual segments of sub-frame structures each having a mesh screen. With this configuration, the anti-icing coating is applied on the surfaces of the screen <NUM> that are in the combustion inlet air path.

As mentioned previously, the FOD screen <NUM> can include more than one screen <NUM> and includes an air sock placed over the screen(s). <FIG> shows an example of two screens <NUM> that can be placed over one another and placed in the frame structure <NUM> depicted in <FIG>. With this configuration, the anti-icing coating can be applied on the surfaces of both of the screens <NUM>.

In one embodiment, the anti-icing coating can be applied to the screen(s) and sock of the FOD screen <NUM> by using any of a number of well-known methodologies. In one embodiment, the anti-icing coating can be applied to each of the screen(s) and sock of the FOD screen <NUM> by using a spray and dip method. The regions of the screen(s) and sock of the FOD screen that are applied with the anti-icing coating include locations where there is direct particle impact and locations without direct particle impact. Applying the anti-icing coating to the screen(s) <NUM> and sock transforms the FOD screen <NUM> to an icephobic FOD screen that inhibits the formation of ice that can lead to damage of the gas turbine engine <NUM> and possible shut down of the turbine.

Although the FOD screen <NUM> is described and depicted with a square or rectangular shape, it is understood that the FOD screen can take the form of other shapes that include, but are not limited to elliptical shapes. The shape of the FOD screen can depend on a variety of factors that include the shape of the ducts used in the combustion inlet air path, the location of FOD screen (e.g., against the wall of the silencer, abutting the bell mouth of the inlet of the gas turbine engine, etc.).

In one embodiment, the controller <NUM> can monitor the effectiveness of the anti-icing coating that is provided to the FOD screen <NUM>. For example, since ice on the FOD screen <NUM> can lead to a differential pressure across the FOD screen, a differential pressure measurement obtained from FOD screen <NUM> can be used as an indication of the presence of ice on the screen. In one embodiment, the system <NUM> can further include at least one differential pressure sensor operatively coupled to the FOD screen <NUM> to obtain a differential pressure measurement across the FOD screen. For example, <FIG> shows a differential pressure sensor P1 and a differential pressure sensor P2 located on opposing sides of the FOD screen <NUM> in the combustion inlet air path. In this manner, the controller <NUM> can obtain the differential pressure measurements from the differential pressure sensors P1 and P2. If the controller <NUM> determines that there is a differential pressure increase across the FOD screen <NUM> (i.e., a reduction in the air flow going through the turbine engine <NUM>), then the controller can correlate this to ice formation, assuming that the differential pressure increase is occurring in an environment in which icing conditions are present.

Other components in the combustion inlet air path between the air filter inlet house <NUM> and the inlet of the gas turbine engine <NUM> can have an anti-icing coating applied to a surface to prevent the formation of ice. These other components can include, but are not limited to, the silencer <NUM>, the inlet plenum/inlet volute <NUM> that supply the combustion inlet air to the inlet of the gas turbine engine, the inlet guide vanes that direct the combustion inlet air to the inlet of the gas turbine engine <NUM>, and the inlet struts that support the combustion inlet air duct <NUM>. Applying an anti-icing coating to one or more of these components can complement the anti-icing coating applied to the FOD screen <NUM>.

The configuration of the system <NUM> that is depicted in <FIG> that includes the array of hydrophobic pulse filters <NUM> along with at least one component (including the FOD screen) in the combustion inlet air path between the air filter inlet house <NUM> and the inlet of the gas turbine engine <NUM> that has a surface with an anti-icing coating, allows the various embodiments of the present invention to eliminate the possibility of ice accretion. This allows the gas turbine engine to operate continuously during icing conditions.

In addition, the configuration that is provided by system <NUM> obviates the need to utilize an anti-icing system to heat the intake air, thereby maximizing efficiency and cost effectiveness of the gas turbine system <NUM>. Nevertheless, for those gas turbine systems already implemented with an anti-icing system, the system <NUM> can be utilized to supplement the anti-icing features provided by those anti-icing systems by providing enhanced anti-icing in the combustion inlet air path. Alternatively, the system <NUM> can be used in place of those anti-icing systems already implemented in a gas turbine system. To this extent, the system <NUM> can be utilized to avoid parasitic loads that are associated with using these anti-icing systems.

In one embodiment, the anti-icing that is provided by the system <NUM> can be enhanced by configuring a heating unit about the combustion inlet air path that can have ice formation when icing conditions are present. For example, <FIG> shows a schematic representation of an optional heating unit <NUM> that can be operatively coupled to the air filter inlet house <NUM>. In one embodiment, the heating unit <NUM> can be placed after the coil section (not illustrated) and the array of hydrophobic pulse filters <NUM>. To this extent, the controller <NUM> can direct the heating unit <NUM> to apply heat to the air intake system <NUM> in response to determining the presence of icing conditions.

The above description of illustrated embodiments of the subject disclosure, including what is described in the Abstract, is not intended to be exhaustive or to limit the disclosed embodiments to the precise forms disclosed. While specific embodiments and examples are described herein for illustrative purposes, various modifications are possible that are considered within the scope of such embodiments and examples, as those skilled in the relevant art can recognize. For example, parts, components, steps and aspects from different embodiments may be combined or suitable for use in other embodiments even though not described in the disclosure or depicted in the figures. Therefore, since certain changes may be made in the above-described invention, without departing from the scope of the invention herein involved, it is intended that all of the subject matter of the above description shown in the accompanying drawings shall be interpreted merely as examples illustrating the inventive concept herein and shall not be construed as limiting the invention.

Claim 1:
A gas turbine system (<NUM>,<NUM>,<NUM>), comprising:
a gas turbine engine (<NUM>);
an air intake system (<NUM>) to intake air for supply to the gas turbine engine (<NUM>), the air intake system (<NUM>) comprising an air filter inlet house (<NUM>,<NUM>) to filter the intake air, wherein the air filter inlet house (<NUM>,<NUM>) includes at least one filter stage having an array of pulse filters (<NUM>), with each of the pulse filters being hydrophobic,
a combustion inlet air path in fluid communication with the air intake system (<NUM>) and the gas turbine engine (<NUM>), the combustion inlet air path receiving the filtered air from the air filter inlet house (<NUM>,<NUM>) and supplying the filtered air as combustion inlet air to an inlet of the gas turbine engine (<NUM>); and
a foreign object damage (FOD) screen (<NUM>,<NUM>) in the combustion inlet air path between the air filter inlet house (<NUM>,<NUM>) and the inlet of the gas turbine engine (<NUM>) to prevent debris from entering the inlet of the gas turbine engine (<NUM>), characterised in that
the FOD screen (<NUM>,<NUM>) includes one or more mesh screens (<NUM>) and an air sock placed over the one or more mesh screens (<NUM>), the one or more mesh screens (<NUM>) enclosed in a frame structure (<NUM>) having horizontally and vertically extending rails defining individual segments of sub-frame structures formed by intersections of the horizontally extending rails with the vertically extending rails, each individual segment of sub-frame structures enclosing portions of the one or more mesh screens (<NUM>), wherein a surface of each of the one or more mesh screens (<NUM>) in the individual segments of sub-frame structures and the air sock placed over the one or more screens comprises an anti-icing coating to prevent ice formation thereon, the anti-icing coating applied to each of the one or more mesh screens (<NUM>) in the individual segments of sub-frame structures and the air sock in locations where there is direct particle impact with particles flowing through the combustion inlet air path and locations without direct particle impact with the particles flowing through the combustion inlet air path.