Mechanical Reliability Operational Experience in the Modern High Temperature Industrial Gas Turbine

1986 ◽  
Author(s):  
J. Korta
Keyword(s):  
High Temperature ◽  
Gas Turbine ◽  
Simple Cycle ◽  
Operational Experience ◽  
Mechanical Reliability ◽  
Industrial Gas Turbine ◽  
Regenerative Cycle

The CW352 two shaft industrial type gas turbine was first put in commercial service in 1979. By mid 1985 units in simple cycle and regenerative modes have accumulated in excess of 200,000 hrs. of operation, with lead units in excess of 50,000 hrs. simple cycle mode and 35,000 hrs. in regenerative cycle mode. The paper discusses the operational experience with emphasis on early field problems and their solutions.

Mechanical Reliability Considerations in the Modern High Temperature Industrial Gas Turbine

1980 ◽  
Vol 102 (2) ◽  
pp. 277-282
Author(s):  
J. J. Korta
Keyword(s):  
High Temperature ◽  
Gas Turbine ◽  
Mechanical Design ◽  
Mechanical Reliability ◽  
Service Experience ◽  
Design Considerations ◽  
Industrial Gas Turbine ◽  
High Degree

The mechanical design considerations of the CW352 two shaft industrial type gas turbine are discussed with emphasis on achieving a high degree of mechanical reliability based on the extensive service experience of the company’s mature 1450°F inlet machines. Problem areas of the early units are discussed and how avoidance of problems has been considered in the design of the CW352.

Development, Fabrication, and Testing of a Prototype Water-Cooled Gas Turbine Nozzle

1983 ◽  
Vol 105 (1) ◽  
pp. 114-119 ◽  
Author(s):  
M. F. Collins ◽  
M. C. Muth ◽  
W. F. Schilling
Keyword(s):  
High Temperature ◽  
Gas Turbine ◽  
Small Scale ◽  
General Electric ◽  
Process Technology ◽  
Aqueous Corrosion ◽  
Post Test ◽  
Efficient Heat Transfer ◽  
Gas Turbine Nozzle ◽  
Industrial Gas Turbine

The design and development of a water-cooled high temperature gas turbine has been under active investigation by the General Electric Gas Turbine Division for the past 15 years. The transition from testing small scale, laboratory-size experimental hardware to full scale industrial gas turbine components was initiated in 1975 by General Electric and extended further under the U.S. Department of Energy’s High Temperature Turbine Technology (HTTT) program. A key element in this transition was the identification of a composite (hybrid) design for the first stage nozzles. This design permits efficient heat transfer to the water-cooling passageways, thus lowering effective strains and increasing part life. This paper describes the metallurgical considerations and process technology required for such hardware. A review of the materials selection criteria utilized for the nozzle is presented, along with the results of several materials development programs aimed at determining metallurgical compatibility of the component materials, diffusion bonding behavior and both hot corrosion and aqueous corrosion performance of key materials. A brief description of the actual cascade testing of the part is given, along with results of a post-test metallurgical analysis of the tested hardware.

Optimizations for Brayton-Joule Gas Turbine Cycles

1992 ◽  
Vol 206 (4) ◽  
pp. 283-288 ◽  
Author(s):  
T H Frost ◽  
B Agnew ◽  
A Anderson
Keyword(s):  
Gas Turbine ◽  
Simple Cycle ◽  
Maximum Output ◽  
Peak Efficiency ◽  
Special Cases ◽  
Compressor Work ◽  
Regenerative Cycle

Traditionally, the simple Brayton–Joule cycle has been optimized for maximum output and for minimum compressor work with inter-cooling and maximum turbine work with reheat. To these Woods et al. (1) have added optimization for peak efficiency of the simple cycle with internal irreversibilities. The results now presented include both maximum output and peak efficiency for both regenerative and intercool/reheat cycles with internal irreversibilities. Two special cases, for a regenerative cycle and for a non-regenerative cycle with both reheat and intercooling, are identified where the conditions for maximum output and peak efficiency coincide.

Recuperating the LM2500 Gas Turbine

1993 ◽  
Author(s):  
Bruce D. Thompson
Keyword(s):  
Low Power ◽  
Gas Turbine ◽  
Fuel Efficiency ◽  
Simple Cycle ◽  
Operational Experience ◽  
Design Point ◽  
Discharge Temperature ◽  
Operational Life ◽  
The Us ◽  
Us Navy

