Initial Operating Experience and Test Results of ABB’s Gas Turbine GT13E2

1995 ◽  
Author(s):  
M. Klohr ◽  
J. Schmidtke ◽  
S. Tschirren ◽  
P. Rihak
Keyword(s):  
Gas Turbine ◽  
Dynamic Pressure ◽  
Operating Experience ◽  
Combined Cycle ◽  
Test Facility ◽  
Vibration Velocity ◽  
Inlet Temperature ◽  
Test Results ◽  
Pressure System ◽  
Annular Combustor

On 20 October 1993, the first ABB GT13E2 gas turbine was put into operation. This 165 MW class gas turbine achieves 35,7% thermal efficiency in single cycle application and up to 54,3% (according ISO standard 3977, Annexe F) in a three pressure system. An optimised turbine and compressor design along with the increased turbine inlet temperature, lead to improved efficiency and electrical output. A new concept for the combustor aimed at meeting the increasing demands on gas turbine emissions. The GT13E2 is equipped with the new single annular combustor and 72 of the ABB EV double cone burners. The commissioning and testing of the first GT13E2 was carried out at the Kawasaki Gas Turbine Research Center (KGRC) in Sodegaura City near Tokyo, Japan. The gas turbine was assembled with various measurement systems to monitor static and dynamic pressure, gas and metal temperature, expansion, vibration, velocity and emissions. The facility will be used during a 15 year joint test program by ABB and Kawasaki Heavy Industries (KHI) to obtain a sound database of operating experience for further improvements of the GT13E2 gas turbine. Therefore, mid 1994 a second test phase was conducted and early 1995 a third test period is scheduled. In parallel, the 2nd and 3rd GT13E2’s were commissioned and tested at the Deeside Combined Cycle Power Plant near Chester, Great Britain. In November 1994, the 4th GT13E2 at Lage Weide was successfully commissioned. This paper describes the operating experience with the GT13E2 during the first commissioning and test phases at KGRC and Deeside. The design features, the test facility, the instrumentation, the commissioning and test results are presented and discussed.

scholarly journals Development and Shop Test Results of a New 25–35MW Class Gas Turbine MF-221

1996 ◽  
Author(s):  
K. Takeishi ◽  
H. Mori ◽  
K. Tsukagoshi ◽  
M. Takahama
Keyword(s):  
Gas Turbine ◽  
High Efficiency ◽  
Axial Compressor ◽  
Combined Cycle ◽  
Load Test ◽  
Test Facility ◽  
Medium Size ◽  
Inlet Temperature ◽  
Test Results ◽  
Turbine Cooling

Mitsubishi Heavy industries Ltd. developed a new high efficiency medium-size (25–35MW) gas turbine MF-221 to be used in a cogeneration plant. This gas turbine is an upscaled design of the MF-111 model, which has accumulated an operation experience of more than 1,020,000hrs. The improvement of performance and reliability was made possible by technology transfer from the latest 501F/701F gas turbine with respect to compressor and turbine aerodynamics, materials, coating and turbine cooling technology. The MF-221 has a base load rating of 30MW at 1250°C turbine inlet temperature. Its thermal efficiency is 32% and 45% for simple and combined cycle application, respectively. It consists of a single shaft, 17-stage axial compressor, 10 can-type combustors and a 3-stage axial turbine. The prototype engine has been tested in a full-load test facility at Takasago Machinery Works to confirm the efficiency and the reliability of all parts exposed to high temperatures.

scholarly journals High-Temperature Turbine Technology Readiness

1982 ◽  
Author(s):  
M. W. Horner ◽  
A. Caruvana
Keyword(s):  
High Temperature ◽  
Gas Turbine ◽  
Phase Ii ◽  
Combined Cycle ◽  
Technology Readiness ◽  
Inlet Temperature ◽  
Test Results ◽  
Turbine Inlet ◽  
Combined Cycle Plant ◽  
Gas Fuel

Final component and technology verification tests have been completed for application to a 2600°F rotor inlet temperature gas turbine. These tests have proven the capability of combustor, turbine hot section, and IGCC fuel systems and controls to operate in a combined cycle plant burning a coal-derived gas fuel at elevated gas turbine inlet temperatures (2600–3000°F). This paper presents recent test results and summarizes the overall progress made during the DOE-HTTT Phase II program.

