Ceramic Stationary Gas Turbine Development Program — Design and Test of a Ceramic Turbine Blade

1998 ◽  
Author(s):  
Oscar Jimenez ◽  
John McClain ◽  
Bryan Edwards ◽  
Vijay Parthasarathy ◽  
Hamid Bagheri ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Turbine Blade ◽  
Gas Turbines ◽  
Fuel Efficiency ◽  
Development Program ◽  
Field Testing ◽  
The United States ◽  
Department Of Energy ◽  
United States Department ◽  
Engine Operation

The goal of the Ceramic Stationary Gas Turbine (CSGT) Development Program, under the sponsorship of the United States Department of Energy (DOE), Office of Industrial Technologies (OIT), is to improve the performance (fuel efficiency, output power, and exhaust emissions) of stationary gas turbines in cogeneration through the selective replacement of hot section components with ceramic parts. This program, which is headed by Solar Turbines Incorporated and supported by various suppliers, and national research institutes, includes detailed engine and component design, procurement, and field testing. A major challenge in the successful introduction of ceramic parts into a gas turbine is the design of the interface between the ceramic parts and metallic hardware. A turbine blade, which incorporated a dovetail root, was designed with such considerations. A relatively thin compliant layer between the ceramic-metallic loading surface was considered for equalizing pressure face load distributions. Five monolithic siliocn nitride ceramic materials were considered: AS800 and GN10, AlliedSignal Ceramic Components; NT164, Norton Advanced Ceramics; SN281 and SN253, Kyocera Industrial Ceramics Corporation. The probability of survival using NASA/CARES for 30,000 hours of engine operation was calculated for each material. The blade frequencies, stresses, and temperatures were predicted. The influence of the dovetail angle was also analyzed to determine the most optimum configuration. Prior to engine installation all blades underwent extensive nondestructive evaluation and spin proof testing. This paper will review the design, life prediction, and testing of the first stage ceramic turbine blade for the Solar Turbines Centaur 5OS engine.

scholarly journals Ceramic Stationary Gas Turbine Development Program: Design and Life Assessment of Ceramic Components

1995 ◽  
Author(s):  
Paul F. Norton ◽  
Gary A. Frey ◽  
Hamid Bagheri ◽  
Aaron Flerstein ◽  
Chris Twardochleb ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Failure Modes ◽  
Development Program ◽  
The United States ◽  
Department Of Energy ◽  
Life Assessment ◽  
United States Department ◽  
Ceramic Component ◽  
Engine Operation

A program is being performed under the sponsorship of the United States Department of Energy, Office of Industrial Technology, to improve the performance of stationary gas turbines in cogeneration through the selective replacement of hot section components with ceramic parts. It is envisioned that the successful demonstration of ceramic gas turbine technology, and the systematic incorporation of ceramics in existing and future gas turbines will enable more efficient engine operation, resulting in significant fuel savings, increased output power, and reduced emissions. The engine selected for the program, the Centaur 50 (formerly named Centaur ‘H’) will be retrofitted with first stage ceramic blades, first stage ceramic nozzles, and a ceramic combustor liner. The engine hot section is being redesigned to adapt the ceramic parts to the existing metallic support structure. The program currently in Phase II focuses on detailed engine and component design, ceramic component fabrication, ceramic component testing, establishment of a long term materials property database, and the development and application of supporting technologies in the areas of life prediction and non-destructive evaluation. This paper outlines the design activities associated with the introduction of a ceramic first stage nozzle and two configurations of ceramic first stage turbine blade. In addition, probabilistic life assessment of the ceramic parts for major failure modes (fast fracture, slow crack growth and where relevant, creep and oxidation) will be discussed.

scholarly journals Ceramic Stationary Gas Turbine Development Program: First Annual Summary

