WO2020104088A1 - A gas turbine system and method for direct current consuming components - Google Patents

A gas turbine system and method for direct current consuming components

Info

Publication number
WO2020104088A1
WO2020104088A1 PCT/EP2019/076202 EP2019076202W WO2020104088A1 WO 2020104088 A1 WO2020104088 A1 WO 2020104088A1 EP 2019076202 W EP2019076202 W EP 2019076202W WO 2020104088 A1 WO2020104088 A1 WO 2020104088A1
Authority
WO
WIPO (PCT)
Prior art keywords
gas turbine
turbine engine
engine system
output
mobile gas
Prior art date
Application number
PCT/EP2019/076202
Other languages
French (fr)
Inventor
Harry TRUMP
Original Assignee
Centrax Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Centrax Limited filed Critical Centrax Limited
Publication of WO2020104088A1 publication Critical patent/WO2020104088A1/en

Links

Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D15/00Adaptations of machines or engines for special use; Combinations of engines with devices driven thereby
    • F01D15/10Adaptations for driving, or combinations with, electric generators
    • EFIXED CONSTRUCTIONS
    • E21EARTH DRILLING; MINING
    • E21BEARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/25Methods for stimulating production
    • E21B43/26Methods for stimulating production by forming crevices or fractures
    • E21B43/2607Surface equipment specially adapted for fracturing operations
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D1/00Non-positive-displacement machines or engines, e.g. steam turbines
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02CGAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS
    • F02C6/00Plural gas-turbine plants; Combinations of gas-turbine plants with other apparatus; Adaptations of gas- turbine plants for special use
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02CGAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS
    • F02C7/00Features, components parts, details or accessories, not provided for in, or of interest apart form groups F02C1/00 - F02C6/00; Air intakes for jet-propulsion plants
    • F02C7/32Arrangement, mounting, or driving, of auxiliaries
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02CGAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS
    • F02C7/00Features, components parts, details or accessories, not provided for in, or of interest apart form groups F02C1/00 - F02C6/00; Air intakes for jet-propulsion plants
    • F02C7/36Power transmission arrangements between the different shafts of the gas turbine plant, or between the gas-turbine plant and the power user
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K7/00Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
    • H02K7/18Structural association of electric generators with mechanical driving motors, e.g. with turbines
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02MAPPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05DINDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2220/00Application
    • F05D2220/70Application in combination with
    • F05D2220/76Application in combination with an electrical generator
    • F05D2220/766Application in combination with an electrical generator via a direct connection, i.e. a gearless transmission

Abstract

A mobile gas turbine engine system comprising: a gas turbine engine having a turbine and an output shaft directly connected to the turbine, a power output of the gas turbine engine being above 3,000 kW; a high speed electrical generator having a shaft that is directly coupled to or coterminous with the output shaft of the gas turbine engine, the high speed electrical generator being configured to generate an AC output with the shaft rotating at a speed greater than 7,000 rpm; a power electronic rectifier configured to convert the AC output from the high speed electrical generator to a DC output; and a DC supply rail configured to receive the DC output from the power electronic rectifier, wherein the DC supply rail has at least one terminal connected thereto, at least one DC consuming unit being connectable to the at least one terminal.