Development of ODS Coating for High Temperature Turbine Components Using DED Additive Manufacturing

2018 ◽  
Author(s):  
Eric Chia ◽  
Bruce S. Kang ◽  
Min Zheng ◽  
Yang Li ◽  
Minking Chyu
Keyword(s):  
High Temperature ◽  
Additive Manufacturing ◽  
Gas Turbine ◽  
Thermally Grown Oxide ◽  
Combined Cycle ◽  
Inlet Temperature ◽  
Internal Cooling ◽  
Test Results ◽  
Dispersion Strengthening ◽  
Thermal Cycles

Current and future designs for advanced turbine systems, such as Integrated Gasification Combined Cycle (IGCC), advanced Natural Gas Combined Cycle (NGCC), and the emerging supercritical CO2 (SCO2) systems require increasing turbine inlet temperature (TIT), which is well beyond the substrate melting temperature. The well-known approach is coating the turbine blade with thermal barrier coatings (TBC) combined with internal cooling channel in the substrate. However, due to thermally grown oxide (TGO) and thermal expansion mismatch stresses, TBC spallation failure is a major concern. Furthermore, neither the ceramic coating layer nor the metallic bond coat in current TBC system can provide structural support to house the internal cooling channels. In this research, a method to fabricate high temperature protective structural coating on top of critical gas turbine components by additive manufacturing (AM) technique using oxide dispersion strengthening (ODS) metal powder is presented. A novel combined mechanochemical bonding (MCB) plus ball milling process is utilized to produce near spherical and uniformly alloyed ODS powders. AM-processed ODS coating by direct energy deposition (DED) method on MAR-247 substrate, with laser powers from 100W to 200W were carried out. The ODS coated samples were then subjected to thermal cyclic loadings for over 2200 cycles. For comparison, in our earlier studies, under the same cyclic testing condition, typical tested TBC coupons showed spallation failure after ∼400 cycles. Correlation of the measured ODS coating Young’s modulus using a unique non-destructive micro-indentation testing method with evolution of the ODS microstructures are studied to identify optimum AM processing parameters for best performance of the ODS samples. In particular, stability of secondary γ′ phase in the ODS coating after thermal cycles is analyzed. Test results revealed a thin steady durable alpha alumina oxide layer on the best performance ODS samples. After 2,200 thermal cycles, strong bonding at ODS/substrate interface is also maintained for most of the ODS coated samples. Test results also showed stable substrate microstructure due to the protective ODS coating even after 2,200 thermal cycles. These preliminary test results showed strong potential for applications of AM-assisted ODS coating on advanced gas turbine components.

scholarly journals The Coal-Fired PFBC Machine: Operating Experience and Further Development

1996 ◽  
Author(s):  
Sven A. Jansson ◽  
Dirk Veenhuizen ◽  
Krishna K. Pillai ◽  
Jan Björklund
Keyword(s):  
Steam Turbine ◽  
Gas Turbine ◽  
Fluidized Bed ◽  
Future Development ◽  
Operating Experience ◽  
Combined Cycle ◽  
Inlet Temperature ◽  
Turbine Inlet Temperature ◽  
Under Construction ◽  
Further Development

The key components of Pressurized Fluidized Bed Combined Cycle (PFBC) plants are the specially designed gas turbine, which we refer to as the PFBC machine, and the pressurized fluidized bed boiler used to generate and superheat steam for expansion in a steam turbine, in ABB’s P200 and P800 modules, ABB Stal’s 17 MWe GT35P and 70 MWe GT140P machines, respectively, are used. Particulate cleanup before expansion in the turbine sections is with cyclones. So far, over 70,000 hours of operation has been accumulated on P200 modules in the world’s first PFBC plants, demonstrating that PFBC meets the expectations. The GT35P machines have been found to perform as expected, although some teething problems have also been experienced. The next P200 plant will be built in Germany for operation on brown coal. The first GT140P machine has been manufactured. After shop testing in Finspong, it will be shipped to Japan for installation in the first P800 plant, which is under construction. Future development of the PFBC machines are foreseen to include raising the turbine inlet temperature through combustion of a topping fuel in order to reach thermal efficiencies which ultimately may be in the range of 50 to 53% (LHV).

