Free Memorandum - District Court of Federal Claims - federal

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IN THE UNITED STATES COURT OF FEDERAL CLAIMS IVAN G. RICE, Plaintiff, v. THE UNITED STATES, Defendant. ) ) ) ) ) ) ) ) )

No. 05-187C Senior Judge James F. Merow

APPENDIX TO THE UNITED STATES' CLAIM CONSTRUCTION BRIEF

GREGORY G. KATSAS Acting Assistant Attorney General JOHN FARGO Director KEN B. BARRETT Attorney Commercial Litigation Branch Civil Division Department of Justice Washington, D.C. 20530 Phone: (202) 307-0343 Facsimile: (202) 307-0345 June 9, 2008 Attorneys for the United States

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TABLE OF CONTENTS FOR THE APPENDIX A. B. C. D. E. F. U.S. Patent No. B1 4,896,499 to Rice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA1 Amendment dated July 25, 1985 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA27 Amendment dated July 9, 1987 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA40 Office Action mailed April 11, 1989, with attached Notice of References Cited . . . DA53 Amendment and Response filed July 7, 1989 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA60 Amendment and Statement Under 37 C.F.R. § 1.510 and § 1.530 dated March 9, 1992 . . . . . . . . . . . . . . . . . . . . . . . . . DA72 U.S. Patent No. 3,273,340 to Hull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA86 U.S. Patent No. 3,486,340 to DuPont . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA91 A. W. Judge, Gas Turbines for Aircraft, Chapman & Hall Ltd., London, England, (1958), pp. 105-106 . . . . . . . . . . . . . . . . . DA94 T. L. Bowen and J. C. Ness, "Regenerated Marine Gas Turbines, Part I: Cycle Selection and Performance Estimation," ASME Paper No. 82-GT-306 (1982) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA97 E. R. Quandt, Jr., J. E. Baskerville and M. R. Donovan, "Future Propulsion Machinery Technology for Gas Turbine Powered Frigates, Destroyers, and Cruisers," ASNE Symposium-1982, (1982), pp. 321-59, 362-77 . . . . . . . . . . . . . . DA109

G. H. I.

J.

K.

-i-

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EXHIBIT A

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UnitedStates Patent [19]
Rice
[54] COMPRESSION INTERCOOLED TURRI~-E COMBINED CYCLE [76] Inventor: GAS

[11] Patent Number:4,896,499
[451 Date of Patent: Jan. 30, 1990
2,645,412 7/1953 Sere .................................. 60/39.161 2,722,802 11/1955 ........................... 60/39.161 2,748,566 6/1956 Fletcher 3,273,340 9/1966 3,289,402 12/1966 3,486,340 12/1969 4,314,442 2/1982 60/39.05 4,545,197 10/1985 .................................... Pdce FOREIGN PATENT DOCUiv[ENTS 60/39.182 60/39.182 60/39.182 60/39.182 975151 9/1961 7713915 8/1979 404958 10/1973 1004660 3/1983 Fed. Rep. of Germany ... Sweden ............................ U,S,S,IL ........................... U.S.S.R ............................

Ivan G. Rice, P.O. Box 233, Spring, Te~ 77383 Sep. 28, 1.988

[21] Appl. No.:. 251,076 [22] Filed:

Related US. Application Data [6~0] Cvndmmdoa Set. No. 818,472, J~n~ 12, i986, abrmof

OTHER PUBLICATIONS Gas Turbine World, Industrial Gas Turbine Handbook & Directory, 1976, pp. 52-53. Treager, L~vin E., Aircraft Gas Turbine Engine Technology, McGraw-Hial, 1970, p. 28. Judge, Arthur W., Gas Turbine for Aircraft, Chapman & Hall; Lofidon, 1958, pp. 105-106. Primary Examiner--Louis J. C.asa~egola [571 ABSTRACT A compression intercooled gm turbine and vapor bottumlng combined cycle system with the gas turbine operating at 30 to 65 atmospheres is disclosed. A twin spool hot gas generator incorporates eompressinn intercooling at the optimuta latercooler pressure ratio to (a) minimize intercooler heat rejection degradation, (b) raise the overall eycla pressure ratio, (e) increase gas generator core mass flow and (d) to increase the gas turbine power output. The gas turbine can operate in either the simple cycle or the reheat cycle modefor optimum combined cyela efficiency. A combined eydie efficiency upw&rds 60 percent can be realized. of 8 Claims, 7 Drawing Sheets

[51] Int~ .......................... Ci.4 F02C 3/19; F02C 7/143 [82] U,S, ............................... Ci 69/39.161; 60/39.182; 60/728 [58] Fteld of Sear~................ 60/39.161,39.182,728, 60/39.04, 727, 266, 267; 415/179 [56] U.S. Refereness Cited PATENT DOCLrMENTS 60/39.16l 2,625,012 1/1953 Larrecq ............................

20 54 .34

57 -LOAD

A C
46

..
66 64 70 69

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55 54

C

20

36-

42

24 30 28

36

42

Fig. 2

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30, 1990

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Fig. 5

190

Fig. 6 a

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UoS.Patent

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Patem J~n.

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0

0

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U.S.PatentJ~.30,
COMB. CYCLE EFF. NONINTERCOOLED

1990

Sheet 6 of 7

4,896,499

Fig. 9

F ig. 10

7O
40 CYCLE PRESS. RATIO 6O ¯ 60 CYCLE PRESS. RATIO

c

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pa/P~ '= 2 3 4 S
IC PRESSURE RATIO

Fig. 11

Fig. 12

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CC EFFIGIENGY~IANGE. , T~ = 100 OF

....

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4,896,499
COMPRESSION ~COOLED GAS TLrRBINE COMBINED CYCLE CROSS REF]~RENCETO P-ELATED 5 APPLICATIONS Tiffs appl~calion a continuation application Set, is of No. 818,472 filed Jan. 13, 1986,(abandoned), winchis continuation-in-part of U.S. application Set. No, 047,571, filed June ll, 1979, now U.S. Pat. No. l0 4,314,442. ¯ Thisapplication is also a contlnuation-in-partof U.S. application Scr. No. 224,496, fried Jan. 13, 1981(U.S. Pat. No.4,438,625),winch a division of U.S. applicais tion SenNo. 954,832,fried Oct. 26, 1978, now S. Pat. t5 U. No. 4,272,953. Thisapplication is also a continuation-in-partof U.S. application Set. No. 274,660, filed June 17, 1981, now U.S. Pat. No: 4,384,452, winchis a divisiou of U.S. application Set. No. 047,571, filed June 11, 1979, now20 U.S. Pat. No. 4,314,442. Tiffs applicationis also a eontinualion-in-partof the four U.S. applieatiou Ser. Nos. 416,171 (abandoned); 416,172(abandoned);416,173(U.S. Pat. No. 4,550,562) and 416,275(U.S. Pat. No. 4,507,914), filed Sept. 9, t982, with each of these beinga continuation-in-past of the heretofore abovestated U.S. Applieatiunsand U.S.

