IP Library › Granted Patent US 12,338,772

Granted Patent B2

US 12,338,772 · App. 17/989,601 · Granted Jun 24, 2025

Systems, assemblies, and methods to enhance intake air flow to a gas turbine engine of a hydraulic fracturing unit

Inventors: Tony Yeung (Houston, TX); Ricardo Rodriguez-Ramon (Houston, TX)

Assignee: BJ Energy Solutions, LLC

F02C7/052 B01D46/4263 B01D46/58 F02C6/00 F02C7/042 F02C7/143 B01D2279/60

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Quick Facts

Patent No.: US 12,338,772
App. No.: 17/989,601
Filed: Nov 17, 2022
Granted: Jun 24, 2025
Kind: B2
Examiner: DUKE, EMMANUEL E
Art Unit: 3763
USPC: 62/317

External Links

USPTO Patent Center↗ Full Patent PDF↗

Abstract

Systems, assemblies, and methods to enhance the efficiency of operation of a gas turbine engine may include a turbine housing positioned to at least partially enclose the gas turbine engine, and a filtration assembly connected to the turbine housing to supply at least partially filtered intake air to an inlet assembly associated with the gas turbine engine. The filtration assembly may include a pre-cleaner including one or more inertial separators configured to separate a first portion of particles and/or liquid from ambient air supplied to the gas turbine engine, thereby to provide at least partially filtered intake air, and one or more filters positioned downstream of the pre-cleaner to separate a second portion of the particles and/or liquid from the at least partially filtered intake air.

Claims (128)

1. A pre-cleaner to enhance the efficiency of separation of one or more of particles or fluid from intake air supplied to a gas turbine engine, the pre-cleaner comprising:

a first panel positioned to face outward from a filtration assembly;

a second panel opposite the first panel, the first panel and the second panel at least partially defining a separator cavity therebetween; and

one or more inertial separators extending between the first panel and the second panel, the one or more inertial separators being positioned to separate a portion of one or more of particles or liquid from ambient air, thereby to provide at least partially filtered intake air for supply to the gas turbine engine, the one or more inertial separators comprising:

an air flow tube having a proximal end connected to the first panel, extending toward the second panel, and terminating at a distal end, the air flow tube defining an interior cross-sectional area;

a diverter connected to the air flow tube and positioned to cause ambient air entering the air flow tube to swirl as the ambient air flows from the proximal end of the air flow tube to the distal end of the air flow tube; and

a separator tube connected to the second panel and extending from the second panel toward the distal end of the air flow tube, the separator tube having an exterior cross-sectional area smaller than the interior cross-sectional area of the air flow tube.

2. The pre-cleaner of claim 1 , wherein the separator tube is positioned relative to the distal end of the air flow tube to provide:

a first separator flow path for the at least partially filtered intake air to exit the pre-cleaner through an interior passage of the separator tube; and

a second separator flow path for the first portion of the one or more of particles or liquid to be separated from the ambient air entering the inertial separator, the second separator flow path passing between an exterior surface of the separator tube and an interior surface of the air flow tube.

3. The pre-cleaner of claim 1 , wherein the diverter comprises one or more stator blades presenting one or more curved surfaces to cause the ambient air entering the air flow tube to swirl as the ambient air passes the one or more stator blades and flows from the proximal end of the air flow tube to the distal end of the air flow tube.

4. The pre-cleaner of claim 1 , wherein the second panel at least partially defines an interior hole, and the separator tube is connected to the second panel such that an interior passage of the separator tube provides a first separator flow path for the at least partially filtered intake air to exit the inertial separator through the interior passage of the separator tube and the interior hole of the second panel.

5. The pre-cleaner of claim 4 , wherein the air flow tube is connected to an exterior surface of the separator tube and at least partially defines a second separator flow path for the first portion of the one or more of particles or liquid to be separated from the ambient air entering the inertial separator, the second separator flow path being positioned to deposit the first portion of the one or more of particles or liquid into the separator cavity.

6. The pre-cleaner of claim 5 , wherein the distal end of the air flow tube terminates between the first panel and the second panel, thereby at least partially defining the second separator flow path.

7. The pre-cleaner of claim 1 , further comprising a pre-cleaner bypass connected to one or more of the first panel or the second panel and positioned to receive a portion of the ambient air not flowing through the second panel and the portion of the one or more of particles or liquid separated from the ambient air.

8. The pre-cleaner of claim 1 , wherein one or more of an interior passage of the air flow tube, an interior passage of the separator tube, or an exterior surface of the separator tube has a substantially circular cross-sectional shape.

9. The pre-cleaner of claim 1 , wherein:

the pre-cleaner comprises a plurality of inertial separators; and

one or more of the first panel or the second panel at least partially defines an upper end and a lower end, and the plurality of inertial separators are arranged in groups extending diagonally between the upper end and the lower end of the pre-cleaner.