Advanced Burner Development for the Vx4.3A Gas Turbines

2001 ◽  
Author(s):  
Holger Streb ◽  
Bernd Prade ◽  
Thomas Hahner ◽  
Stefan Hoffmann
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Field Evaluation ◽  
Test Facility ◽  
Nox Emissions ◽  
Exhaust Gas ◽  
Test Results ◽  
Exhaust Gas Emission ◽  
Annular Combustor ◽  
Base Load

The Vx4.3A gas turbine family has already been well received by the market. Nevertheless the market drives technology towards both increased turbine inlet temperatures and reduced emissions. The HR3 burner was originally developed for the V4.2 and Vx4.3 fleet featuring silo combustors in order to mitigate the risk of flashback and to improve the NOx- emissions (Prade, Streb, 1996). Due to its favourable performance characteristics in the Vx4.3 family the advanced HR3 burner was adapted to the Vx4.3A series with annular combustor. The paper reports upon the design, testing and field evaluation steps which were necessary to implement the burner for the 50 and 60 cycle gas turbines. With CFD calculations the flow field and the mixing of natural gas and combustion air have been optimised. A number of tests in the Siemens test facilities confirmed these predictions. The atmospheric 3 burner segment combustion test rig allows to test flame interaction, stability and exhaust gas emission simultaneously. In the Siemens Berlin Test Facility which provides a platform for full scale gas turbine testing 24 HR3-burners were implemented into a V84.3A gas turbine with a base load power output of 184 MW at ISO conditions for prototype testing before introducing this new burner generation into the bigger 50 cycle family V94.3A. Implementation of 24 scaled HR3 burners were installed in the V94.3A of Cottam Development Centre (Great Britain) and demonstrated an excellent performance. The gas turbine reached an ISO base load output of 265 MW with NOx emissions well below 25 ppmvd. Due to the very promising test results in Berlin and Cottam, this burner modification, which can be retrofitted to all VX4.3A gas turbines, was implemented nearly fleet wide.

scholarly journals Experimental Evaluation of a Two-Stage Slagging Combustor Design for a Coal-Fueled Industrial Gas Turbine

1992 ◽  
Author(s):  
L. H. Cowell ◽  
R. T. LeCren
Keyword(s):  
Gas Turbine ◽  
Combustion Zone ◽  
Combustion Process ◽  
Coal Ash ◽  
Pollutant Emissions ◽  
Test Facility ◽  
Inlet Temperature ◽  
Water Mixture ◽  
Test Results ◽  
Industrial Gas Turbine

A full-size combustor for a coal-fueled industrial gas turbine engine has been tested to evaluate combustion performance prior to integration with an industrial gas turbine. The design is based on extensive work completed through one-tenth scale combustion tests. Testing of the combustion hardware is completed with a high pressure air supply in a combustion test facility at the Caterpillar Technical Center. The combustor is a two-staged, rich-lean design. Fuel and air are introduced in the primary combustion zone where the combustion process is initiated. The primary zone operates in a slagging mode inertially removing coal ash from the gas stream. Four injectors designed for coal-water mixture (CWM) atomization are used to introduce the fuel and primary air. In the secondary combustion zone additional air is injected to complete the combustion process at fuel-lean conditions. The secondary zone also serves to reduce the gas temperatures exiting the combustor. The combustor has operated at test pressures of 7 bars with 600K inlet temperature. Tests have been completed to set the air flow split and to map the performance of the combustor as characterized by pollutant emissions, coal ash separation, and temperature profile. Test results with a comparison to subscale test results are discussed. The test results have indicated that the combustor operates at combustion efficiencies above 98% and with pollutant emissions below design goals.