2

applied through proper modifications. The advantage of quick installation and removalof aeroderivative gas generators can be retai~ed. A pressure retaining casing m-rangnment around the ingh pressure portion of said gas generator, that is the ingh pressure compressor,the combusturand tlie turbine section, is provided to contain the higher thrm normal prnssumeof said gas generator. TheGELMS000 operates at a cycle pressure ratio of about 30 and the newengines to be derived from the Es program will operate at presanre ratios of about 38 atmospheres.The gas generator of this invention wouldoperate at prossumsof 35 to 65 atmospheres,but preferably at about 50. The pressure-retaining casing makes possible to it adapt light-weight aero-derlvative g~ generators with light-weight casings for the higher pressure levels of this invention ~ithout exceedingsafe blow-out casing The reheat-gas-turbine combined cycle is being seriously considered as a wayto obtain a higher combinedcycle efficiency than otherwise obtainable from the simpin-cyale gas turbine. The Japanese Government is well along in tesling its 122 MW compression-intercooledreheat gas turbine and field-test results wilt be madeavailable in mid-1984. The Japanesereheat-gas-turbine configuration incorporates compressionintereooling to accomplisha pro-

....... tact condensate spray water. The intercooling of my 4,545,197); 486,336 (U.S. Pat. No. 4,565,490) inventiontakes place at a much lower and specific pros486,495(U.S. Pat. No. 4,543,781)filed Apr. 19, 1983, sure with a~ optimum ratio range of about 2,0 to 2.5 and with each of these being a continuation-in-part of the uses condensateand cooling-tower, lake, river or sea heretofore above stated U.S. Applications and U.S. 35 water as the coolant in a primary closed loop and an Patents. open or closed secondary loop. Ammonia a mixture or BACKGROUNDTHE INVENTION OF of ammonia and water can also be used r~ the interThis invanllon relates to an open-cycle compression- eodier coolant wherea dry-type atmosphetle cooling intercooind gas generator operating at ingh eyale prossystemis employed. Direct-contact water-spraycooling sure ratios of 35 to 65 atmospheres. said g~ genera-40 can also be used. The Studies of the non-intercodied reheat-gas-tuthlne tot exhausts hot gas at ralatively high veloalty and combinedcycle show that such an mrtangement will pressure to a diffuser wherea majority of the veinalty efficiency for any pressure is convertedto static pressure. Theconverted producethe inghnst combined-cycle given gas generator a~d reheat-tumbine inlet temperagas then is reheated in a reheat combustor before being expmaded through a powerturbine to produce mechaui- 45 ture~. However,the noinntercooled gas generator is cai work, generally considered to be electrical power, limited to about 40 atmospheresprimarily due to the tfigh compressor discharge temperatures associated The air is intercooled at a particular and specific with the high compressorpressure~ Myinvention makes pressure to minimizethe overall combined cycle effiit possible to exceedthe 40 atmospheres provide a and elency degradation whensaid gas generator, diffuser, reheat combnstorand power turbine are operating in 50 lower compressor-discharge temperature needed for said gas generator combustor-Ii~er cooling and NOx conjunction with a heat recoveryboiler and a stormsor vapor turbine. The boiler camevaporate water, ammc- control. 3 Industrializing the E engine gas generators, considuia, freon or someother liquid or a mixturethereof to ered to be the third generation of a~rcraft engines, is form superheated vapor for expansion through a vapor turbine such as a steam turbine. A combined cycle is 55 inevitable based on past instory, and adapting themfor intercooling can be accomplished using the basic engine accordingly formed whereby the overall combined designs comingfrom the E3 program madapplying the cyale efficiency can range from 50 to 65%(LHV)deprocessprinciples and designfeatures of this invention. pendinguponthe gas generator and powerturbine inlet Adaptation the E3 enginesuch as the Pratt and Whitof temperatures and the bottoming steam or vapor cycle selected. ~ ney Aircraft 2037 and 4000 series engines as well as similar engines by Geaet-ui Einctrie and Roils Royce Anintegral single-bodied g~ generator with a coaxbeingreadied for aircraft service can be applied. ial shafilng arrangementfor driving the low pressure and ingh-pressure compressorsections with intercoolIn U.S. Pat. No.4,272,953applinant h~ disuiosed that secondgeneration, high-eyuiepressure ratio, high-fir. ing connections is madepossible wherebygas generagas tors such as the GELMS0~O, RB211, P&WA 65 ing temperature generators ccmbe used in the reheat RR JT9 and subsequent third-generation gas generators exgas turbine/steam tttthine combined cycle to yield increased efficiency and output heretofore unexpected pected to be devaloped from the NASA 3 (Energy E from reheat-gas-turblne combined cycles. A unval reEfficient Engine) aircraft gas turbine programcan be

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pressure and theprevention of distortion and blow-out heat gas turbine without intercooling combined with a steamturbine is further dischisedin applicant's pending by incorporating a special and unique cylindrical presapplication, U.S. Set. Ho.224,496 Filed Jan. 13, 1981.In sure chamber with thermal expansion joints around the th~s pending application the reheat gas turbine com- gas generator. Air is presently being used to cool the prises a juxtaposed and axially aligned gas generator 5 advancednero gas-turbine casings to control rotating and power turbine in which gas flow through the gas blade-tip clearance. This inventionuses steaminside the generator, reheat combustorand powerturbine is subpressure chambernot only to provide casing cooling stanfialiy linear throughout,but nothingis given on the but to also prov!decooling for the internal gas-generacompression intercooling in either dischisure. tor parts. Other U,S. patents and pendingapplications by the SUMMARY TH]~ IlffVENTION OF applicant, all pertaining to the reheat gas turbine and This invention contemplatesa process and apparatus steamcooling, but not specifically to compression intercooling are as follows: for generating a high-pressure, high-temperature to gas be reheated and expandedin a powerturbine whereby U.S. Pat. No. 4,314,442 15 useful mechanicalworkis produced. Additional power U.S. Pat, No. 4,384,452 is also producedby a steamor vapor turbine operating U.S. Set. No. 416,171 in a combined cycle mode using the heat from the gasU.S. Set. No. 416,172 turbine exhaust to generate the steamor vapor. U.S. Set. No, 416,173 The process comptlses the compression of air in a U.S. Set. No. 416,275 20 low-pressure compressorat a specified pressure ratio, U.S. Set. No. 486,334 intercooling said air by beat exchange direct contact or U.S. Ser. No. 486,336 and then compre~-sing said air to a higher than normal U.S. Sen No. 486,495, Imercoolinghas been used for manyyears with com- pressure whereafter said compressed is heated diair pression of air and other gaseous fluids to reduce the rectly by fuel and partially expanded a gas generator in powerrequired for compression. Also slmple-wchi and 25 arrangement.The gas.gnnexatorexit gas is further rereheat-cychi gas turbines have incorporated air heated by fuel and further expanded through a power prassinn intercooling to reduce compressionwork and turbine to produce mechanical work before being exconsequently increase the gas turbine output, pardou- hausted to a heat recovery boiler. Steamor vapor gento erated in said heat recovery bni~er drives a steam or larly for regenerativecycle gas turhines not involvinga combinedcycle. However,in such cases the emphasis 30 vapor turbine to produce secondary mechardcal work. has been on maximizingoutput and gas turbine effiAccordingly, is an object of this invention to proit ciency and not to optimize combined cycle efficiency. vide an intercooled gas generator of a higher than norAs will be shown,the compreesion intercooling in past mai cycle pressure ratio of 35 to 65 atmospheres, prefergas turbines tukes place at a much higher pressure ratio abty about50, with a coaxial shafting arrangement an as than the analytical discoveryof myinvention indicates 35 integral modularunit for easy instalindon and removal as being optimum combinedcycle efficiency. The with respect to the intercooler(s), gas-generator exit for Japanese Governmentis developing an intercooled diffuser, reheat combustor powerturbine. and reheat gas turbine for combined cycle service, but waA further object is to provide a gas generator with a preferred cycle pressure ratio of about 50 atmospheres ter-spray intercoollng is employedat a muchhigher intercooled compression rado than that of myinven- 40 for a gas-generatorf'ufng temperatureof up to 2600"F. tion. or even higher. A coaxial shafting arrangement is contemplated A further object of this invention is to provide an whereby initial (low pressure) compressor driven the is intercoohid gas generator with a much larger than norby a turbine by meansof a shaft Binning through the mal low-pressure compressor pitch-line diameter to high-pressure compressor, the high-prassurc turbine 45 allow adequate~pace for an exit elbowand radial difand the interconnectingshaft. Coaxialdrives are highly fuser and an associated low-pressure-dropreturn ductdevelopedfor high-bypassfan jets and indeed gas gening to the high-pressure compressor said gas-generaof tor module. erators such as General Electdc's LMS000, General Still another object of the invention is to provide a Motors 570Kand Rolis-Royce's RB-211.However, no intercoolingis used or evenremotely suggested.It is the 50 wlindrical-pressure container arrangementaround the increase in the low-pressure compressordiameter made high-pressure section of the gas-generator moduleto possible by the intercooling that permitsadequatephysalhiw steampressure and/or bleed air pressure to presical space for the air to be exited and readmittedeffisurlze the outer g~-generator casing thus allowing ciently with a minimum pressure loss. of light-weight aero-derivatlve type gas generators to be Further, when such type generators as the LMS0~0 adapted for muchhigher than normal pressure ratigs 55 or 570K future thi~d-generatinn aeroderivatives are or without dangerof presanre rupture or casing distortion. modilSedfor intercoollng, the high-pressure sections Thermalexpansion joints are provided in the pressure (high-pressure compressorhousing, combustorhousing container to compensate differential thermal expanfor and high-pressure turbine housing) are subjected to sion. muchhigher internal pressures. The cycle pressure 60 A further object of the invention is to provide an ratios will increasefrom18, 30 or 38, ~s the case may be, annular plenum aroundthe high-pressure section of said to some to 65 due to the supercharger. In order for 35 gas-generator module wherebycooling steam can be such gas generators to be adapted for compressioninadmittedto the intetior ofsald gas generatorto cool the tercooling madthe higher cycle pressure ratios suitable stationary parts and nozzle vanesand rotating disks and for the reheat gas turbine and the combined cycle some-65 blades wherebymultiple separate inlet headers:and thing has to be done about the added pressure to preconnectorsare eliminated. vent casing rupture and/or distortion due to the higher Still another object of this inventionis to provide a internal pressure. This invention deals with the added process for intercoollng the air at the proper pressure