10. The pre-cleaner of claim 1 , wherein the pre-cleaner comprises one or more flanges extending outward from a perimeter of the pre-cleaner and providing a connection for connecting the pre-cleaner to a filtration assembly via the one or more flanges.

11. An intake air treatment assembly to enhance the efficiency of operation of a gas turbine engine including an inlet assembly positioned to supply intake air to the gas turbine engine, the intake air treatment assembly comprising:

a turbine housing configured to at least partially enclose the gas turbine engine and the inlet assembly and positioned to facilitate supply of intake air to the inlet assembly of the gas turbine engine;

a filtration assembly connected to the turbine housing and positioned to provide a flow path to supply at least partially filtered intake air to the inlet assembly of the gas turbine engine, the filtration assembly comprising:

a pre-cleaner positioned to receive ambient air drawn into the filtration assembly via operation of the gas turbine engine and comprising one or more inertial separators configured to separate a first portion of one or more of particles or liquid from the ambient air, thereby to provide at least partially filtered intake air; and

one or more filters positioned in the flow path downstream of the pre-cleaner and configured to separate a second portion of the one or more of particles or liquid from the at least partially filtered intake air, thereby to provide the at least partially filtered intake air to the inlet assembly of the gas turbine engine.

12. The intake air treatment assembly of claim 11 , wherein the pre-cleaner comprises:

an exterior panel facing outward from the filtration assembly; and

an interior panel opposite the exterior panel and facing inward toward an interior of the filtration assembly, the one or more inertial separators extending between the exterior panel and the interior panel.

13. The intake air treatment assembly of claim 12 , wherein the one or more inertial separators comprise:

an air flow tube having a proximal end connected to the exterior panel, extending toward the interior panel, and terminating at a distal end, the air flow tube defining an interior cross-sectional area;

a separator tube connected to the interior panel and extending from the interior panel toward the distal end of the air flow tube, the separator tube having an exterior cross-sectional area smaller than the interior cross-sectional area of the air flow tube.

14. The intake air treatment assembly of claim 13 , wherein the separator tube is positioned relative to the distal end of the air flow tube to provide:

a first separator flow path for the at least partially filtered intake air to exit the pre-cleaner through an interior passage of the separator tube; and

15. The intake air treatment assembly of claim 13 , wherein the diverter comprises one or more stator blades presenting one or more curved surfaces to cause the ambient air entering the air flow tube to swirl as the ambient air passes the one or more stator blades and flows from the proximal end of the air flow tube to the distal end of the air flow tube.

16. The intake air treatment assembly of claim 13 , wherein the interior panel at least partially defines an interior hole, and the separator tube is connected to the interior panel such that an interior passage of the separator tube provides a first separator flow path for the at least partially filtered intake air to exit the inertial separator through the interior passage of the separator tube and the interior hole of the interior panel.

17. The intake air treatment assembly of claim 16 , wherein:

the exterior panel and the interior panel at least partially define a separator cavity therebetween; and

the air flow tube is connected to an exterior surface of the separator tube and at least partially defines a second separator flow path for the first portion of the one or more of particles or liquid to be separated from the ambient air entering the inertial separator, the second separator flow path being positioned to deposit the first portion of the one or more of particles or liquid into the separator cavity.

18. The intake air treatment assembly of claim 17 , wherein the distal end of the air flow tube terminates between the exterior panel and the interior panel, thereby at least partially defining the second separator flow path.

19. The intake air treatment assembly of claim 13 , wherein one or more of an interior passage of the air flow tube, an interior passage of the separator tube, or an exterior surface of the separator tube has a substantially circular cross-sectional shape.

20. The intake air treatment assembly of claim 11 , further comprising a pre-cleaner collector connected to the pre-cleaner and positioned to receive the first portion of the one or more of particles or liquid separated from the ambient air.

21. The intake air treatment assembly of claim 11 , wherein the one or more filters comprise one or more of a pre-filter or a final filter.

22. The intake air treatment assembly of claim 21 , wherein the one or more filters comprise the pre-filter downstream of the pre-cleaner and the final filter downstream of the pre-filter.

23. The intake air treatment assembly of claim 21 , wherein the one or more of a pre-filter or a final filter comprises one or more of a medium-efficiency intermediate filter or a high-efficiency final filter.

24. The intake air treatment assembly of claim 21 , wherein the one or more of a pre-filter or a final filter comprises one or more of a cartridge-type pre-filter or a bag-type pre-filter.

25. The intake air treatment assembly of claim 11 , wherein the pre-cleaner comprises a plurality of inertial separators.