1994 ◽  
Author(s):  
Mark van Roode ◽  
William D. Brentnall ◽  
Paul F. Norton ◽  
Gary L. Boyd
Keyword(s):  
Gas Turbine ◽  
Phase Ii ◽  
Gas Turbines ◽  
Development Program ◽  
The United States ◽  
Department Of Energy ◽  
Phase Iii ◽  
United States Department ◽  
Engine Operation ◽  
Component Design

A program is being performed under the sponsorship of the United States Department of Energy, Office of Industrial Technology, to improve the performance of stationary gas turbines in cogeneration through the selective replacement of hot section components with ceramic parts. It is envisioned that the successful demonstration of ceramic gas turbine technology, and the systematic incorporation of ceramics in existing and future gas turbines will enable more efficient engine operation, resulting in significant fuel savings, increased output power, and reduced emissions. The engine selected for the program, the Centaur 50 (formerly named Centaur ‘H’) will be retrofitted with first stage ceramic blades, first stage ceramic nozzles, and a ceramic combustor liner. The engine hot section is being redesigned to adapt the ceramic parts to the existing metallic support structure. The work in Phase 1 of the program involved concept and preliminary engine and component design, ceramic materials selection, technical and economic evaluation, and concept assessment. A detailed work plan was developed for Phases II and III of the program. The work in Phase II addresses detailed engine and component design, and ceramic specimen and component procurement and testing. Ceramic blades, nozzles, and combustor liners will be tested in subscale rigs and in a gasifier rig which is a modified Centaur 50 engine. The Phase II effort also involves long term testing of ceramics, development of appropriate nondestructive technologies for part evaluation, and component life prediction. Phase III of the program focuses on a 4,000 hour engine test at a cogeneration site. This paper summarizes the progress on the program through the end of 1993.

scholarly journals Ceramic Stationary Gas Turbine Development Program — Design and Test of a First Stage Ceramic Nozzle

1998 ◽  
Author(s):  
Leslie Faulder ◽  
John McClain ◽  
Bryan Edwards ◽  
Vijay Parthasarathy
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Fuel Efficiency ◽  
Development Program ◽  
The United States ◽  
Turbine Rotor ◽  
Department Of Energy ◽  
Inlet Temperature ◽  
United States Department ◽  
Engine Test

The goal of the Ceramic Stationary Gas Turbine(CSGT) Development Program, under the sponsorship of the United States Department of Energy (DOE), Office of Industrial Technologies (OIT), is to improve the performance (fuel efficiency, output power, exhaust emissions) of stationary gas turbines in cogeneration through the selective replacement of hot section components with ceramic parts. Phase II of this program includes detailed engine and component design, procurement and testing. This paper will review the design and test of the first stage ceramic nozzle for the Centaur 50S engine. For this test an uncooled monolithic ceramic nozzle made from SN-88 silicon nitride(NGK Insulators Ltd.) was used. A major challenge in the successful introduction of ceramic parts into a gas turbine is the design of the interface between the ceramic parts and metallic components. The design and attachment of the ceramic nozzle was greatly influenced by these considerations. Metallic components in the stationary structure of the turbine have been added or redesigned to retrofit the ceramic nozzle into the all metallic Centaur 50S engine. This paper will also discuss special handling and assembly techniques used to install the ceramic nozzle into the engine. Trial assemblies were used in the engine build process, this proved most beneficial in identifying problems and reducing the risk of damage to the ceramic nozzles. Assembly techniques were designed to reduce assembly loads and to eliminate blind assemblies. Before installing any ceramic nozzles into the engine they were first required to successfully pass both mechanical and thermal proof tests. Details of these proof tests and the final full load engine test will be described in this paper. The engine test was run at a turbine rotor inlet temperature(TRIT) of 1010°C. Total number of engine starts was six, and the total run time was approximately 10 hours.

scholarly journals Ceramic Stationary Gas Turbine Development Program — Fifth Annual Summary