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FIG. 10 is a graph showingthe relationship of comratio to opth~ze comblned-cycleefficiency and minipressor temperaturesto cycle-pressureratio. mire comblned-cycleel~clency degradation, Heat changeor direct-contact waterspraycooling is contemFIG, 11 is a graph showingincremental cycle efficiency versus intercooinr pressure ratio for a 40 cycle plated. A further object the of invention provide isto a low- pressureratio condition. 5 pressure-compressor c~scade-airfofi andan diffuser FIG. 12 is a graph showingincremente3cycle effiassociated process recover to additional pres- einncyversus intercooinr pressure ratio for a 60 eynle dyna~c sure othatavlse lost to the cycle. Anincrcmentaily pressure rado condition. higher combined-cycle efficiency is obtained. FIG. 13 is a graph showing incremental work saved Anotherfurther object of the invention is to provide by intereooling ~s a functionof cycle pressure ratio for gas-generator outer-casing cooling to control thermal 40 and 60 cycle pressure ratio conditions, growthof the casing and to control rotating blade-tip FIG. 14, is a graph showingpercent change in comclearance. binedcycle efficiency as a functionof intercooler presAlso contemplated the within scope the of invention sure ratio for 40 and60 oyele.gressureratio conditions. isa combined intercodied gas reheat turbine steam and 15 FIG. lg is a graph showinggas generator combustor orvapor rarbine for oycle production ofuseful power inlet temperaOarerise and compressordischarge temwherein superheated or vapor produced steam is by perature as a funetlon of intercodier pressure rado for ° heat exchangein either the powertuthineexhaust-duct 40 and 60 cycle.pressure ratio conditions and 2600 F. section or the reheat combastor wherein sand super., ¯ heated steam or vapor drives a steam or vapor power 20 gas maet temperature. DESCRIPTION OF ~ PREFERRED turbine for production of additional useful powerto EMBODIMENTS that of the power produced by the reheat gas power turbine. The steam or vapor can optionally be exIn FIG. 1 a schematicdiagramof the intercooled gas tracted, reheated and readmitted to the steam or vapor ~,eneratur of the nresent invention shows~as ~en~rator turbine and normeily condensedfor higher cycle era- ~5 30which receiv~ Mrthrough inlet line ~2 p~odueing ciency and increased incremental poweroutput, which compressedair by low-pressure compressor24 whichis will become subsequentlyapparent reside in the details driven through A shaft 26 by Iow-prassure gas-generaof construction and operation as morefully hereinafter ter turbine 28 xvhinhis powered heated gas produced by described and nlaimed, reference being had to the achi first combustur30 from air enteting combustor30 companying drawings forming a part hereof, wherein 30 through line 32 and fuel entering combustor through 30 like numerals refer to llke parts throughout. fuel llne 34-. Low-pressure is discharged Mr throughline 36 and is cooledby series intercoolers 38 and 40 before BRTEF DESCRIPTION OF ~ DRAWINGS being discharged through line 42 to the high-pressure FIG-. 1 is a schematicview of ¯ compressionintercompressor44. The air is further compressed highby cooled gas generator exhamting through a diffuser to a 35 pressure compressor driven by high-pressure turbine 44 reheat combustur.and then to a powerturbine to drive 46 throughB shaft 48. High.pressureturbine 46 is powa mechanical or electrietd load with exhaust gasses ered by said heated gas producedin the first combustor being ducted to a heat recovery meems forming.a for 30. Reheat or second combastor SOreceives exhaust combinedcycleFIG. 2 is a top plan view, partially in diagramatic 40 from gas-generator turbine 28 through reheat diffuser 52 and fuel throughline 54 maddischarges reheated gas section, of the intereooted gas generator of the present through line 56 to powerturbine 58 whichdrives load invention illustrating the intercooling exit and re60, preferablyan electxie generator, directly by Cshaft entrance arrangement. 62. Thegas exits powerturbine 58 through line 63 to a FIG.3 is an enlargedtop plan viewin partial section 45 heat-recovery boiler wheresteam or a vapor such as of FIG'. 2 showing moredetails. is FIG. 4 is a top plan viewin partial section showing freon or a mixture of water and ammohia producedto drive a secondsteamor vapor turbine, formingwhat is increase in the low-pressure compressorpitehdine racommouly referred to hi the industry as a combined dirts resulting fromintercooling. cycle. Refer to FIG. 1. FIG. S is an enlarged plan view in section of FIO.2 shoxving pressure-easing expansion joint and cooling 50 Power turbine 58 discharges hot exhaust gasses throughline 63 to heat recoverymeans and exits said 49 arrangement. gas through line 71. Steamor vapor generated in heat FIG. 6a is a perspective view of the gas generator high-pressura seetlon showinginwzpressure compres- recovery means 49 is expanded through turbine 55 steam or vapor is consor on theleft and diffuser, reheat combustor power whichdrives load 57. Expanded mad turbine on the right. 55 densed in condenser means61. OptinnMly,condensate is pumped through intercodier meanssection 38 to cool FIG.6b is a perspective view with partial section of compressed entering said intcrcooler means air through compression-intereooled reheat ga3 turbine incorporatline 36. Heated condensate returns to heat recovery ing an industrial low.pressure compressorin the gas means throughllne 69. Lines 73 and 7g feed steamto gas generator. FIG. 7a is a pan quarter top seedonal view showing60 generator 21} madpowerturbine 58. Low-pressure compressor 24 discharge air can be an Mrfoil diffuser andtoroidai-shapedoutlet duet. cooled t'u'st by combined-cycle steamor vapor condenFIG. 7b is an enlargedsectional view of the diffuser sate in a counterflowdirection with the coolant entercascedeairfoils of FIG.70. ing intercooler 58 through llne 64 and diseharglng FIG.8 is a front quarter top sectional viewof FIG.7a 65 throughline 66. Theair eatl be further cooledby coolviewed direction of axial ant flow. in ing-tower, lake, river or sea water or a coolant from a FIG. 9 is a graph of comblned-eycle efficiency as a functionof cycle-preasure ratio, fu'in g temperatures and dry-codling system with the coolant counterflowing and entering secondseries intercooler 40 through line steamconditions.