Description

A GAS TURBINE SYSTEM AND METHOD FOR DIRECT CURRENT
CONSUMING COMPONENTS
Technical Field
The present disclosure relates to a mobile gas turbine engine system and method and particularly, but not exclusively, relates to a mobile gas turbine engine system and method in which a gas turbine engine is directly coupled to a high speed electrical generator with a power electronic AC to DC converter.
Background
In hydraulic fracturing (“fracking”) applications, it is necessary to provide power to pumps used to pressurise the fracking fluid for the wellbore. The pressures required are high and the pumps therefore have a high power rating. Fracking locations are however often remote with limited power supply options ft is therefore desirable to provide a mobile power unit that can be transported to the fracking site.
Mobile diesel engine units with electrical generators have previously been used to provide the power required on a fracking site. However, diesel engines are relatively inefficient. To this end, gas turbine engines have been proposed. To allow the gas turbine engine to operate efficiently, a gearbox is provided between the gas turbine engine and a generator. Such a gearbox adds to the size of the power unit, which makes it less suited to a mobile application.
Statements of Invention
According to an aspect of the present disclosure, there is provided a mobile gas turbine engine system comprising:
a gas turbine engine having a turbine and an output shaft directly connected to the turbine;
a high speed electrical generator having a shaft that is directly coupled to or coterminous with the output shaft of the gas turbine engine, the high speed electrical generator being configured to generate an Alternating Current (AC) output;
a power electronic rectifier configured to convert the AC output from the high speed electrical generator to a Direct Current (DC) output; and a DC supply rail configured to receive the DC output from the power electronic rectifier, wherein the DC supply rail has at least one terminal connected thereto, at least one DC consuming unit being connectable to the at least one terminal.
A power output of the gas turbine engine may be above 3,000 kW. The generator shaft may rotate at a speed greater than 7,000 rpm. The generator shaft may rotate at rotational speeds in excess of 10,000 rpm and even in excess of 14,000 rpm.
The shaft of the high speed electrical generator may be connected to the output shaft of the gas turbine engine without a gearbox therebetween.
The gas turbine engine may further comprise a compressor. The output shaft may or may not be connected to the compressor. Accordingly, the output shaft may extend through the gas turbine engine or the output shaft may only connect to a power turbine of the gas turbine engine. The gas turbine engine may comprise a further turbine provided upstream of the turbine. The further turbine may be connected to the compressor or a further compressor downstream of the compressor.
The high speed electrical generator may comprise a squirrel cage rotor. The high speed electrical generator may comprise a motor having the squirrel cage rotor.
The components of the mobile gas turbine engine system (such as the gas turbine engine, high speed generator and power electronic rectifier) may be provided on a common structural platform. The DC supply rail may also be provided on the common structural platform, although the DC supply rail may extend beyond the platform. By way of example, the components of the mobile gas turbine engine system may be provided in a container, such as a shipping container or any other similar container. Accordingly, the mobile gas turbine engine system may be transportable on a lorry, truck or trailer thereof.
The mobile gas turbine engine system may further comprise a storage battery connected to the DC supply rail. The storage battery may store electrical power generated by the gas turbine engine and may provide additional power when required, e.g. for a peak load or when the gas turbine engine is temporarily unavailable. The high speed electrical generator may be configured to start the gas turbine engine upon the provision of power to the DC supply rail. The high speed electrical generator may be the only starter for starting the gas turbine engine.
The mobile gas turbine engine system may further comprise the at least one DC consuming unit.
The DC consuming unit may comprise a hydraulic fracturing pump system. The hydraulic fracturing pump system may comprise at least one motor and at least one pump. The at least one motor may drive the at least one pump. The hydraulic fracturing pump system may comprise a DC to AC converter that converts DC power from the DC supply rail to AC for the at least one motor.
The DC consuming unit may comprise a data centre. The data centre may comprise a DC to AC or DC to DC converter to provide either AC or DC power required by the data centre. The mobile gas turbine engine system may provide back-up power for the data centre.
The DC consuming unit may comprise a DC to AC converter for a power grid connection. As such, the mobile gas turbine engine system may provide additional power for a grid network.
The mobile gas turbine engine system mentioned above may be used in hydraulic fracturing.
According to a further aspect of the present disclosure there is provided a method comprising: operating a gas turbine engine having a turbine and an output shaft directly connected to the turbine;
driving a high speed electrical generator having a shaft that is directly coupled to or coterminous with the output shaft of the gas turbine engine;
generating an AC output from the high speed electrical generator;
converting the AC output from the high speed electrical generator to a DC output with a power electronic rectifier; and
