Durability Surveillance of Advanced Gas Turbines: Performance and Mechanical Baseline Development for the GE Frame 7F

1993 ◽  
Author(s):  
Cyrus B. Meher-Homji ◽  
A. N. Lakshminarasimha ◽  
G. Mani ◽  
Clark V. Dohner ◽  
Igor Ondryas ◽  
...  
Keyword(s):  
Electric Power ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Dynamic Pressure ◽  
Pressure Sensors ◽  
Practical Interest ◽  
Advanced Technology ◽  
Surveillance Program ◽  
Inlet Temperature ◽  
Base Line

This paper describes the methodology and approach of baseline development as part of a comprehensive Durability Surveillance Study Program of an Advanced Gas Turbine (AGT) sponsored by the Electric Power Research Institute (EPRI) on a GE Frame 7F gas turbine operating in peaking service. The gas turbine is an advanced technology 156 MW (ISO), 955 lb/sec machine operating at a turbine inlet temperature of 2300° F (rotor inlet temperature) and a pressure ratio of 13.5:1. The turbine is located at Potomac Electric Power Company (PEPCO) Station H plant in Dickerson, Maryland. In order to facilitate the durability surveillance, the turbine has a data acquisition and analysis system which obtains data from the control system (via serial port) as well as from special sensors such as proximity probes, dynamic pressure sensors, strain gauges and hot section pyrometers. With the GE Frame 7F and FA machines becoming very popular in utility applications worldwide, the EPRI Durability Surveillance Program and baseline generation methodology will be of considerable practical interest to gas turbine users. The basic methodology presented for baseline development can be used for any single shaft gas turbine. We believe the base-line to be of considerable importance in evaluating future condition of the machine as well as for maintenance planning. The paper also briefly describes the status and future plans of the EPRI durability surveillance program.

Gas Turbine Performance Improvement by Retrofit of Advanced Technology

1983 ◽  
Author(s):  
V. C. Tendon ◽  
A. Zabrodsky
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Advanced Technology ◽  
Inlet Temperature ◽  
Performance Improvements ◽  
Turbine Performance ◽  
Higher Power ◽  
Available Technology ◽  
Life Consumption ◽  
Implementation Technique

Development and operation of larger size gas turbines have demonstrated that higher turbine inlet temperature can be sustained due to advancement in material and cooling technology. After a feasibility study it was determined that modern available technology can be applied to existing previous generation of machines. These programs are identified as “The Performance Upgrade of Gas Turbine”. Amongst the significant benefits that can be realized by retrofitting state of art parts in existing machines are higher power and more durable parts. This paper discusses various programs that are currently offered and implementation technique of upgrading the machines. A recent example is also presented. These unique programs are particularly attractive at the time of overall life consumption of the initial set of hot parts. At that point in an operating gas turbine it will be beneficial to retrofit the latest configuration parts to realize the performance improvements.

Readings on Specific Gas Turbine Flame Behaviours Using an Industrial Combustion Monitoring System

2016 ◽  
Author(s):  
Fabrice Giuliani ◽  
Hans Reiss ◽  
Markus Stuetz ◽  
Vanessa Moosbrugger ◽  
Alexander Silbergasser
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Dynamic Pressure ◽  
Pressure Sensors ◽  
Research Programme ◽  
Response Measurement ◽  
Efficient Operation ◽  
Maintenance Costs ◽  
Full Field ◽  
Combustion Monitoring