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six stages according to the particular design and manu68 and discharging through llne 70. Direct-contact wafacturer. ter-spray coolingcan also be applied. Low-pressure compressor 24, discharges a:dally at It is to be particularly notedthat the component parts of coaxial-shaft gas generator 28 shownin FIG. I are about Math0.3 Mrvelocity correspondingto about 400 conventional and ouly the particular physical modular5 to 450 ft/sec at the flowingtemperature. Said Mrflows arrangementand methodof getting the puslially com- into elbow 100 wherethe airflow direction is changed fromthat of axial to radial. TheMrflow at this point is pressed air out of and backinto said CO~Lxiui shaftedmodula~ gas-generator compressor24 and 44 at a spethen diffi~ed by fiat or parallel wall vaneless diffuser cilie low-pressure range and the physical arrangement 102 before beingdischargedto a scroll collector 35 and ~.ud methodof controlling blow-out pressure and the 10 then to duct 36. Thegas velocity exiting diffuser 102 is introduction of coopt to said modular gas-ganerator at about Mach0.14 corresponding to about 200 ft/sec according to the base temperature invoIved. About65 internal and external parts as well as the interrelated to 70 percent of the velocity pressure headis recovered process involved with the combinedcycle leading to advantages and efflulencies disclosed in the present by diffuser 102 and the remainder dissipated and lost is 15 to the cycle. Thecooled air caters the high-pressure invention are intended to be described as new. Fuel for combustota and gOcan be liquid such as :30 compressor44 through a separate duct 42 by meansof petroleumdistillates, crude oil, Bunker"C" or petroa special "S" shapedinlet duct 104 detachablyattached lanmliquid products such as methanol,orsaid fuul can to compressor outer casing 78, inner housing 79 and elbow100. Struts 77 joins together forwardand aft sides be gaseous such as natural gas or gas produced from coal (low, medium high BTL0 said fuel cembe 20 of inlet duct 104. The cooledak counterflowsin direcor and burnedin conjunctionwith an integrated coal gasification to that of the hot dischargeMrflowinginside diffuser 102. Diffuser 102 and elbow100 fit adjacent and tion combined turblne/steam turbine powerplant. gas close to the outer wall 108 of inlet duct 104 and are FIGS.2 and 3 are overaLlrepresentations of the typica1 modulargas generator 20 showinginlet line 22, 25 removablysecured together. Generouscruss-sectinnal low-pressurecompressor and associated outer casing 24 area of the inlet duct 104is provided keepthe inlet air to 72, variable stator blades74, variable.stator-bladelinkvelocity low at a value of approximately to 75 ft/sec 50 age mechanism discharge duct gg, return duct 42, 76, to reduceinlet pressureloss. nigh-pressure compressor44, associated outer casing The added low-pressure compressor 24 pitch-Line 78, combustor high-pressure turbine 46, low-gres- 30 radius, r, FIG. 2, madepossible by the cooler and more 30, sure turbine 28, coaxial shafting 26 and48 andexit gl to. dense air to the nigh-pressure compressor44 provides diffuser 52. the neededradiul space and therefore makesit possible There can be two discharge ducts 36, one on each to exit the low-pressurecompressor hot air, diffuse 24 side of gas generator 20 and two return ducts 42, one on the hot air and return the cooledair to the nigh pressure each side of gas generator 20 to feed two mirror-image compressor44 efficiently and with low-pressure loss 35 twin intereoulers 38 and 40 located on each side of gas and at the sarae time retain the coaxial shafting and generator 20. Thedual ducting and intercodier arrange. unitized znigle-unit modular construction of gas generator 20. It is obvious if the pitch-line radius, r, of the that meat makesit possible to manage flow of the lowthe density nigh-volume to and from the intereooler(s) air low-pressure compressor 24 were the same or very moreefficiently with a lower overall pressure loss. as 40 nearly the same the plich-line radius of the high-presReferring to FIG. 3, an enlargedpartial viewof FIG. sure compressor there wouldnot be adequate radial 44, 2, the low-gressurecompressor24 is supported by forspace without the shafting 26 to the low-pressure comwardantifriction steel ball bearing 80 and is cantilevpressor being lengthened considerably makingit imered or overhung. Said compressor rotor dn~m 114 is practical froma structural standpoint to adapt an aeromountedto shaft 26 by flange 82. The high-pressure 45 derivitating gas generator to a unitized single module compressor is supportedby duplex antifrietintx bea44 and structural design x, Ath the given bearing arrangering(s) 84 for coaxial shafts :26 and 48. Thehigh-presmeat provided. sure turbine 46 and iow-prassure turbine 28 are supReference is made to FIG. 4 which shows the Iow ported by rear duplex anfifriction bearlng(s) 86. The pressure compressor of this invention with radius r_~ 24 low-pressure shaft 26 and compressor 24, components50 superimposedover the low-pressure compressor or a foragasgeneratorwithanairflowofg001b/sec, would normal gas generator with radius rl. Also note the typically rotate at about 3600RPM the nigh-presand smaller pltch-Lineradius, rg, of the nigh-pressurecornsure shaft 48 and compressor44 wouldtypically rotate pressor 44. As previously mentioned,the greater lowat about 8500 RPM. Note that hydrodynamlc-type bearpressure compressor24 radius is madepossible by the ings (usually babbit) can be applied for nidustriai-type 55 changein density of the air when is interconied. The it construction, forward-bearing arrangementis basically the samefor FIG.;3 is an enlargedviewof FIG.2 representativeof both cases and the stationary stnletural support to the the typical nigh-cycle pressure-ratio intercooled gas bearing needs only minor changes to accomodatethe generator 20 of the present invention including lowinlet "S" shapedduet 104 whereinthe duct 104 becomes pressure compressor24, nigh-prassure compressor44, 60 part of the stationary structural part of said modular gas low-pressureturbine 28, nigh-pressureturbine 46, coaxgenerator 20. The low-pressure compressor support iai shafting A and B (26 and 48), outlet ducting 36, funnel-shaped rotating members and 112 likewise 110 return inlet ductlng42 andexit 51 to diffuser 52. Gas- change ouiy slightly in shape to accomodata inlet the generator low-pressure compressor 24 is madeup of duct 104 and low-pressure-compressorrotor drum114. stages 88, 90, 92, 94, 96, 98 of a six-stage axial-flow 65 Note that the low-pressure compressor drum 114 is compressor.There can be fewer stages or more stages mounted shaft 26 similar to howa dual truck tire and to as required to producethe desired pressure ratio, and rim are cantilevered and bolted to an axle shaft which for a typical pressureratio of 2.5 there would four to be protrudes beyondthe wheel-axinbearing.