Advancements in H Class Gas Turbines and Combined Cycle Power Plants

2018 ◽  
Author(s):  
Christian Vandervort
Keyword(s):  
Power Plant ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Power Plants ◽  
Operating Experience ◽  
Combined Cycle ◽  
Test Facility ◽  
Air Cooling ◽  
Operational Flexibility ◽  
Cycle Efficiency

The power generation industry is facing unprecedented challenges. High fuel costs combined with an increased penetration of renewable power has resulted in greater demand for high efficiency and operational flexibility. Imperative for a reduced carbon footprint places an even higher premium on efficiency. Power producers are seeking highly efficient, reliable, and operationally flexible solutions that provide long-term profitability in a volatile environment. New generation must also be cost-effective to ensure affordability for both domestic and industrial consumers. Gas turbine combined cycle power plants provide reliable, dispatch-able generation with low cost of electricity, reduced environmental impact, and improved flexibility. GE’s air-cooled, H-class gas turbines (7/9HA) are engineered to achieve greater than 63% net, combined cycle efficiency while delivering operational flexibility through deep, emission-compliant turndown and high ramp rates. The largest of these gas turbines, the 9HA.02, exceeds 64% combined cycle efficiency (net, ISO) in a 1 × 1, single-shaft configuration. In parallel, the power plant has been configured for rapid construction and commissioning enabling timely revenue generation for power plant developers and owners. The HA platform is enabled by 1) use of a simple air-cooling system for the turbine section that does not require external heat exchange and the associated cost and complexity, and 2) use of well-known materials and coatings with substantial operating experience at high firing temperatures. Key technology improvements for the HA’s include advanced cooling and sealing, utilization of unsteady aerodynamic methodologies, axially staged combustion and next generation thermal barrier coating (TBC). Validation of the architecture and technology insertion is performed in a dedicated test facility over the full operating range. As of February 2018, a total of 18 HA power plants have achieved COD (Commercial Operation). This paper will address three topics relating to the HA platform: 1) gas turbine product technology, 2) gas turbine validation and 3) integrated power plant commissioning and operating experience.

Design and Operating Experience on the Recent Application of the Fuel Staging Technology for AE94.3A Gas Turbine

2013 ◽  
Author(s):  
Marco Alecci ◽  
Alessia Bulli ◽  
Enrico Gottardo ◽  
Giulio Mori ◽  
Carlo Piana ◽  
...  
Keyword(s):  
High Pressure ◽  
Power Plant ◽  
Gas Turbine ◽  
Operating Experience ◽  
Combined Cycle ◽  
Inlet Temperature ◽  
Recent Application ◽  
Turbine Engine ◽  
Fuel Staging ◽  
Promising Solution

The paper describes the experience made on the first, recent application of the fuel staging technology on AE94.3A gas turbine engine. The experience started in the frame of combustion upgrade projects by the beginning of 2011 when some conceptual ideas rose. The most effective solution was found in the application of radial fuel staging through the modification of an existing, dual fuel, diagonal swirler. CFD calculation was carried out in order to evaluate numerically the differences that the introduction of the radial fuel staging would have brought in comparison with the standard, reference configuration. After that one promising solution was selected and applied to a prototype, the test phase started. The experimental test was initially performed at the engine conditions on a high pressure test rig. The rig architecture was designed to be as representative as possible of the GT annular combustion chamber. The rig was equipped with the most advanced instrumentation in order to monitor and store all the main parameters of the burner during the test. High pressure tests showed a good agreement with the CFD calculation and an effective capability of the prototype to stage the fuel by generating a “co-pilot” flame. The word “co-pilot” was coined for the behaviour of the resulting flame to act as a second pilot in supporting and stabilizing the main premix flame. The on site validation was carried out on Enel La Casella GT1 power plant, downstream the upgrade of the gas turbine with the last recent AE94.3A model. The validation phase was performed according to two separate sessions: the first one using the standard, reference burner solution and the second one with the radial staged configuration. The advantage of the fuel staging technique was twofold. The first one was concerning the minimum environmental load: the contribution of the fuel staging was approximately 7 MW. The second one was concerning the global performance of the whole combined cycle power plant at the base load. It was possible to increase turbine inlet temperature of about 30 °C and the GT power output of about +7% in comparison with the standard, reference burner solution.

