Inlet Air Cooling & Wet Compression

ETN- Brussels
2006-10-12

Mohsen Assadi
LU ND UN IVE RSITY

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Inlet Air Cooling - Overview

Why do we need inlet air cooling?

Cooling techniques available

A short description of its functionality and
applicability

Operating experience and analysis (PG & PG I)

No time left for questions - do not hesitate to stop

me and ask your question while still in your head

Prof. Mohsen Assadi

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Why Do We Need Inlet Air Cooling?

The general benefits associated with inlet cooling are:

Decreases the work of compression

Increase air density also means that the gas turbine

can operate with higher mass flow

The compressor discharge temperature is being

lowered giving the possibility to burn more fuel in order
to reach the same TIT, hence increasing power output

Prof. Mohsen Assadi

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Potential enhancement
Inlet cooling techniques
Potential performance enhancement - GT10B
27000

25000

Chillers

Power output [kW]

23000

Cooling not
applicable due
to icing risk

21000

RH 30%

19000

ISO conditions GT10B

Media based evaporative cooler, RH 60%

RH 60%

Media based evaporative cooler, RH 30%

Fogging, RH 60%

17000

Fogging, RH 30%

ISO

Chiller, RH 60%
Chiller, RH 30%

15000

10

20

30

40

50

60

Ambient temperature [C]

Prof. Mohsen Assadi

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Cooling Techniques Available

Mechanical Chiller

Inlet fogging

Prof. Mohsen Assadi

Media based evaporative cooler

Wet compression

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Cooling Techniques Available

Mechanical Chiller

Mechanical chiller
Refrigerant cooling technique
Has cooling coils placed in the airstream
Consists of

One huge fridge

Inlet coils
Cooling tower

Prof. Mohsen Assadi

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Cooling Techniques Available

Mechanical Chiller

Prof. Mohsen Assadi

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Cooling Techniques Available

Mechanical Chiller

Found in study
Performance

Can cool the inlet air back to 15C from any ambient condition

Expensive, High investment, and O&M costs

Construction time is 6-9 months and require a turbine down time
about 7-10 days

Advantages

The gas turbine will regain its original efficiency

Economy

Great power output augmentation. 15% at 35C and 50% RH

Not susceptible to ambient conditions

Disadvantages

Large footprint, bulky construction, water tower

Require large face area across chilling coil
Added pressure drop in the air intake system

Prof. Mohsen Assadi

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Cooling Techniques Available

Media Based Evaporative Cooler

Based on the principle of adiabatic saturation

Media where water and air interacts is
placed in the airstream
Water evaporates from the surface
The air is cooled by the latent heat of
vaporization
Consist of:
Media based cooler unit
Distribution pads
Media

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Cooling Techniques Available

Media Based Evaporative Cooler

Found in study
Performance

Economy

Investment cost is low. About 1 00 000 Euro

O&M is low. Media change every 3 year
Construction time: 30 days. Turbine down time 7-10 days

Advantages

Usually have an effectiveness of 85-90 %

Increases the power output. 5 % at 35C and 50% RH

Low risk for overspray, Passive system

Potable water can be used
No integration with GT needed

Disadvantages

The effectiveness is limited by ambient conditions

Added pressure drop in the air intake system

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Cooling Techniques Available

Inlet Fogging

Based on the adiabatic saturation

process

Water is injected through nozzles

Small droplets in the airstream

Droplets evaporate and air is

cooled

Consists of

Pump skid

Nozzle rack

Prof. Mohsen Assadi

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Cooling Techniques Available

Inlet Fogging

Found in study
Performance

Economy

Investment cost is low. About 60 000 Euro

O&M is low. Nozzle replacement every 2nd year
Construction time: 20 days. Turbine down time 2-3 days

Advantages

Effectiveness around 90-97 %

Increases the power output. 6 % at 35C and 50% RH

Achieves lower inlet temperature compared to media based evap.

Requires small footprint
No added pressure loss in air intake system

Disadvantages

Integration with GT control system required

Demineralized water needed
Large droplet can cause erosion
Require inlet drain consideration & careful implementation

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EU Related Projects

Based on the adiabatic saturation process

Achieves cooling by
Normal evaporative cooling
Intercooling effect in compressor
Water is injected through nozzles
Small droplets in the air stream
Droplets evaporate and air is cooled
Consist of:
Pump skid
Nozzle rack

Prof. Mohsen Assadi

Wet compression
recommended location of
installation

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Cooling Techniques Available

Wet Compression

Power output vs. ambient temperature

Prof. Mohsen Assadi

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Cooling Techniques Available

Wet Compression

Found in study
Performance
Great

power output augmentation. Increases by 10-15 %

Great efficiency augmentation. Improves and regain efficiency by 1-3 %

Economy
Investment

cost about 3 00 000 Euro

Low O&M costs. Nozzle replacements every 2-3 year
Construction time: 30 days. Turbine down 5 days

Advantages
More

independent of ambient conditions

Can be placed downstream of media based cooler or inlet fogging

Disadvantages
Must

be integrated with GT control system

Gas turbine adjustments might be needed to adapt to new operating
conditions for compressor and combustor
Risks associated with wet compression
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Wet Compression Evaluation

Results

Velocity triangles

Axial velocity is lowered

Leads to off-design blade operation

Blade angles is no longer optimized to

Rear stage

the flow

Increased risk for stall and surge

Increased fouling is seen in the latter

stages. Increased incidence angles
can be the explanation

C - absolute velocity
W - relative velocity
Ca - axial velocity
U - blade rotational speed
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Cooling Techniques Available

Wet Compression

For a first time wet compression installation a couple of issues needs

to be investigated
Components life

Prof. Mohsen Assadi

Pulsation

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Operating Experiences

Operating experience
Leading edge erosion seen. Worst at row 1 blades and
decreases downstream. In a 16 stage compressor, last
signs of erosion can be seen at stage 12.

Pitting corrosion is considered a medium risk if the

system is not running constantly.

Other potential risks have not been encountered or

have successfully been mitigated.

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Operating Experiences

Prof. Mohsen Assadi

Erosion on inlet guide vane

Pitting corrosion potential

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Summation and Analysis

Media based evaporative cooler is well-known and proven technique

Inlet fogging is a cost-effective and promising technique but

Great power output

Expensive and bulky installations. Inconvenient technique for medium
sized gas turbines.

Absorption chillers

Should be used on certain GT with enough inlet duct length

Mechanical chillers

Should be recommended for the present

Great power output

Expensive and bulky installations. Promising technique if cheaper

Wet compression

Great performance enhancement

Cost-effective and flexible. Involves a lot of unknown risks.
If risks can be mitigated, this technique is the best alternative

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Prof. Mohsen Assadi

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