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The thermodynamicexplanation of the incre~e in The"core" portion can also havetwo spools such as the tedium,r, will be discussedas follows: Thehigh.pressure Rolls-Royce ILB-211wllh two compressors, turbines compressor rum, ring at a constant RPM rminlet 44 has and shafts to formthe high-pressuresection and thus the voinmc flow that remains practically constant, i~ not "core". The LMS~00 "core" (one-spodi design) has constant, for varying conditions of inlet pressure and 5 18 compression ratio and the new Es "core" engine temperature, that is changes its inlet density. Thea'tr in (also a one-spool design) has a compressionratio that is compressed the low-pressurecompressor is by 24 about 23, giving examples. The low-pressure comprescooledbeforeit is admitted the inlet of the high-pres- ¯ sor 24 of this invention wouldhavea compression to ratio sure compressor44 and as a result the density is in. of 1.8 to 3.2 to produce fi0 total pressure ratio, this a creased according to Boyles Law given as follows: to total ratio consideredpreferable for this invention although totul ratio as low as 35 or as high as 65 ~ also a pV=WKT (1) be considered and accomplished by varying the compresslon ratio of the low pressure compressor24, the whereP is the absolute pressure, V is the volume,Wis total ratio be'rag the product of the high and low presthe weight flow, R is the gas constant madT is the sure ratios. It should he noted that the low-pressure absolute temperature. compressor2A. ned associated low-pressure turbine 28 A~ an example, if the inw-pressure eompre~or24 a~e not extremely high.teehnulogy, high-temperatttre discharge air is cooled from300*F. to 80* F. then the eh~uge density, aeeordhigto formula(1) wouldbe in parts, and these parts can be readily modifiedby adding percent. The low-pressure eompresanr7A.-wouldhave stages and diameter to obtain the required pressure to compress percent greater massof air to satisfy the 20 ratio. 41 high-pressure compressor44 inlet volume. Considering The mass-flowincrease to the "core" portion of the gas-generator moduleis significant because the highthe pitch-lhie radius, rl, of a normallow-pressurecom- technology"c~re" portion wouldbe a key part of a new pressor wouldincrease by about 19 percent to r2 (square gas generator 20 system developingsignificantly more root of 1.41) See FIG-. 4. Dynamic similarity principles 25 poweroutput in terms of discharge pressure and mass apply. flow to the reheat combustor powerturbine 58, this and There is another significant difference whinhcr~u powerbeing in all prantieul purposes direcdy proportional to the increase in "core" mnssflow.Therewould dins, r, evenfurther. Asanotherexample,in the c~se of also be an additional increase in gas generator power the GELMS000 generator converted to intercool- 30 gas output because of the powersaved by the intercooled ing, the front inw-pressure compressorwouldnormally compression process whichwill be discussed later. have a 1.667 pressure ratio and a 152" F. discharge The partially compressedand cooled air enters the temperature to the high-pressure compressor44 for a hlgh-pressure compressor44 by wayof inlet duct 104 44 has an 18 pressure ratio and discharges at 30 atmo- 35 and is further compressed by ~xJul-flow compressor spheresfor a 30 total ratio. If the inw-pressure compres- stages 116, 118, 120 and subsequentstages of a typlc~ sor is modifiedto discharge at 2.5 atmospheres form eleven-stage compressor to a high-pressure compresto sion ratio of 12 to 24 as the case may andas requited. be low-pressurecompressor instead of its normal1.667, 2~. Additional high-pressure compressor stages can be then the discharge temperature wouldbe about 236* F. for a 59* F. ambientinint. The inlet massflow to the 40 added as required. The high-pressure compressor 44 can be equipped with variable statur blades 122 and "core" of high-pressure compressor44 wouldbe 1.59 times as great if the compressed is codiedto I00" F., sk mechanism to provide operating flexibility. 124 considering a 3 percent pressure drop in the cooling The high-pressure compressed flows through gasair process. The pitch-llne radius, r2, FIG. 4, would generator combustur and ls heated by fuel from fuel 30 45 lines 34 before being expandedthrough the high-prescrease by about 1.26 times. It is of particular interest to note that the changein sure turbine 46 and lo~v-pressure turbine 28. FIG. 3 radius ofrl to r2 Withrespect to high-pressurecompres- showstypically one turbine stage for the high-pressure sor radius 44, rs, will be about75 percent;that is consid- nozzle vanes 126, rotating blades 128 anddisk 130 but it ering r l to be unity in length, r2 would appro~rnataly should be noted that two or morestages can be applied. be 2 units in length andrs would approximately a units 50 Similarly, one turbine stage of low-pressure nozzle be 2~ in length or ~ ofa un/t longer than the one unit length vanes132, rotating blades 1;34and disk 136 are typically of r3 as can be seen in FIG-. 4. Theadded length of shownand two or morestages can be utilized. Thehot radiusr2 is critical in making possibleandpractin~d it to gas exits by duct 51 to the diffuser 52 (showrt in FIG. re~aln one single moduleof gas generator 20 and to ~a). provide the outer elbow11}0, diffuser 102 and the re- 55 ram"S'" shapedinlet duct 104 all with the shafting 26 PtLESSURE CONTAINING- CASING and 48 and forward bearing 80 arrangement coul'meARRANGEMENT meatsof the aero-derlvative design. Theradial length of the low-pressure compressor24 radius r2 can, however, Referenceis again madeto FIG. 4 and the enlarged range from 2.2 to 3.0 times that of the high-pressure 60 gas-generator portion given in FIG. 5 showingthe high-pressurecasing arrangement this invention. The of compressor radius rs to provide roomfor said inlet 44 gas generator czsing 142 retains the compressordisand exit ducting, charge pressure in cavity 144 whichsurrounds annular The"core" gas-turbine portion of the gas-generatur combustor liner 146. A second casing 148 surrounds module,that is the integral assemblyconsisting of the high-pressure compressor44, the eombustor30, shaft 65 gas-generator casing 142 whereina dual manularcavity 150 and 151 is formed. Cooling steam ifils cavity 48, the high-pressureturbine 4~i and associated casing 150/151 will be subsequently as explained. Athfi'd outer can have a pressure ratio of 12 to 24 according to its easing 152 surrounds casing 148 to form dual annular design with the preferred ratio range being 18 to 24.