Externally-Fired Combined Cycle Repowering of Existing Steam Plants

1993 ◽  
Author(s):  
Christian L. Vandervort ◽  
Mohammed R. Bary ◽  
Larry E. Stoddard ◽  
Steven T. Higgins
Keyword(s):  
Heat Exchanger ◽  
Steam Turbine ◽  
Gas Turbine ◽  
High Efficiency ◽  
Low Cost ◽  
Operating Experience ◽  
Capital Cost ◽  
Combined Cycle ◽  
Plant Design ◽  
Generating Capacity

The Externally-Fired Combined Cycle (EFCC) is an attractive emerging technology for powering high efficiency combined gas and steam turbine cycles with coal or other ash bearing fuels. The key near-term market for the EFCC is likely to be repowering of existing coal fueled power generation units. Repowering with an EFCC system offers utilities the ability to improve efficiency of existing plants by 25 to 60 percent, while doubling generating capacity. Repowering can be accomplished at a capital cost half that of a new facility of similar capacity. Furthermore, the EFCC concept does not require complex chemical processes, and is therefore very compatible with existing utility operating experience. In the EFCC, the heat input to the gas turbine is supplied indirectly through a ceramic heat exchanger. The heat exchanger, coupled with an atmospheric coal combustor and auxiliary components, replaces the conventional gas turbine combustor. Addition of a steam bottoming plant and exhaust cleanup system completes the combined cycle. A conceptual design has been developed for EFCC repowering of an existing reference plant which operates with a 48 MW steam turbine at a net plant efficiency of 25 percent. The repowered plant design uses a General Electric LM6000 gas turbine package in the EFCC power island. Topping the existing steam plant with the coal fueled EFCC improves efficiency to nearly 40 percent. The capital cost of this upgrade is 1,090/kW. When combined with the high efficiency, the low cost of coal, and low operation and maintenance costs, the resulting cost of electricity is competitive for base load generation.

Experimental Study of Combustion on a Micro Gas Turbine Combustor

2008 ◽  
Author(s):  
Feng-Shan Wang ◽  
Wen-Jun Kong ◽  
Bao-Rui Wang
Keyword(s):  
Gas Turbine ◽  
Pressure Loss ◽  
Loss Factor ◽  
Total Pressure ◽  
Combustion Efficiency ◽  
Total Pressure Loss ◽  
Test Facility ◽  
Inlet Temperature ◽  
Micro Gas Turbine ◽  
Oil Fuel

A research program is in development in China as a demonstrator of combined cooling, heating and power system (CCHP). In this program, a micro gas turbine with net electrical output around 100kW is designed and developed. The combustor is designed for natural gas operation and oil fuel operation, respectively. In this paper, a prototype can combustor for the oil fuel was studied by the experiments. In this paper, the combustor was tested using the ambient pressure combustor test facility. The sensors were equipped to measure the combustion performance; the exhaust gas was sampled and analyzed by a gas analyzer device. From the tests and experiments, combustion efficiency, pattern factor at the exit, the surface temperature profile of the outer liner wall, the total pressure loss factor of the combustion chamber with and without burning, and the pollutants emission fraction at the combustor exit were obtained. It is also found that with increasing of the inlet temperature, the combustion efficiency and the total pressure loss factor increased, while the exit pattern factor coefficient reduced. The emissions of CO and unburned hydrogen carbon (UHC) significantly reduced, but the emission of NOx significantly increased.

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