The new energy mix places greater demands on power gas turbine operation; precision combustion monitoring, therefore has become a major issue. Unforeseen events such as combustion instabilities can occur and represent a danger to the integrity of the hot parts and also lead to a limitation of the output power. This is usually accompanied by an increase in maintenance costs. The enlarged off-design operating envelope of gas turbines to adapt to a fast-changing grid has made this issue even more acute, necessitating an expansion of the operating envelope into areas that were — for many engines — not foreseen in the original combustor design process. A good understanding of what happens within the gas turbine combustor is crucial. Complex and costly full-field measurements such as laboratory optical instrumentation in precision combustion diagnostics are not suitable for permanent fleet deployment. For practical and financial reasons, the monitoring should ideally be achieved with a limited amount of discrete sensors. If installed and interpreted correctly, fast response measurement chains could lead to a better gas turbine combustion management, possibly yielding considerable savings in terms of operating and maintenance costs. The firm Meggitt Sensing System (MSS), assisted by Combustion Bay One (CBOne), initiated an applied research programme dedicated to this topic — with MSS providing the instrumentation and CBOne providing the facility and test conditions. The objective was to investigate realistic combustion phenomena in a precisely controlled and reproducible way and to document the individual readings of the heat-resistant fast pressure transducers mounted on the combustor casing, as well as the accelerometers mounted on the outer surface of the machine. Particular attention was paid to the correlation between these two types of sensor readings. This paper reports on the monitoring of the flame using piezoelectric dynamic pressure sensors and accelerometers in a number of different situations that are relevant to the safe and efficient operation of gas turbines. Discussed are single events such as flame ignition, lean blow-out and flash-back, as well as longer test sequences observing the effect of warming-up or the presence of flame instability. The measurement chains and processing techniques are discussed in detail. The atmospheric test rig used for this purpose and the different testing configurations required for each of these situations are also illustrated in detail. The results and recommendations for their implementation in an industrial context conclude this paper.

scholarly journals Development of Ceramic Rotor Blade for Power Generating Gas Turbine

1994 ◽  
Author(s):  
Tetsuo Teramae ◽  
Yutaka Furuse ◽  
Katsuo Wada ◽  
Takashi Machida
Keyword(s):  
High Temperature ◽  
Electric Power ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Rotor Blade ◽  
Evaluation System ◽  
Research Work ◽  
Inlet Temperature ◽  
Cooperative Research ◽  
Metal Disc

To cope with the increasing demand of electric power, many research and development programs have been performed in the field of electric power industry. Among them, the application of highly thermal resistive ceramics to hot parts of the gas turbines is one of the most promising ways to raise the thermal efficiency of the gas turbine, and several projects have been executed in the U.S.A., Europe and Japan. Tokyo Electric Power Co., Inc. (TEPCO) also has been conducting a research project to apply ceramic components to hot parts of a 20MW class gas turbine with a turbine inlet temperature of 1300C. In this project. TEPCO and Hitachi have been conducting the cooperative research work to develop a first stage ceramic rotor blade. After several design modifications, it was decided to select ceramic blades attached directly to a metal rotor disc, and to insert metal pads between the dovetail of the ceramic blade and metal disc to convey the centrifugal force produced by the blade smoothly to the metal disc. The strength of this ceramic blade has been verified by a series of experiments such as tensile tests, room temperature spin tests, thermal loading tests, and high temperature spin tests using a high temperature gas turbine development unit (HTDU). In addition, the reliability of the ceramic blade under design and test conditions has been analyzed by a computer program GFICES (Gas turbine - Fine Ceramics Evaluation System) which was developed on the basis of statistical strength theory using two parameter Weibull probability distribution. These experiments and analyses demonstrate the integrity of the developed ceramic rotor blade.

scholarly journals Durability Surveillance Program on the Advanced Gas Turbine GE Frame 7 F

1992 ◽  
Author(s):  
Igor S. Ondryas ◽  
Cyrus Meher-Homji ◽  
Pierre Boehler ◽  
Clark Dohner
Keyword(s):  
Electric Power ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Surveillance Program ◽  
Operational Parameters ◽  
Hot Gas ◽  
High Temperature Materials ◽  
Close Observation ◽  
Generation Costs ◽  
New Generation