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possible rapture without the strong outer casing rangement. Reference is again madeto FIGS. 3 and 6a showing the compressor bleed air line 188 whichpressurizes dual cavities 153 and 154. The air pressure w~ibe somewhat higher than half that of the compressor discharge. Asan example, for a 50 atmospheredischarge pressure, the correct compressor stage is selected to provide about a 30 atmospheric pressure to surcound casing 148 and pressurize outer casing 152 through cavities 153 and 154. Theouter casing 152 thus is subjectedto a substantialiy lower pressure tlum the compressor discharge pressure. Innercasing 148is subjectedto the differential pressure of 50 minus30 or about 20 atmospheres.Steam chamber1~50is selected to be slightly more than 50 atmospheres the 50 cycle pressure ratio, as will be for discussed. Theair pressure in cavities 153 and 154 has no outlet and flow is normally zero with the deadeed situation. Flow o~ly occurs during startup, load changes or shutdownto charge or discharge cavities 153 and 154. Cooling steam enters cavity 150 by meansof flange connection190 to ring distribution header 192 then to cortueet to flexible tubing pipes 194. Thesteamis produced by a heat recovery boiler and/or is extracted froma steamturbine at a pressure substantially equal to the compressordischarge pressure or preferably at a pressure 30 to 50 psi greater. The steamsurrounds gas generator casing 142 and thus neutralizes the internaIannular-discharge pressure. In fact, the gas generaair tor cas~ng 142 can be placed in a slight condition of compression the 30 to 50 psi added pressure. by The steam is preferably dry and saturated for maximum cooling capacity with maximum specific heat and the lowest temperature. However,the steam can have 10" to 30* F. superheat to insure dryness as no water particles should be present at entrance through pipes 194. The steam cools the gas generator casing 142 as required. Baffles not showncan be applied to control the flow around the casing 142 if required to control casing 142 cooling. Againreferring to FIG-. 5, cooling steam in cavity 1SOflows to inner casing 142 by meansof open tubing 196. Coolingsteam enters open tubing 198 to cool the first-stage turbine disk 130 and blades 125. Cooling steam enters nozzle vane opening2{}0, one or two for each vane, to cool each t'rrst-stage nozzle vane 126. Coolingsteam enters openhag202 to control the cooling of gas generator casing rear section. Thus, cavity 150 serves as an armular plenum cooling steamdistribuor tion chamber.Hot steam can be taken out of turbine 20 by outlets 204, 206 and 208 for admissionback to the steamturbine, but the exit eonnecilons external heador ers for these tubes are not shown.Alternately, this hot steam can be piped by tubing not shownto rear steam cavity 151 downstream orifice 218. Cooling steam of not used for internal gas-generator cooling is discharged at a higher temperature through tubing 210 to ring header 212 and through flange 214. Dam with orifice or orifices 218, in numberas 216 needed, control downstream steam pressure as required to lower the downstreampressure and control total steam flow to header 212. Control of steampressure and flow to cavity 150/151 during startup and shutdown gas generator 20 can be of by meansof computercontrol of a pressure regulating valve not shownthat feeds steamto flange 190 and ring header 192. Such control prevents over-pressurizing

cavities 153 and 1S4whereinbleed air from the axial compressor deedended,as wlfi be discussed. is A curved fo~rd casing 156 attaches to the gas generator easing clreumferentially at gas-generator compressor flange 158 (See FIG. 3) forming a leak. proofjdint to preventsteamleakage. Inner casing 148 is thin-walled flexible to allowfor differential thermal and and pressure expansion.Insulation 160 covers the entire outer surface. Fuel is fed to combustor by fuel line 30

enough side wall 16~i to allowfor some flexibility. For-

rear cavity 154.

rear, Assembly disassemblyof the outer casing 152 and Lockingpins 1"/8 whichare free to float secure and

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12, 3 of w~eh be seen in FIG.8. Side walls 2~6and can inner cavity 150/151and endangeringblowoutof inner 2~8 can have an included divergent angle of zero to 30 easing 148 undertransient conditions. degrees, but preferably no morethan 20 degrees, that is Reference is madeto FIG. 6b showinga perspective view with partial section of an intercodied reheat gas I0" on each side wall 2]6 and 238. Inner wall 2.32 and turbine incorporatinga separate and independent induzouter wall 2,34 each curve outwardly like the outlet of a horn. Theratio of the rectangularcross-sectionalarea at trlal-type low-pressure compressor24" coupled to the high-preasure compressor 44 by coupling 220 and exthe radial entrance 240 to that of the exit 242 can be hausting to intercoolers 38 and 40. G~generator 20 typically about4 to effect a velocity changeof 4. Typiextmuststhrough diffuser 52 to reheat eomb~tor and 50 cally the discharge vehielty at exit 240 will be about expands heated ga~ by power turbine 58 which drives 10 Maeh whichtranslates to about 400 ft/sec for the 0.3 load 60 by C shaft 62 being connectedthereto by couflowing temperature involved. The exit 242 velocity pling flange 59. The powerturbine hot gas exhaust~ would be about 100 R/see (Much0.075). through exhaust hood 222 to a heat recovery boiler. Separation and thus channeling of the air causing Referto FIG.1. Diffuser 52 is connected gas genera- eddy currents and valoalty-prassure-headdissipation is to mr 20 by mew~s expansionjoint 49 and is connected15 prevented by a series of two or morestages of cascade of to reheat combustur by meansof flange 53. Diffuser Sg airfoils. Three stages are shownin FIG. 76. Thefirst 52 can be a separate ~ssembly which can be removed stage has airfoils 246, the secondstage has airfoils 248 independentlyof gas generator 20 or reheat combustur and the third stage has airfoils 2~0, 50 and powerturbine 58 assembly. Theairfoils are held in precise positionbyradial-duct present-day aero-derlvative gas generators such ~s 20 sidewalls 7~6and 238. Welding be used. Eachironer can the GELMS00, 570K, R-R RB211 drive through GM duct is supportedby struts 252. Theairfoils 246, 248and the cold end, that is havean inner coaxialshaft extend- 250are precisely shaped accordingto specific specificaing through the gas generator with a coupling flange tions provided by NASA the ~ to produce the or connectionprotruding out the center of the high-preslowest drag and best lift (and thus diffusion) for the sure air compressor 44. Someheavy-duty non-aero 25 associated velocitias. Thesurfaces of the airfoils are industrial gas turbines likewise drive out the edid (com- very smooth similar to stator vanes of an axial-flow pressor) end. It is therefore po~slbleto drive a separate compressorto reduce frletinn and loss. Referring to low.pressure compressorof this invention by such FIG. 7b, the airfoils ~re .positioned to have a precise . . generators. This physical arrangement,per so, is not specified low-ratio compressorof a low-pressureratio drag (pressureloss). Theairfoils diffuse the hot air as it of 1.8 to 3.2 for intercoolJngand specifically for a com- flows from the maximum width point B and then to the bined cycle for optimum combined.cycle efficiency, trailing edge point C. Eachstage of cascadeairfoils is For instance, the Japanese Government reheat gas tt~cbine AGT-J-100A intercodis at a 4.85 low-pressure 35 staggered so that the wakeof the upstream airfoils will ratio. Also, supercharging large forced draft fans to -not interfere with the downstream by airfoil. Thehot air is diffused efficiently withoutseparation 50 inches of water and cooling by humidification has arrangement. flow been used but not at the specified low-pressure com- by the cascade airfoilcontrolled so it The airfan outand direction thereof is will or prezsor ratio of this invention. Secondly,the pressurizing container required for aero-durlvative light-walght 40 spread apart Thedirection of flow of the air at the inner surface 134 is mostlytangential to the inner surface and casings is liknv~e quite unique. No such process or the flow at the center pitch line is tangential to the ~tangement has ever been proposed or contemplated center pitch line and the outer surface flow is tangential before, to this inventor's knowledge. with the outer surface .~4. Thedirection of the flow CASCADEAII~FOIL DIFFUSER 45 with respect to the radial position can be curved backReference is nowmadeto FIGS.7a, 75, and 8 show- wardsto give space for flange 258, expansionjoint 260 and transition 262. The curvature can also be slightly ing a unique low-pressurecompressor-diffuserarrangeforward with less curvature of elbow100 and with the mentof a cascade-airfdil eonftguration,which part of is inlet 280 being moved farther backward increase the to this invention, to convert a greater amount velocity of head to statin pressure than made possible by the appa- 50 curvature of the "S" shape of the inlet 280. Thegas, after leaving the cascade airfoil diffuser ratus of FIGS.3 and 6a. As stated, the straight wall section, passes through an expansion joint 160 which vanaless diffuser of FIGS.3 and 6b can only recover about65 to 70 percent of the valoeity head. Thecascade ha~ internal flow shielding not shownto form smooth a~-rfoil diffuser of this inventioncan increase this con- hiternal surfaces. Flanges ~ and 266 connect the exversion fromthe 65 to 70 percent level to approximately pansinn joint 260 to the ducting. The ak then p~sass 55 through the transition piece 262 which changes the 85 to 90 percent. Theprocess and associated apparatus rectangular duct cross-seetinn to a roundcross-sectlon wig now be explained. Convenient gas genemtur 20 at roundflange connection268. Theair is diffused furduct connectionscan also be provided, as will be exther in the processand the exit velocity at flange 265is pluined, to imu, ll and remove said gas generator. Air is discharged from the low-pressure compressor60 nowabout 50 to 75 ft/ase, or the desired velocity for low pressure loss flow for the piping and ducting ;36 to 24 through elbowllJ0. Oneor more turning vanes 274 are attached to elbowwall 226 by radial struts 228. The the intercooler~38 and 40 and the return ductlng to the high-pressure compressor ~4. The air, after leaving turning vanes 224 prevent flow d~sturtlon and separatransition piece 262, enters a toroidal-shapedring*type tion. Theradial dischargeof the elbow100 enters typitally ~2. sections of easential rectangularcross-sectional65 duct 270 with two outlet connections2"/2, one on each side of ring duct 270. Theair flow is aided by internal ducts 230 each bounded inner wall 2;32, outer wall by turning vanes 274. Flanges276 are connectedto line ;36 234 and side walls 2~6and 258. Therecan be fewer or whichduets the air to interandiers 38 and 40. more than 12 sections of duct 7.30 but typinally there are