1998 ◽  
Author(s):  
Jeffrey R. Price ◽  
Oscar Jimenez ◽  
Les Faulder ◽  
Bryan Edwards ◽  
Vijay Parthasarathy
Keyword(s):  
Gas Turbines ◽  
Development Program ◽  
Field Testing ◽  
The United States ◽  
Turbine Rotor ◽  
Department Of Energy ◽  
Inlet Temperature ◽  
United States Department ◽  
Performance Improvements ◽  
Ceramic Components

A program is being performed under the sponsorship of the United States Department of Energy, Office of Industrial Technologies, to improve the performance of stationary gas turbines in cogeneration through the selective replacement of metallic hot section components with ceramic parts. The program focuses on design, fabrication, and testing of ceramic components, generating a materials properties data base, and applying life prediction and nondestructive evaluation (NDE). The development program is being performed by a team led by Solar Turbines Incorporated, and which includes suppliers of ceramic components, U.S. research laboratories and an industrial cogeneration end user. The Solar Centaur 50S engine was selected for the development program. The program goals included an increase in the turbine rotor inlet temperature (TRIT) from 1010°C (1850°F) to 1121°C (2050°F), accompanied by increases in thermal efficiency and output power. The performance improvements are attributable to the increase in TRIT and the reduction in cooling air requirements for the ceramic parts. The ceramic liners are also expected to lower the emissions of NOx and CO. Under the program uncooled ceramic blades and nozzles have been inserted for currently cooled metal components in the first stage of the gas producer turbine. The louvre-cooled metal combustor liners have been replaced with uncooled continuous-fiber reinforced ceramic composite (CFCC) liners. Modifications have been made to the engine hot section to accommodate the ceramic parts. To-date all first generation designs have been completed. Ceramic components have been fabricated, and are being tested in rigs and in the Centaur 50S engine. Field testing at an industrial co-generation site was started in May, 1997. This paper will provide an update of the development work and details of engine testing of ceramic components under the program.

CSGT: Final Design and Test of a Ceramic Hot Section

2003 ◽  
Author(s):  
Oscar Jimenez ◽  
Hamid Bagheri ◽  
John McClain ◽  
Ken Ridler ◽  
Tibor Bornemisza
Keyword(s):  
Silicon Nitride ◽  
Gas Turbines ◽  
Fuel Efficiency ◽  
Development Program ◽  
The United States ◽  
Department Of Energy ◽  
United States Department ◽  
Engine Test ◽  
Metallic Component ◽  
Ceramic Components

The Ceramic Stationary Gas Turbine (CSGT) Development Program was performed under the sponsorship of the United States Department of Energy (DOE), Office of Industrial Technologies (OIT). The goal was to improve the performance (fuel efficiency, output power, and exhaust emissions) of stationary gas turbines in cogeneration through the selective replacement of hot section metallic components with ceramic components. The team was headed by Solar Turbines Incorporated and supported by ceramic component suppliers and national research institutes. The team performed a detailed engine and component design, fabrication, and field-testing of ceramic components. This program culminated in an engine test at 1121°C (2050°F) TRIT. This was a major challenge in that the engine ran with a continuous fiber reinforced ceramic composite liner (CFCC) and with silicon nitride (Si3N4) stage one ceramic blades and nozzles. The design and testing of all three components will be discussed in this paper, with emphasis on the ceramic nozzles. Another test that will be discussed in this paper is a heavily instrumented engine test that took place prior to the test mentioned above. This instrumented engine test was performed in order to better understand the temperature effects between the ceramic and metallic component interfaces. The results from this were then used to correlate the analytical model with test data. This led to additional design changes to the outer and inner shroud ceramic / metallic interfaces, as well as ceramic nozzles, fabricated from Kyocera SN 282 silicon nitride material. These nozzle changes were then engine tested successfully for a total of 100 hours at full load [1010°C (1850°F) TRIT and 100% speed]. During the engine test, the firing temperature was increased to 1121°C (2050°F) TRIT for an adequate duration to ensure meaningful performance data were gathered.