supplying a DC supply rail with the DC output from the power electronic rectifier, wherein the DC supply rail has at least one terminal connected thereto, at least one DC consuming unit being connectable to the at least one terminal.
The output shaft may rotate at a speed greater than 7,000 rpm (e.g. above 10,000 rpm or above 14,000 rpm). A power output of the gas turbine engine may be above 3,000 kW. The method may further comprise connecting at least one DC consuming unit to the at least one terminal.
By way of example, the method may further comprise providing power from the DC supply rail to a motor connected to a hydraulic fracturing pump, a data centre, a DC to AC converter for a power grid connection, or any other DC consuming unit.
To avoid unnecessary duplication of effort and repetition of text in the specification, certain features are described in relation to only one or several aspects or embodiments of the invention. However, it is to be understood that, where it is technically possible, features described in relation to any aspect or embodiment of the invention may also be used with any other aspect or embodiment of the invention.
Brief Description of the Drawings
For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which:
Figure 1 is a schematic diagram depicting a mobile gas turbine engine system according to an example of the present disclosure; and
Figure 2 is a flow chart depicting a method for a mobile gas turbine engine system according to an example of the present disclosure.
Detailed Description
With reference to Figure 1, the present disclosure relates to a mobile gas turbine engine system 10 comprising a gas turbine engine 20, a high speed electrical generator 30, a power electronic converter (e.g. rectifier) 40 and a DC supply rail 50.
The gas turbine engine 20 has a turbine 21 and an output shaft 22 directly connected to the turbine 21. The gas turbine engine 20 further comprises a compressor 23. The output shaft 22 may or may not be connected to the compressor 23. Accordingly, the output shaft 22 may extend through the gas turbine engine 20 or the output shaft 22 may only connect to a power turbine of the gas turbine engine. The gas turbine engine may comprise a further turbine provided upstream of the turbine 21. The further turbine may be connected to the compressor 23 or a further compressor downstream of the compressor 23. Regardless of its configuration, a power output of the gas turbine engine (e.g. the motive power at the output shaft 22) may be above 3,000 kW.
The high speed electrical generator 30 has a shaft 31 that is directly coupled to or coterminous with the output shaft 22 of the gas turbine engine 20. In other words, there may be a coupling between the shaft 31 and output shaft 22 or the shaft 31 and shaft 22 may be the same shaft. Accordingly, the shaft 31 of the high speed electrical generator may be connected to (or coterminous with) the output shaft 22 of the gas turbine engine without a gearbox therebetween. As a result, the shaft 31 and output shaft 22 rotate at the same speed. For example, the generator shaft 31 may rotate at a speed greater than 7,000 rpm (and“high speed” may refer to such speeds). In fact, the generator shaft 31 may rotate at rotational speeds in excess of 10,000 rpm and even in excess of 14,000 rpm. Such high speeds are desirable for efficient operation of the gas turbine engine 20.
The high speed electrical generator 30 is configured to generate an Alternating Current (AC). The AC output may be at a frequency above 50 or 60 Hz and may in fact be significantly higher than these typical power distribution frequencies, e.g. due to the high rotational speed of the shaft 31.
In a particular example, the high speed electrical generator 30 may comprise a squirrel cage rotor rotatably provided within a stator. The high speed electrical generator 30 may in fact be a motor, but may operate as a generator when rotation of the rotor is driven. The squirrel cage rotor may comprise a cylinder (e.g. of steel laminations) with substantially longitudinally extending conductors (e.g. aluminium or copper) embedded in or beneath its surface. Other types of generators are also contemplated (e.g. generators with permanent magnet). However, the inventors of the present invention have realised that a squirrel cage motor is well suited to use as a high speed generator thanks to its rotor construction. Although the use of a squirrel cage rotor has an efficiency penalty, the overall efficiency of the system 10 is increased because a gearbox between the gas turbine engine 20 and generator 30 can be omitted.
The power electronic rectifier 40 is configured to convert the AC output from the high speed electrical generator 30 to a Direct Current (DC) output. The DC supply rail 50 receives the DC output from the power electronic rectifier 40. The components of the mobile gas turbine engine system 10 (such as the gas turbine engine 20, high speed generator 30 and power electronic converter 40) may be provided on a common structural platform, such as a flatbed. The DC supply rail 50 and terminals 52 may also be provided on the common structural platform, although the DC supply rail may extend beyond the platform. By way of example, the components of the mobile gas turbine engine system 10 may be provided in a container, such as a shipping container or any other similar container or housing. Accordingly, the mobile gas turbine engine system 10 may be transportable on a lorry, truck or trailer thereof.
The high speed electrical generator 30 may be configured to start the gas turbine engine 20 upon the provision of power to the DC supply rail 50. The high speed electrical generator 30 may be the only starter for starting the gas turbine engine 20 or may be in addition to a conventional start system. Accordingly, the high-speed generator 30 and associated power electronics may be used to provide the starting power for the gas turbine engine 20, potentially eliminating the conventional start system. This provides an added benefit or much increased starter power capability allowing very fast start-up for standby generation applications.