26. The intake air treatment assembly of claim 25 , wherein:

the pre-cleaner comprises an exterior panel facing outward from the filtration assembly and an interior panel opposite the exterior panel and facing inward toward an interior of the filtration assembly; and

one or more of the exterior panel or the interior panel at least partially defines an upper end and a lower end, and the plurality of inertial separators are arranged in groups extending diagonally between the upper end and the lower end of the pre-cleaner.

27. The intake air treatment assembly of claim 11 , wherein the pre-cleaner comprises one or more flanges extending outward from a perimeter of the pre-cleaner, and the pre-cleaner is connected to the filtration assembly via the one or more flanges.

28. The intake air treatment assembly of claim 11 , wherein the filtration assembly comprises a plurality of pre-cleaners.

29. The intake air treatment assembly of claim 28 , wherein:

the filtration assembly comprises a filtration housing connected to the turbine housing, the filtration housing and the plurality of pre-cleaners at least partially defining a filtration chamber; and

the one or more filters are positioned in the filtration chamber.

30. The intake air treatment assembly of claim 29 , further comprising one or more sound attenuation baffles positioned in the filtration chamber to attenuate sound generated during operation of the gas turbine engine.

31. The intake air treatment assembly of claim 29 , wherein the filtration housing comprises one or more access panels positioned to facilitate access to the filtration chamber.

32. A hydraulic fracturing unit to enhance flow of fracturing fluid into a wellhead during a high-pressure fracturing operation, the hydraulic fracturing unit comprising:

a chassis having a longitudinal chassis axis and a width perpendicular to the longitudinal chassis axis;

a gas turbine engine supported by the chassis;

an inlet assembly connected to the gas turbine engine to supply intake air to the gas turbine engine;

a hydraulic fracturing pump connected to the gas turbine engine; and

an intake air treatment assembly associated with the intake assembly to enhance the efficiency of operation of the gas turbine engine, the intake air treatment assembly comprising:

a turbine housing at least partially enclosing the gas turbine engine and the inlet assembly and positioned to facilitate supply of intake air to the inlet assembly of the gas turbine engine;

a filtration assembly connected to the turbine housing and positioned to provide a flow path to supply at least partially filtered intake air to the inlet assembly, the filtration assembly comprising:

33. The hydraulic fracturing unit of claim 32 , wherein the pre-cleaner comprises:

an exterior panel facing outward from the filtration assembly; and

34. The hydraulic fracturing unit of claim 33 , wherein the one or more inertial separators comprise:

35. The hydraulic fracturing unit of claim 34 , wherein the separator tube is positioned relative to the distal end of the air flow tube to provide:

a first separator flow path for the at least partially filtered intake air to exit the pre-cleaner through an interior passage of the separator tube; and

36. The hydraulic fracturing unit of claim 34 , wherein the diverter comprises one or more stator blades presenting one or more curved surfaces to cause the ambient air entering the air flow tube to swirl as the ambient air passes the one or more stator blades and flows from the proximal end of the air flow tube to the distal end of the air flow tube.

37. The hydraulic fracturing unit of claim 34 , wherein the interior panel at least partially defines an interior hole, and the separator tube is connected to the interior panel such that an interior passage of the separator tube provides a first separator flow path for the at least partially filtered intake air to exit the inertial separator through the interior passage of the separator tube and the interior hole of the interior panel.

38. The hydraulic fracturing unit of claim 37 , wherein:

the exterior panel and the interior panel at least partially define a separator cavity therebetween; and

39. The hydraulic fracturing unit of claim 38 , wherein the distal end of the air flow tube terminates between the exterior panel and the interior panel, thereby at least partially defining the second separator flow path.

40. The hydraulic fracturing unit of claim 32 , further comprising a pre-cleaner collector connected to the pre-cleaner and positioned to receive the first portion of the one or more of particles or liquid separated from the ambient air.

41. The hydraulic fracturing unit of claim 32 , wherein one or more of an interior passage of the air flow tube, an interior passage of the separator tube, or an exterior surface of the separator tube has a substantially circular cross-sectional shape.

42. The hydraulic fracturing unit of claim 32 , wherein the one or more filters comprise one or more of a pre-filter or a final filter.

43. The hydraulic fracturing unit of claim 42 , wherein the one or more filters comprise the pre-filter downstream of the pre-cleaner and the final filter downstream of the pre-filter.

44. The hydraulic fracturing unit of claim 42 , wherein the one or more of a pre-filter or a final filter comprises one or more of a medium-efficiency intermediate filter or a high-efficiency final filter.

45. The hydraulic fracturing unit of claim 42 , wherein the one or more of a pre-filter or a final filter comprises one or more of a cartridge-type pre-filter or a bag-type pre-filter.