13

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The cooled air is returned to gas generator 211 by THERMODYNAMIC ANALYSIS return air line 42 whinh connected said gas generais to The thermodynarule analysis of the heat-rate advantor by range connection 278 one on each side of said gas generator 20. The"S" walled inlet ducts 280 which tage of this invention will nowbe presented pinpointing are on each side of said gas generator 20 have a gener- 5 the best intereooling low-pressure-compressor pressure.ratio range for optimum combined-cycin efficiency ous cross-sectional area to provide a low velocity htlet and the specific intercooling pressure for optimum comof 50 to 75 R/see or as required for low-pressureloss. bined-cyule efficiency of this invention. Increased Guidevanes 282 held by struts 204 guide the air to the poweroutput derived by intercooling wtil be set forth. hlgh-pressure compressor as can be seen in FIG. 70. 44 I0 The general reheat-gas-turbine cycle arrangement is The exit flange 276 and the inlet flange 278 can be given in the schematic diagramof FIG. 1. Air is comreadily discomaectedto allow gas generator 20 to be pressed in a low-pressurecompressor whichis driven 24 installed and removedfor overhaul. Toroldal-shaped coaxially by turbine 28. Said air is diffused and then ring duet 270 need not be removed.Transition pieces ductedto intercoulers 38 and 40 wheresaid air is cooled 262 and a section of return duct wadassociated expan- 15 before being dueted back to be further compressedby sins joint not shown that connectsline 42 to inlet flange high-pressure compressor 44 driven by turbine 46. 278 can be removedto allow ulearanee. FIG. 8 shows High-pressureair at 40 to 60 atmospheres heated in is the transition duets 262 as having been removed. first combustion chamber30, is then expandedthzough Thestraight-wall vaneless diffuser of FIGS.3 and 6b turbines 46 and 28, is subsequently fully diffused by will only providean effective area ratio change about 20 diffuser 52 and then reheated in second combustion of 2 without flow separation and the exit velocity will be chamber at a total pressure of 4 to 9 atmospheres, S0 about 200 R/see resulting in a maximum some 70 of depending on the cynic-pressure ratio and amountof percent velocity pressure recovery when consldedng steam.coollng/injeetlon and is finally expandedto atmospherepressure through power turbine 58 to drive the velocity headvaries as the square of the velocity. Also the outlet and inlet ducts for the eonfiguratlon 25 load 60. Thehot exhaustgases generate steamin a boiler for a conventional 2400psig reheat-steam turbine not shown FIG-. 3 extendradially outwardwhichnecessiin shown. The reheated hates a longer radial distance making moreclumsy it to Theintercoolers can be madein two sections 38 and disconnectthe gas generator20 from outlet lines 36 and 40 with condensatebeing used to cool the high end and inhit lines 42. Thedesign andassembly the gas generof ator 20 becomesmorecomplleated and disassemblyfor 30 cooling water used to cool the low end as shownin FIG. 1. The following expected and typical pressure overhauls wouldlikewise be more dlffieult. There are losses are assumed the intercooler. Theselosses are for these additional advantagesfavoring the apparatus expressed as percentages of the compressorintercooler rangementshownin FIG-. 7a, 7b and 8. total pressure: The gas generator 20 of this invention consists of 35 individual modular sections whichare assembledone to another to form a complete assembly which is essentially cylindrical in shape. Thelow-pressurecompressor 24 with discharge duct 36 or 230 modulefits to the high.pressure compressor and return inlet duct 42 or 44 280 module~. The high-pressure secdon 44/42 or 280 fits to the comb~tor secdon30. The combustor section Incrementalpa*asitlc heat and mechanical losses that 30 fits to the high-pressure turbine 44 assemblywhinh must be assigned to the incremenhal additional work then fits to the low-pressureturbine assembly28. The saved by the intercooling process are also associated shafting andbearingparts 26, 48, 80, 84 and 86 andtheh" 45 with the intercouler. These losses are assumedto be associated sub-parts are assembledwith the aforemen- constant at five percent of the gross incremental work tioned modulesto connectthe rotating parts together. saved and are listed as follows: Theouter-casing assemblyconsisting of parts 48, 152, 164 and 166 and associated sub-assembly parts fit over 5o the high-pressuresection of gaz generator 20. All these a~semblies or sub.modules comprise one completetotal module thus forminggas generator 20. Sucha modulmr assemblyof aero-derivative gas genTheintercouler is sized to effect an exit temperature erators is well "known those smiled in the art. Only by 55 of 100" F. whenconsidering a standard 59* F. day. The -the addition and arrangement (a) the exit elbow100, of minimum approachtemperature is thus considered to be diffuser 102 or 230 and duct connection36, (b) the 41" F. turn parts consisting of the duct connection42, the "S" The adiabatic compressioneffioiencies of both the shapedduct 104 or 280 turning vanes 282 and the like low-pressure and high-pressure compressors are and (e) the pressurizing casing parts 148, 152, 164 and 60 sumedto be.88 percent. Noattempt is madeto increase 166 are new, all madepossible by the oversized lowthe efficiency at the low-pressure end or decrease the pressure compressor with a longer radius, r. This unique efficiency at the high end to simulate what actually arrangementallows more or less standard "core" parts takes place. of high-temperature high-technology to be wedded Careful studies of the non-intereooled reheat-gus-turwith the lesser technology low-pressure compressor, 65 bine combinedeyule have produced data for the three the duct connections and the pressurizing cannister curves shownin FIG. 9. Note that three different gasassembly to form the complete cylindrically-shaped turbine initial andreheat firing temperatures shown, are ° module ga~ generator 20. of namely:(a) 2400'/2100" (b) 2600°/2200 F. and (c) F.,