Ceramic Stationary Gas Turbine Development Program—Fifth Annual Summary

1999 ◽  
Vol 121 (4) ◽  
pp. 586-592 ◽  
Author(s):  
J. R. Price ◽  
O. Jimenez ◽  
L. Faulder ◽  
B. Edwards ◽  
V. Parthasarathy
Keyword(s):  
Gas Turbines ◽  
Development Program ◽  
Field Testing ◽  
The United States ◽  
Turbine Rotor ◽  
Department Of Energy ◽  
Inlet Temperature ◽  
United States Department ◽  
Performance Improvements ◽  
Ceramic Components

A program is being performed under the sponsorship of the United States Department of Energy, Office of Industrial Technologies, to improve the performance of stationary gas turbines in cogeneration through the selective replacement of metallic hot section components with ceramic parts. The program focuses on design, fabrication, and testing of ceramic components, generating a materials properties data base, and applying life prediction and nondestructive evaluation (NDE). The development program is being performed by a team led by Solar Turbines Incorporated, and which includes suppliers of ceramic components, U.S. research laboratories, and an industrial cogeneration end user. The Solar Centaur 50S engine was selected for the development program. The program goals included an increase in the turbine rotor inlet temperature (TRIT) from 1010°C (1850°F) to 1121°C (2050°F), accompanied by increases in thermal efficiency and output power. The performance improvements are attributable to the increase in TRIT and the reduction in cooling air requirements for the ceramic parts. The ceramic liners are also expected to lower the emissions of NOx and CO. Under the program uncooled ceramic blades and nozzles have been inserted for currently cooled metal components in the first stage of the gas producer turbine. The louvre-cooled metal combustor liners have been replaced with uncooled continuous-fiber reinforced ceramic composite (CFCC) liners. Modifications have been made to the engine hot section to accommodate the ceramic parts. To date, all first generation designs have been completed. Ceramic components have been fabricated, and are being tested in rigs and in the Centaur 50S engine. Field testing at an industrial co-generation site was started in May, 1997. This paper will provide an update of the development work and details of engine testing of ceramic components under the program.

Ceramic Stationary Gas Turbine Development Program: Fourth Annual Summary

1997 ◽  
Author(s):  
Mark van Roode ◽  
William D. Brentnall ◽  
Kenneth O. Smith ◽  
Bryan D. Edwards ◽  
John McClain ◽  
...  
Keyword(s):  
Oil Recovery ◽  
Gas Turbines ◽  
Operating Time ◽  
Development Program ◽  
The United States ◽  
Department Of Energy ◽  
Phase Iii ◽  
United States Department ◽  
Concept Design ◽  
Engine Testing

A team led by Solar Turbines Incorporated is conducting a three phase program under the sponsorship of the United States Department of Energy, Office of Industrial Technologies, to improve the performance of stationary gas turbines in cogeneration through the selective replacement of metallic hot section components with ceramic parts. Preliminary and concept design were completed in Phase I. Detailed design, component fabrication, and rig and engine testing are all being conducted in Phase II. Field engine testing will be performed in Phase III. This review summarizes progress on Phases II and III for the program for 1996. In 1996 the primary activities involved testing of uncooled first stage silicon nitride blades and SiC/SiC CFCC liners in a Centaur 50S engine modified to accept the ceramic components. Cumulative engine test experience by the end of November, 1996 has reached 52 hrs. The longest operating time on a single engine build at full load is 16 hours. Ceramic parts were also proof tested in rigs prior to engine testing. Preparations are currently underway for a 4,000 hour field test at the enhanced oil recovery site of ARCO Western Energy in Bakersfield, California.