46. The hydraulic fracturing unit of claim 32 , wherein the pre-cleaner comprises a plurality of inertial separators.

47. The hydraulic fracturing unit of claim 46 , wherein:

the pre-cleaner comprises an exterior panel facing outward from the filtration assembly and an interior panel opposite the exterior panel and facing inward toward the interior of the filtration assembly; and

48. The hydraulic fracturing unit of claim 32 , wherein the pre-cleaner comprises one or more flanges extending outward from a perimeter of the pre-cleaner, and the pre-cleaner is connected to the filtration assembly via the one or more flanges.

49. The hydraulic fracturing unit of claim 32 , wherein the filtration assembly comprises a plurality of pre-cleaners.

50. The hydraulic fracturing unit of claim 49 , wherein:

the filtration assembly comprises a filtration housing connected to the turbine housing, the filtration housing and the plurality of pre-cleaners at least partially defining a filtration chamber; and

the one or more filters are positioned in the filtration chamber.

51. The hydraulic fracturing unit of claim 50 , further comprising one or more sound attenuation baffles positioned in the filtration chamber to attenuate sound generated during operation of the gas turbine engine.

52. The hydraulic fracturing unit of claim 50 , wherein the filtration housing comprises one or more access panels positioned to facilitate access to the filtration chamber.

53. A method to enhance efficiency of operation of a gas turbine engine, the method comprising:

causing ambient air to flow toward an inlet assembly connected to the gas turbine engine;

passing the ambient air through one or more pre-cleaners to cause the ambient air to swirl and separate a first portion of one or more of particles or liquid from the ambient air, thereby to provide at least partially filtered intake air;

passing the at least partially filtered intake air through one or more filters to separate a second portion of the one or more of particles or liquid from the at least partially filtered intake air, thereby to provide further filtered intake air; and

supplying the further filtered intake air to the intake assembly.

54. The method of claim 53 , wherein passing the ambient air through one or more pre-cleaners comprises:

passing the ambient air through an air flow tube and a diverter connected to the air flow tube and positioned to cause the ambient air entering the air flow tube to swirl as the ambient air flows from a proximal end of the air flow tube to a distal end of the air flow tube to thereby generate swirling ambient air;

passing the swirling ambient air to a separator tube extending from the distal end of the air flow tube; and

separating the first portion of the one or more of particles or liquid from the swirling ambient air via the separator tube.

55. The method of claim 54 , wherein passing the ambient air through an air flow tube and the diverter comprises passing the ambient air through one or more stator blades presenting one or more curved surfaces to cause the ambient air entering the air flow tube to swirl.

56. The method of claim 55 , wherein passing the at least partially filtered intake air through the one or more filters comprises passing the at least partially filtered intake air through one or more of a pre-filter or a final filter.

57. The method of claim 56 , wherein passing the at least partially filtered intake air through the one or more of a pre-filter or a final filter comprises one or more of:

passing the at least partially filtered intake air through a pre-filter downstream of the pre-cleaner and the final filter downstream of the pre-filter;

passing the at least partially filtered intake air through one or more of a medium-efficiency intermediate filter or a high-efficiency final filter; or

passing the at least partially filtered intake air through one or more of a cartridge-type pre-filter or a bag-type pre-filter.

58. The method of claim 54 , wherein separating the first portion of the one or more of particles or liquid from the swirling ambient air via the separator tube comprises:

passing the at least partially filtered intake air through an interior passage of the separator tube; and

passing the first portion of the one or more of particles or liquid or tube around an exterior surface of the separator tube.

59. The method of claim 58 , further comprising causing the first portion of the one or more of particles or liquid to be deposited into a separator cavity of the one or more pre-cleaners.

60. The method of claim 59 , wherein causing the first portion of the one or more of particles or liquid to be deposited into the separator cavity comprises causing the first portion of the one or more of particles or liquid to pass between an exterior panel of the pre-cleaner and an interior panel of the pre-cleaner.

61. The method of claim 60 , further comprising:

connecting the proximal end of the air flow tube to the exterior panel; and

connecting the separator tube to the interior panel, such that the separator tube extends toward the distal end of the air flow tube and provides flow communication between an interior passage of the air flow tube and an interior passage of the separator tube and an exterior surface of the separator tube.

62. The method of claim 61 , further comprising connecting the air flow tube to an exterior surface of the separator tube to at least partially define a separator flow path for the first portion of the one or more of particles or liquid to be separated from the ambient air entering the inertial separator and to be received in the separator cavity.

63. The method of claim 60 , further comprising causing the first portion of the one or more of particles or liquid to pass through the separator cavity into a pre-cleaner collector connected to the pre-cleaner and positioned to receive the first portion of the one or more of particles or liquid separated from the ambient air.

64. The method of claim 53 , wherein passing the ambient air through the one or more pre-cleaners comprises passing the ambient air through a plurality of inertial separators.

65. The method of claim 53 , further comprising passing the further filtered intake air through one or more sound attenuation baffles to attenuate sound generated during operation of the gas turbine engine.