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¯ 18

2600"/2400"F, Also, as can be se~n, two different steamreheattempezatvcelevels are given for the 2400 ° pslg initial pressure, These are: 1000°/1000 F. attd . F. 1100°/1050/850 for the double reheat. Highersteam 5 and gas temperature can be considered. Each curve representing the gas-tuthine and steamturbine.temperature conditions peaks out at a speaifle cycle-pressureratio as shown point A 38 cycle presat sure ratio (CPR),B 44 CPP,trod C 48 CPP,. Tt~esethree curves are consideredas the basin standards for comparI0 ing the intercodied cycle in terms of overall maximumcycle efficiency obtainable for the conditions given, Referring to FIG,1 again, it is assumed that the work saved by compression intercoollng is extracted through if A sh~ft 26 madthat the rest of the reheat-gas-turbine cyale remains tmchanged with the exception of incrementM heat being addedto the first combnstorto heat the air back to the original eompressor-dianharge temperature associated with the nortintercooled compre.s-20 sion for any given cycle-pressureratio. This procedure greatly slmplJfles the almlysis and neglects the small variations introduced by the heat required to vaporizeand/or heat the fuel, the expamion workof the fuel itself madthe slight increase in the 25 secondcombustorpressure due to the savlugs in compressina workand the incremental fuel-expansion work when consideringa fixed er3aansttemperutu~ce. Also, the very small amountOf low-level heat recovery by the condensate,if this scheme used, is neglected for the 30 is sakeof simplinity. Finally, with reference to FIG. 9 the three basic non-intercooled gas turbines employstem as the blade and combusturcoolant and therefore, a lower compressor-dischargetemperature resulting fizomthe intercool. 35 ing and resulting cooling-air fluctuations does not enter into the reheat-gas.ttttbinecycle to distort the results. There are three basic thermodytmmJc formulas to apply in calculating compressionworkand temperature40 rise. Thefirst formuladeals with the changein enthalpy of the air and thus the workof compression:

(at2 - h'il = (T,. The specific heat of air (Co) is considered to have constant value of 0.24 BTUAb*F. (1.005 Kff/Kg *C.) and the gas constamk is consideredto be 1.4. Theaforestuted three formulas and ozsumptionswill produceclose results whichare valid for incremental. eompressinn work saved through intercouling and incremental heat added after compressionto raise the temperature back to the nonintercooled level. More exact results using the gas tables are not warrearedfor comparisesxand relative compression work and changes in cyuleeffialeaeies. Formulas (2), (3) and (6) can be used to develop of temperature versus pressure ratio as given in FIG. 10 where, for an inlet temperature of 59* F., the outlet temperature for any given rude is plotted against the natural log of the pressure ratio. Thenatural log of pressureratio is used to shrink the higherpressure-ratio scale and broadenthe lower ratio scale whereneeded for closer analysis. Theactual pressureratios are given by the lower scale for easy reference. Air is compressedfrom point 1 to point $ without intercodiing. TbSsincus of tempertuure points is used as a standard for comparison. Considering intercoollng, air is first compressed from point 1 to point 2 at which point the air is cooledby the intercouler to point g. Theair is then compressed further to point 4. Thetotal workof compression repreis sented by the sumof the two temperature differences: accordingly (Ta--TI)+(T4--Tg). This temperature difference summation given as point 6 in FIG. is Obviouslythe incremental worksaved by the intercool. ing process is represented by (Ts--T~). The extra heat required to heat the air back to temperature T5 without intercooling(and thus the incremental heat to be added)is represented by (Ts--T~) FIG. 10. The intercooling pressure at point 2 can be varied froma pressureratio of 1 to 60, for purposes analysis, of giving complete data of incremental work saved and inerementul heat added. The incremental cycle aieney is then readily calculated using formula (5) whichincorporates the 5 percent parasitic losses:

where (Ha--HI) is the enthalpy change and work required, w is the weightflow, C.o is the speulfie heat considered to be constant, (Tx--Tt) is the change temperatureresulting from the compression constant 5O at entropy and n is the adiabatic compression efficiency. Thesecondformulagives the relationship of temperature andpressure ratio as follows:

Ei 55 where is the incrementaleyule efficiencyof the intercooling process and where the numerical subscripts refer to FIG. 10. This analysis assumes that the compression work where T1 and Ta are the absolute temperature before saved will be hypothetically extracted out shaft A of and aRercompression,P2 is the absolute pressure after 60 FIG.1 so that the rest of the eyule is not disrupted.This eompressinn, is the absolute initial pressureand k is PI assumptionis va~d for purposes of a general analysis the gas eo~tatu(ratio of the twospecific heats within the scope of accuracyof the other assumptions. This formula is based on a constant entropy compres- Thetotal cycle wouldhave to be evaluated for precise sion with no losses, thus, at 1O0percent efficiency. accuracy wheremore exact values of compressionefflThethird fox~aulais a combination the two previ- 65 aleney, expansion of effiulency, pressurelosses andthe like ous formulasand gives the temperaturerise of compres- are known a specific design. for sion whichis disecdy related to the workof compresFirst, considering no intercodier pressure loss and considering air to be cooledall the way the stunthe to sion and the heat content of the aft:

DA17

Case 1:05-cv-00187-JFM

Document 54-2

Filed 06/09/2008

Page 21 of 57

19

4,896,499
There is another factor that must be considered to obtain the overall combined-cycledegradation. This factor is the amountofincremental compressionwork saved by the intercooling process. Referenceis made to FIG. 13 whichis a pint of incremental workin BTU/lb of airflow versus pressure ratio for both the 40 CPR and ° 60 CPR ceses and for 100 F. I-IPC inlet and 3 percent It can be seen that maxlimmx work saved by intercooling occurs at the square root of the total pressure ratio, points A and B of FIG. 13. Theincremental specific work, Wi, saved can be determined by applying formula (6) following:

dard inlet temperature 59" F., a graph of incremental of cycIe efficiency versus the natural log of cyale pressure ratio is obtained~ given in the top lines C of FIGS.11 and 12 for twototal cycle-pressureratios of 40 and 60, the general area of concern, Notathat FIG.10 presents an example a CPR for being intercooled at n 4 pressure ratio. It can be seen that the inerementa! oyale efficiency is mmdmum very low intercooling pressures and falls at off as the intercooling pressure rises, Theeftioieney is is saved. Alsoit can be noted as ascertained fi'om FIG. 9 that the combined cycle efficiency range is from 55 to 60 percent as shown the shadedarea of FIGS.11 and by 12. Therefore the only wayinterconling can possibly improve or equate to the knowncombinedcycle alency is in the lowintarcoollng pressure-ratio image of about 1.8 to 3.2 whenconsidering high-tttthine inlet ° temperaturesabove2400 F. ]geyonda pressure ratio of 3, the combined cycles of FIG, 9 (points A, B and C) will be degradedin proportion to the amount increof mental worksaved and the incremental efficiency derived. Using the modelof FIG. l0 developed from Formula (5) and the zero intercooler pressure-loss target curves C of FIGS.11 and 12, morereMistin plots of incremen-

where Cp is the specific heat considered to be 24 BTU.Ob °F. (1,005 K.ff/Kg- °C.) for standard air and wherethe numericalsubscripts refer to FIG. 1O. Anintercooler pressure rangeof 1.8 to 3.2 is shmvn in the range area whereincremental cycle efficiency remainsat a relatively high level. Theselowerinterconler pressures must be considered for maximum combinedcycle efficiency, but nevertheless at some sacrifice in overall combined cycle efficiency and moreoverat less than maximum incremental gas turbine and combinedcycle output. Theordinate has an additional scale for be developed for both the 40 CPRand 60 CPR cases. percent gas turbine power increase and another for Asstated earlier, a 3 percent total interconler pressure percent combined-cycin powerincrease based on calcuinss is believedto be realistic and is assumed. Also, the 30 lated values of 303.36 BTU/lbnet work for the gas air is assumed be cooled to 100of and alternately to to turbine and 121.49 BTU/Ib work for the steam turnet 150" F. for comparison the theoretical curves C of to bine. FIGS.11 and 12. Referenceis madeto FIG. 11 for the Intercooling does increase gas turbine output from 40 CPR case and FIG. 12 for the 60 CPR case wherean about 6 to 14 percent and combined cycle output by 4