The LM2500 Gas Turbine is a reliable simple cycle gas turbine that has been in US Navy service for more than 15 years. For a simple cycle gas turbine its design point fuel efficiency is quite good, approximately 0.400 (lb/hp-hr) at 26,250 BHP under US Navy rating conditions. Off design it is not quite as efficient, although its efficiency does not start to degrade significantly until operation below 10,000 BHP is reached. Operational experience with the LM2500 gas turbine in the US Navy has shown that at least 90% of its operational life will be spent at horsepowers that are less than 10,000. Therefore, in an effort to increase the range and the ability to remain on station of LM2500 powered US Navy ships, methods to improve the LM2500’s low power fuel efficiency were investigated. One area that had been discounted in the past was recuperating the LM2500. On the surface recuperating the LM2500 does not appear to provide much. The primary reason for this is that the design point compressor discharge temperature is within 200 degrees F of the gas turbine exhaust temperature. But off-design the situation changes, particularly if variable area turbine nozzles (VATNs) are introduced to maintain cycle temperatures. This paper will discuss the initial concept design process that was performed by the gas turbine division in the Naval Sea Systems Command (NAVSEA), the activity that is responsible for ship design in the US Navy. This will include the initial assumptions and the gas turbine cycle modeling that was undertaken to determine the potential benefits of recuperating the LM2500. Based on the success of these preliminary efforts, General Electric Company was then tasked to help perform additional cycle analysis. GE, working together with NAVSEA, proceeded to determine the optimum configuration of a Recuperated LM2500 (or LM2500-R). The guiding philosophy behind this effort is “maximum gain with minimal change.” The direction of this effort was to provide a cost effective, retrofitable package, in a reasonable amount of time, to upgrade the LM2500 for improved low power fuel efficiency.

Development and F-Class Industrial Gas Turbine Engine Testing of Smart Components With Direct-Write Embedded Sensors and High Temperature Wireless Telemetry

2008 ◽  
Author(s):  
David Mitchell ◽  
Anand Kulkarni ◽  
Edward Roesch ◽  
Ramesh Subramanian ◽  
Andrew Burns ◽  
...  
Keyword(s):  
High Temperature ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Condition Based Maintenance ◽  
Direct Write ◽  
Turbine Engine ◽  
Wireless Telemetry ◽  
Industrial Gas Turbines ◽  
Engine Testing ◽  
Industrial Gas Turbine

The potential for savings provided to worldwide operators of industrial gas turbines, by transitioning from the current standard of interval-based maintenance to condition-based maintenance may be in the tens of millions of dollars per year. Knowledge of the historical and current condition of life-limiting components will enable more efficient use of industrial gas turbine resources via increased operational flexibility, with less risk of unplanned outages as a result of off-parameter operations. To date, it has been impossible to apply true condition-based maintenance to industrial gas turbines because the extremely harsh operating conditions in the heart of a gas turbine preclude using the necessary advanced sensor systems to monitor the machine’s condition continuously. The U.S. Department of Commerce’s National Institute of Standards and Technology – Advanced Technology Program (NIST-ATP) awarded the Joint Venture team of Siemens Power Generation, Inc. and MesoScribe Technologies, Inc. a four-year, $5.4 million program in November, 2004, titled Conformal, Direct-Write-Technology-Enabled, Wireless, Smart Turbine Components. The target was to develop a potentially industry-changing technology to build smart, self-aware engine components that incorporate embedded, harsh-environment-capable sensors and high temperature capable wireless telemetry systems for continuously monitoring component condition in both the compressor and turbine sections. The approach involves several difficult engineering challenges, including the need to embed sensors on complex shapes, such as turbine blades, embedding wireless telemetry systems in regions with temperatures that preclude the use of conventional silicon-based electronics, protecting both sensors and wireless devices from the extreme temperatures and environments of an operating gas turbine, and successfully transmitting the sensor information from an environment very hostile to wireless signals. The program included full-scale, F-class industrial gas turbine engine test demonstrations with smart components in both the compressor and turbine sections. The results of the development program and engine testing to date will be discussed.

The Upgraded Power Turbine for the Industrial Gas Turbine THM 1304 Development and First Operational Experience

2004 ◽  
Author(s):  
E. Aschenbruck ◽  
M. Beukenberg ◽  
M. Blaswich ◽  
Horst Bokelmann
Keyword(s):  
Gas Turbine ◽  
Operational Experience ◽  
Test Bed ◽  
Test Program ◽  
Load Range ◽  
Aerodynamic Efficiency ◽  
Power Turbine ◽  
Single Piece ◽  
Service Data ◽  
Industrial Gas Turbine

The THM 1304 industrial gas turbine is a two shaft machine incorporating a two stage free power turbine suitable for mechanical and generator drive applications (Fig. 1). As part of an ongoing uprating and upgrading program design modifications were made to the power turbine. The aim was not only to increase power output and efficiency but also to improve on the high availability. The latest design incorporates new blades and vanes, increasing the aerodynamic efficiency and improving the high temperature endurance. Additionally, a new single piece casing and a redesigned mechanical turbine discs arrangement and shaft leads to a higher performance and optimized maintainability. The up rated turbine covers the entire nominal design load range from 9 to 14 MW and extends the available speed range compared to its predecessor. Furthermore, compatibility with the existing product range has been considered. A test program was carried out on the MAN TURBO test bed in Oberhausen, Germany to verify the achievement of the design goals. The program covered not only thermodynamic and aerodynamic measurements but also temperature and mechanical measurements. Special emphasis was put on the validation of the vibration characteristics by means of a telemetry system. Examples will highlight the development testing program in detail. The first production engine went into service at the WINGAS pipeline compression station in Reckrod, Germany. Not only the station layout but also the purpose of the station will be described. Service data registered by the installed monitoring system within the first 10,000 service hours will be discussed and the service experience with the new engine will be presented. During the in house test program the entire turbine performance map was covered.