The system 10 may further comprise a storage battery 60 connected to the DC supply rail 50. The storage battery 60 may store electrical power generated by the gas turbine engine 20 and generator 30. The storage battery 60 may provide additional power when required, e.g. for a peak load or when the gas turbine engine 20 is temporarily unavailable. The storage battery 60 may provide power to a grid or driven loads on a no break basis in the event of a grid failure. When the generator 30 is running a further no break transition to generator derived power may be facilitated. The storage battery 60 may also at least partially provide the power to start the gas turbine engine 20.
The DC supply rail 50 has at least one terminal 52 for connecting one or more DC consuming units 70. In other words, the generator 30 may be used in conjunction with power electronics to drive a DC connected distributed load.
In one example, one or more of the DC consuming units 70 may comprise a hydraulic fracturing pump system 71 for use in hydraulic fracturing (“fracking”) during oil and gas production. The hydraulic fracturing pump system 71 may comprise at least one motor 71a to drive at least one pump 71b. The hydraulic fracturing pump system 71 may comprise a DC to AC converter 71c that converts DC power from the DC supply rail 50 to AC for the at least one motor 71a. Additionally or alternatively, the DC consuming unit 70 may comprise a data centre 72. The data centre may comprise a DC to AC or DC to DC converter 72a to provide either AC or DC power required by the data centre 72. In one application, the mobile gas turbine engine system 10 may provide back-up power for the data centre 72. The mobile gas turbine engine system 10 may also be the prime supplier of power for the data centre 72.
The DC consuming unit 70 may comprise a DC to AC converter 73a for a power grid connection 73. As such, the mobile gas turbine engine system may provide additional power for a grid network. The mobile gas turbine engine system 10 may thus provide back-up power for the grid network and may operate in conjunction with the storage battery 60 to provide strategic support for the grid network.
Although several examples of DC consuming units 70 have been described above, it will be appreciated that other DC consuming devices are also contemplated. Also, one or more of the different types of DC consuming units 70 may be used with the same DC rail 50. In each case it may be desirable to distribute the power as direct current (DC) and utilise power electronics to connect the driven load.
With reference to Figure 2, the present disclosure relates to a method 100 comprising a first block 101 in which the gas turbine engine 20 is operated. In a second block 102 the high speed electrical generator 30 is driven. In a third block 103, the high speed electrical generator 30 generates an AC output. In a fourth block 104 the AC output from the high speed electrical generator 30 is converted to a DC output with the power electronic rectifier 40. In a fifth block 105, the DC supply rail 50 is supplied with the DC output from the power electronic rectifier 40. It will be appreciated that the first, second, third, fourth and/or fifth blocks 101, 102, 103, 104,
105 may not necessarily be carried out sequentially and may be carried out concurrently.
The method 100 may further comprise connecting at least one DC consuming unit 70 to the at least one terminal 52. By way of example, the method 100 may further comprise providing power from the DC supply rail 50 to the motor 71a (e.g. via the DC to AC converter 71c) connected to the hydraulic fracturing pump 71b; a data centre 72 (e.g. via the converter 72a); a DC to AC converter 73 for a power grid connection; and/or any other DC consuming unit.
In mobile applications where a transportable power source is required, it is desirable to provide a compact arrangement and a low maintenance solution. Omitting the gearbox between the gas turbine engine 20 and the generator 30 frees up valuable space on a mobile platform and provides a more compact and lighter arrangement. In addition, omitting the gearbox improves the overall efficiency as the losses associated with the gearbox have been eliminated. The cost of providing and maintaining the gearbox has also been saved. Thus, it is foreseen to generate electricity from the prime -mover (gas turbine engine) using a directly driven high speed generator without a speed reduction gearbox. The power electronics is used to transform the high frequency alternating current from the generator into DC power for distribution over a DC link to the load(s), thus eliminating the cost and inherent losses of the reduction gearbox.
Furthermore, having a DC link rail 50 and not an AC link rail obviates the need for a further DC to AC converter. By contrast, with a previously-proposed high speed generator, the high frequency AC output (greater than 50/60Hz) is converted to DC with an AC to DC converter and is then converted back to AC (using a DC to AC converter) with a standard output frequency, typically 50 or 60 Hz. However, in the present arrangement such a DC to AC converter is not necessary, which further increases the efficiency of the overall system. ft will be appreciated by those skilled in the art that although the invention has been described by way of example, with reference to one or more examples, it is not limited to the disclosed examples and alternative examples may be constructed without departing from the scope of the invention as defined by the appended claims.

