This paper describes the design implementation of the Intercooler System of the WR-21 Intercooled Recuperated Gas Turbine Engine (ICR). The Intercooler System extracts heat from the gas exiting the Intermediate Pressure Compressor (IPC) by means of on-engine, air-to-liquid heat exchangers. The heat transfer liquid is 50/50 ethylene glycol/water (EG). The heat is carried out of the engine by the EG to an off-engine EG-to-seawater heat exchanger. The seawater ultimately dumps the heat into the sea. The ICR is designed primarily for ship application where space is at a premium. Three design innovations that provide solutions to operational and emergency problems, resulting in a compact off-engine skid assembly will be introduced.
1. A system design that will handle pump shut downs and allow engine operation while the intercooler is isolated (bypass mode) — without putting the liquid system outside the enclosure under pressure.
2. A reservoir that is vented to atmosphere, that is only about 130 gallons in volume, that provides make-up and allows flow of 800–1000 US gpm (3000–3785 l/min) without causing turbulence in the reservoir.
3. A device that removes slugs of air trapped in the system during initial fill-up and continually deaerates the system.