Worldwide pressures for reduction of power generation costs force the manufacturers of gas turbines to develop highly efficient units. Recent advances in the developments of high temperature materials coupled with advanced cooling techniques allow the developments of the new generation of advanced gas turbines with firing temperatures at 2300*F, which are being presently deployed in the marketplace. In order to establish a reference point regarding the durability of these machines, EPRI (Electric Power Research Institute) has launched a program to assess the durability of this new generation of advanced gas turbines. The first gas turbine to be observed is the General Electric MS 7001 F, located at the Potomac Electric Power Co. (PEPCO) Station H in Dickerson, Md. The Durability Surveillance Program shall be performed for 3 years during peaking operation (mostly summer and winter) beginning in May 1992 and continuing till 1995. Close observation of the gas turbine operation and maintenance, extensive monitoring of turbine operational parameters, detailed recording of performance and operational parameters and expanded inspection of the hot gas path hardware are the main activities in this Durability Surveillance program. Similar test programs are planned for the Westinghouse 501 F gas turbine and the GE MS 7001 FA gas turbine. The results of these tests shall be available to EPRI member utilities and other advanced gas turbine users.

Development and Fabrication of Silicon Nitride Components for Ceramic Gas Turbine

1997 ◽  
Author(s):  
Keisuke Makino ◽  
Ken-Ichi Mizuno ◽  
Toru Shimamori
Keyword(s):  
High Temperature ◽  
Silicon Nitride ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Turbine Blades ◽  
High Strength ◽  
Inlet Temperature ◽  
Turbine Inlet Temperature ◽  
Spark Plug ◽  
Power Turbine

NGK Spark Plug Co., Ltd. has been developing various silicon nitride materials, and the technology for fabricating components for ceramic gas turbines (CGT) using theses materials. We are supplying silicon nitride material components for the project to develop 300 kW class CGT for co-generation in Japan. EC-152 was developed for components that require high strength at high temperature, such as turbine blades and turbine nozzles. In order to adapt the increasing of the turbine inlet temperature (TIT) up to 1,350 °C in accordance with the project goals, we developed two silicon nitride materials with further unproved properties: ST-1 and ST-2. ST-1 has a higher strength than EC-152 and is suitable for first stage turbine blades and power turbine blades. ST-2 has higher oxidation resistance than EC-152 and is suitable for power turbine nozzles. In this paper, we report on the properties of these materials, and present the results of evaluations of these materials when they are actually used for CGT components such as first stage turbine blades and power turbine nozzles.

Three Spool High Efficiency Small Scale Gas Turbine Concept

2017 ◽  
Author(s):  
Matti Malkamäki ◽  
Ahti Jaatinen-Värri ◽  
Antti Uusitalo ◽  
Aki Grönman ◽  
Juha Honkatukia ◽  
...  
Keyword(s):  
Power Generation ◽  
Gas Turbine ◽  
Gas Turbines ◽  
High Efficiency ◽  
Small Scale ◽  
Inlet Temperature ◽  
Substantial Impact ◽  
Electrical Efficiency ◽  
Partial Load ◽  
Reciprocating Engines

Decentralized electricity and heat production is a rising trend in small-scale industry. There is a tendency towards more distributed power generation. The decentralized power generation is also pushed forward by the policymakers. Reciprocating engines and gas turbines have an essential role in the global decentralized energy markets and improvements in their electrical efficiency have a substantial impact from the environmental and economic viewpoints. This paper introduces an intercooled and recuperated three stage, three-shaft gas turbine concept in 850 kW electric output range. The gas turbine is optimized for a realistic combination of the turbomachinery efficiencies, the turbine inlet temperature, the compressor specific speeds, the recuperation rate and the pressure ratio. The new gas turbine design is a natural development of the earlier two-spool gas turbine construction and it competes with the efficiencies achieved both with similar size reciprocating engines and large industrial gas turbines used in heat and power generation all over the world and manufactured in large production series. This paper presents a small-scale gas turbine process, which has a simulated electrical efficiency of 48% as well as thermal efficiency of 51% and can compete with reciprocating engines in terms of electrical efficiency at nominal and partial load conditions.