Claims

Claims
1. A mobile gas turbine engine system comprising:
a gas turbine engine having a turbine and an output shaft directly connected to the turbine, a power output of the gas turbine engine being above 3,000 kW;
a high speed electrical generator having a shaft that is directly coupled to or coterminous with the output shaft of the gas turbine engine, the high speed electrical generator being configured to generate an AC output with the shaft rotating at a speed greater than 7,000 rpm; a power electronic rectifier configured to convert the AC output from the high speed electrical generator to a DC output; and
a DC supply rail configured to receive the DC output from the power electronic rectifier, wherein the DC supply rail has at least one terminal connected thereto, at least one DC consuming unit being connectable to the at least one terminal.
2. The mobile gas turbine engine system of claim 1, wherein the shaft of the high speed electrical generator is connected to the output shaft of the gas turbine engine without a gearbox therebetween.
3. The mobile gas turbine engine system of claim 1 or 2, wherein the gas turbine engine further comprises a compressor and the output shaft is connected to the compressor.
4. The mobile gas turbine engine system of claim 1 or 2, wherein the gas turbine engine further comprises a compressor and the output shaft is not connected to the compressor.
5. The mobile gas turbine engine system of any of the preceding claims, wherein the high speed electrical generator comprises a squirrel cage rotor.
6. The mobile gas turbine engine system of any of the preceding claims, wherein the components of the mobile gas turbine engine system are provided on a common structural platform.
7. The mobile gas turbine engine system of any of the preceding claims, wherein the components of the mobile gas turbine engine system are provided in a container.
8. The mobile gas turbine engine system of any of the preceding claims, wherein the mobile gas turbine engine system is transportable on a lorry, truck or trailer thereof.
9. The mobile gas turbine engine system of any of the preceding claims, wherein the system further comprises a storage battery connected to the DC supply rail.
10. The mobile gas turbine engine system of any of the preceding claims, wherein the high speed electrical generator is configured to start the gas turbine engine upon the provision of power to the DC supply rail.
11. The mobile gas turbine engine system of any of the preceding claims, wherein the mobile gas turbine engine system further comprises the at least one DC consuming unit.
12. The mobile gas turbine engine system of claim 11, wherein the DC consuming unit comprises a hydraulic fracturing pump system.
13. The mobile gas turbine engine system of claim 12, wherein the hydraulic fracturing pump system comprises at least one motor and at least one pump.
14. The mobile gas turbine engine system of claim 13, wherein the hydraulic fracturing pump system comprises a DC to AC converter that converts DC power from the DC supply rail to AC for the at least one motor.
15. The mobile gas turbine engine system of any of claims 11 to 14, wherein the DC consuming unit comprises a data centre.
16. The mobile gas turbine engine system of any of claims 11 to 15, wherein the DC consuming unit comprises a DC to AC converter for a power grid connection.
17. Use of the mobile gas turbine engine system of any of the preceding claims in hydraulic fracturing.
18. A method comprising:
operating a gas turbine engine having a turbine and an output shaft directly connected to the turbine, with the output shaft rotating at a speed greater than 7,000 rpm and a power output of the gas turbine engine being above 3,000 kW;
driving a high speed electrical generator having a shaft that is directly coupled to or coterminous with the output shaft of the gas turbine engine; generating an AC output from the high speed electrical generator;
converting the AC output from the high speed electrical generator to a DC output with a power electronic rectifier; and
supplying a DC supply rail with the DC output from the power electronic rectifier, wherein the DC supply rail has at least one terminal connected thereto, at least one DC consuming unit being connectable to the at least one terminal.
19. The method of claim 18, wherein the method further comprises connecting at least one DC consuming unit to the at least one terminal.
20. The method of claim 18 or 19, wherein the method further comprises providing power from the DC supply rail to a motor connected to a hydraulic fracturing pump.
PCT/EP2019/076202 2018-11-23 2019-09-27 A gas turbine system and method for direct current consuming components WO2020104088A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB1819099.1 2018-11-23
GB1819099.1A GB2579207A (en) 2018-11-23 2018-11-23 A gas turbine system and method for direct current consuming components

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