Status of the Multi-Annular Swirl Burner at the Power Systems Development Facility

2000 ◽  
Author(s):  
John Brushwood ◽  
John Foote ◽  
Frank Morton ◽  
Larry Wallace
Keyword(s):  
High Temperature ◽  
Power Systems ◽  
Gas Turbine ◽  
Fluidized Bed ◽  
Scale Up ◽  
Systems Development ◽  
Department Of Energy ◽  
Operational Experience ◽  
Gas Filtration ◽  
Swirl Burner

The Power Systems Development Facility (PSDF) is an engineering scale demonstration of two advanced coal-fired power systems and several high-temperature, high-pressure gas filtration systems. The PSDF was designed at sufficient scale so that advanced power systems and components could be tested in an integrated fashion to provide data for commercial scale-up. The PSDF is funded by the U.S. Department of Energy, Electric Power Research Institute, Southern Company Services, Foster Wheeler, Kellogg Brown & Root, Siemens Westinghouse Power Corporation (SWPC), Combustion Power Company and Peabody Holding Company. The PSDF is configured into two separate test trains: the Kellogg Brown & Root (KBR) transport reactor train and the Foster Wheeler Advanced Pressurized Fluidized Bed Combustor (APFBC) train. The APFBC train also includes a topping combustor and gas turbine generator to produce electrical power. The APFBC train is designed for long term testing of the filtration systems and the assessment of control and integration issues associated with the APFBC system. The Siemens Westinghouse Multi-Annular Swirl Burner (MASB) has been developed as the topping combustor for the APFBC application. In this application, the combustion air is vitiated air, a depleted oxygen (10 to 16 vol %), high temperature (1200 to 1400°F) (650 to 760°C) gas stream, which is the exhaust gas from the fluidized bed combustion of solid fuel. The topping combustor fuel is a synthetic low-Btu fuel gas at high temperature (1200 to 1400°F) (650 to 760°C) generated by gasifying coal in the APFBC. The hot MASB combusted gas is expanded through a gas turbine for power generation. Commissioning of the MASB began in January, 1998. Over 400 hours of operation have been accumulated through November 1999. Several improvements have been designed and installed during commissioning. This paper explains the design basis of the MASB, describes design changes implemented at the PSDF and reviews the operational experience of the MASB at the PSDF.

scholarly journals Design and Development of a New 11,000 HP Industrial Gas Turbine

1969 ◽  
Author(s):  
R. C. Petitt
Keyword(s):  
High Pressure ◽  
Control System ◽  
Remote Control ◽  
Solid State ◽  
Gas Turbine ◽  
State Control ◽  
Design And Development ◽  
Technical Advances ◽  
Industrial Gas Turbine ◽  
Regenerative Cycle

This paper describes the design and development of a new series 3000 two-shaft regenerative and simple cycle gas turbine for mechanical drive applications. Technical advances in the areas of aero-thermal, mechanical, controls, and materials design were combined to produce a machine with a regenerative cycle thermal efficiency of 32%. Increased automation and adaptability to remote control were provided by a new solid state control system and high pressure hydraulics.

scholarly journals Development of the Taurus 70 Industrial Gas Turbine

1995 ◽  
Author(s):  
George Rocha ◽  
Mohammad Saadatmand ◽  
Gary Bolander
Keyword(s):  
Gas Turbine ◽  
Development Strategy ◽  
Thermodynamic Cycle ◽  
Simple Cycle ◽  
Basic Engine ◽  
Premix Combustion ◽  
Final Design ◽  
Product Development Strategy ◽  
Industrial Gas Turbine ◽  
Cycle Efficiency

Solar Turbines Incorporated has developed the Taurus 70 gas turbine in response to growing market demands in the 7 MW size range. The simple cycle, two shaft engine is rated for 7.1 MW and 34% thermal efficiency at the ISO inlet condition. The product development strategy adopted for the Taurus 70 was to incorporate proven technology that has been demonstrated with the existing Taurus 60 and Mars engines. The final design configuration was influenced by the use of an uprated Taunts 60 compressor assembly to achieve thermodynamic cycle parameters similar to the Mars engines. The standard engine configuration also includes a dry, lean-premix, combustion system to provide a gas turbine with the lowest emission and highest simple cycle efficiency in its size class. This paper describes the proven product technology, basic engine configuration and development test strategy involved in the development of the new Taurus 70 gas Turbine.

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