Expectations and Recent Experience for Gas Turbine Reliability, Availability, and Maintainability (RAM)

2007 ◽  
Author(s):  
Robert F. Steele ◽  
Dale C. Paul ◽  
Torgeir Rui
Keyword(s):  
Power Systems ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Advanced Technology ◽  
Recent Experience ◽  
Reliability Growth ◽  
Market Place ◽  
New Product Introductions ◽  
Low Emission ◽  
The Cost

Since the early 1990’s there have been significant changes in the gas turbine, and power generation market place. The ‘F-Class’ Gas Turbines, with higher firing temperatures, single crystal materials, increased compressor pressure ratios and low emission combustion systems that were introduced in the early 1990’s have gained significant field experience. Many of the issues experienced by these new product introductions have been addressed. The actual reliability growth and current performance of these advanced technology machines will be examined. Additionally, the operating profiles anticipated for many of the units installed during this period has been impacted by both changes in the anticipated demand and increases in fuel costs, especially the cost of natural gas. This paper will review how these changes have impacted the Reliability, Availability, and Maintainability performance of gas turbines. Data from the ORAP® System, maintained by Strategic Power Systems, Inc, will be utilized to examine the actual RAM performance over the past 10 to 15 years in relation to goals and expectations. Specifically, this paper will examine the reliability growth of the F-Class turbines since the 1990’s and examine the reliability impact of duty cycle on RAM performance.

Rolls Royce/Allison 501-K Gas Turbine Anti-Fouling Compressor Coatings Evaluation

2002 ◽  
Author(s):  
Daniel E. Caguiat
Keyword(s):  
Gas Turbine ◽  
Fuel Consumption ◽  
Gas Turbines ◽  
Performance Degradation ◽  
Specific Fuel Consumption ◽  
Inlet Temperature ◽  
Test Results ◽  
Turbine Inlet ◽  
Compressor Performance ◽  
Compressor Efficiency

The Naval Surface Warfare Center, Carderock Division (NSWCCD) Gas Turbine Emerging Technologies Code 9334 was tasked by NSWCCD Shipboard Energy Office Code 859 to research and evaluate fouling resistant compressor coatings for Rolls Royce Allison 501-K Series gas turbines. The objective of these tests was to investigate the feasibility of reducing the rate of compressor fouling degradation and associated rate of specific fuel consumption (SFC) increase through the application of anti-fouling coatings. Code 9334 conducted a market investigation and selected coatings that best fit the test objective. The coatings selected were Sermalon for compressor stages 1 and 2 and Sermaflow S4000 for the remaining 12 compressor stages. Both coatings are manufactured by Sermatech International, are intended to substantially decrease blade surface roughness, have inert top layers, and contain an anti-corrosive aluminum-ceramic base coat. Sermalon contains a Polytetrafluoroethylene (PTFE) topcoat, a substance similar to Teflon, for added fouling resistance. Tests were conducted at the Philadelphia Land Based Engineering Site (LBES). Testing was first performed on the existing LBES 501-K17 gas turbine, which had a non-coated compressor. The compressor was then replaced by a coated compressor and the test was repeated. The test plan consisted of injecting a known amount of salt solution into the gas turbine inlet while gathering compressor performance degradation and fuel economy data for 0, 500, 1000, and 1250 KW generator load levels. This method facilitated a direct comparison of compressor degradation trends for the coated and non-coated compressors operating with the same turbine section, thereby reducing the number of variables involved. The collected data for turbine inlet, temperature, compressor efficiency, and fuel consumption were plotted as a percentage of the baseline conditions for each compressor. The results of each plot show a decrease in the rates of compressor degradation and SFC increase for the coated compressor compared to the non-coated compressor. Overall test results show that it is feasible to utilize anti-fouling compressor coatings to reduce the rate of specific fuel consumption increase associated with compressor performance degradation.

Application of Ultra-Low NOx Combustor to the MHPS Existing Gas Turbine

2021 ◽  
Author(s):  
Takashi Nishiumi ◽  
Hirofumi Ohara ◽  
Kotaro Miyauchi ◽  
Sosuke Nakamura ◽  
Toshishige Ai ◽  
...  
Keyword(s):  
High Pressure ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Combined Cycle ◽  
Inlet Temperature ◽  
Operational Experience ◽  
Emission Rates ◽  
Gas Temperature ◽  
Design Development ◽  
And Control

Abstract In recent years, MHPS achieved a NET M501J gas turbine combined cycle (GTCC) efficiency in excess of 62% operating at 1,600°C, while maintaining NOx under 25ppm. Taking advantage of our gas turbine combustion design, development and operational experience, retrofits of earlier generation gas turbines have been successfully applied and will be described in this paper. One example of the latest J-Series technologies, a conventional pilot nozzle was changed to a premix type pilot nozzle for low emission. The technology was retrofitted to the existing F-Series gas turbines, which resulted in emission rates of lower than 9ppm NOx(15%O2) while maintaining the same Turbine Inlet Temperature (TIT: Average Gas Temperature at the exit of the transition piece). After performing retrofitting design, high pressure rig tests, the field test prior to commercial operation was conducted on January 2019. This paper describes the Ultra-Low NOx combustor design features, retrofit design, high pressure rig test and verification test results of the upgraded M501F gas turbine. In addition, it describes another upgrade of turbine to improve efficiency and of combustion control system to achieve low emissions. Furthermore it describes the trouble-free upgrade of seven (7) units, which was completed by utilizing MHPS integration capabilities, including handling all the design, construction and service work of the main equipment, plant and control systems.

Micro Gas Turbine With Ceramic Nozzle and Rotor

2005 ◽  
Author(s):  
Takayuki Matsunuma ◽  
Hiro Yoshida ◽  
Norihiko Iki ◽  
Takumi Ebara ◽  
Satoshi Sodeoka ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Turbine Rotor ◽  
Total Power ◽  
Inlet Temperature ◽  
Present System ◽  
Outlet Temperature ◽  
Micro Gas Turbine ◽  
Buffer Material ◽  
Inconel 713C

A series of operation tests of a ceramic micro gas turbine has been successfully carried out. The baseline machine is a small single-shaft turbojet engine (J-850, Sophia Precision Corp.) with a centrifugal compressor, an annular type combustor, and a radial turbine. As a first step, an Inconel 713C alloy turbine rotor of 55 mm in diameter was replaced with a ceramic rotor (SN-235, Kyocera Corporation). A running test was conducted at rotational speeds of up to 140,000 rpm in atmospheric air. At this rotor speed, the compression pressure ratio and the thrust were 3 and 100 N, respectively. The total energy level (enthalpy and kinetic energy) of the exhaust gas jet was 240 kW. If, for example, it is assumed that 10% of the total power of the exhaust jet gas was converted into electricity, the present system would correspond to a generator with 24 kW output power. The measured turbine outlet temperature was 950°C (1,740°F) and the turbine inlet temperature was estimated to be 1,280°C (2,340°F). Although the ceramic rotor showed no evidence of degradation, the Inconel nozzle immediately in front of the turbine rotor partially melted in this rotor condition. As a second step, the Inconel turbine nozzle and casing were replaced with ceramic parts (SN-01, Ohtsuka Ceramics Inc.). The ceramic nozzle and case were supported by metal parts. Through tests with the ceramic nozzle, it became evident that one of the key technologies for the development of ceramic gas turbines is the design of the interface between the ceramic components and the metallic components, because the difference between the coefficients of linear thermal expansion of the ceramic and metal produces large thermal stress at their interface in the high-temperature condition. A buffer material made of alumina fiber was therefore introduced at the interface between the ceramic and metal.

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