Ceramic Stationary Gas Turbine Development Program: Second Annual Summary

1995 ◽  
Author(s):  
Mark van Roode ◽  
William D. Brentnall ◽  
Paul F. Norton ◽  
Bryan D. Edwards
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Fatigue Testing ◽  
The United States ◽  
United States Department ◽  
Ceramic Component ◽  
Support Structure ◽  
Engine Operation ◽  
Ceramic Components ◽  
Combustor Liner

A program is being performed under the sponsorship of the United States Department of Energy, Office of Industrial Technologies, to improve the performance of stationary gas turbines in cogeneration through the selective replacement of hot section components with ceramic parts. Solar Turbines Incorporated leads a team that includes major U.S. and offshore suppliers of ceramic components, recognized test laboratories and a cogeneration enduser to develop and demonstrate ceramic insertion in a stationary gas turbine with the objectives of more efficient engine operation, resulting in significant fuel savings, increased output power, and reduced emissions. The engine selected for the program, the Centaur 50 is being retrofitted with first stage ceramic blades, first stage ceramic nozzles, and a ceramic combustor liner. The engine hot section is being redesigned to accommodate the ceramic parts to the existing metallic support structure. Detailed design of the ceramic components and of the interfacing metallic support structure has been completed. Two blade designs with different attachments and a nozzle design with a modified airfoil geometry have been developed. Three combustor liner designs are being evaluated based on monolithic tiles or rings, or integral cylinders of continuous fiber-reinforced ceramic matrix composites (CFCC). Fabrication of first generation prototype blades and nozzles is in progress. Fabrication of subscale combustor hardware has been completed. Materials property data are being gathered in support of the ceramic component design and life prediction. Fast fracture and dynamic fatigue testing were performed for the candidate blade and nozzle materials. Creep and oxidation testing is in progress. Nondestructive methodologies are being applied to test specimens, simulated components, subscale hardware and prototype components. A Centaur 50 engine was procured and has been modified for ceramic component testing in a full-size engine configuration.

Assessment of Solar Steam Injection in Gas Turbines

2016 ◽  
Author(s):  
C. Kalathakis ◽  
N. Aretakis ◽  
I. Roumeliotis ◽  
A. Alexiou ◽  
K. Mathioudakis
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Fuel Efficiency ◽  
Thermal Power ◽  
Steam Injection ◽  
Power Production ◽  
Engine Operation ◽  
Efficiency Increase ◽  
Solar Receiver ◽  
Steam Production

The concept of solar steam production for injection in a gas turbine combustion chamber is studied for both nominal and part load engine operation. First, a 5MW single shaft engine is considered which is then retrofitted for solar steam injection using either a tower receiver or a parabolic troughs scheme. Next, solar thermal power is used to augment steam production of an already steam injected single shaft engine without any modification of the existing HRSG by placing the solar receiver/evaporator in parallel with the conventional one. For the case examined in this paper, solar steam injection results to an increase of annual power production (∼15%) and annual fuel efficiency (∼6%) compared to the fuel-only engine. It is also shown that the tower receiver scheme has a more stable behavior throughout the year compared to the troughs scheme that has better performance at summer than at winter. In the case of doubling the steam-to-air ratio of an already steam injected gas turbine through the use of a solar evaporator, annual power production and fuel efficiency increase by 5% and 2% respectively.

Application of SPSLIFE to Preliminary Design Evaluation and Life Assessment of CSGT Components

1995 ◽  
Vol 117 (3) ◽  
pp. 424-431
Author(s):  
A. Saith ◽  
P. F. Norton ◽  
V. M. Parthasarathy
Keyword(s):  
Gas Turbines ◽  
Computer Code ◽  
The United States ◽  
Department Of Energy ◽  
Life Assessment ◽  
Design Evaluation ◽  
United States Department ◽  
Preliminary Design ◽  
Detail Design ◽  
Stage 1

The Ceramic Stationary Gas Turbine (CSGT) Program has utilized the SPSLIFE computer code to evaluate the preliminary design of ceramic components. The CSGT program is being performed under the sponsorship of the United States Department of Energy, Office of Industrial Technology, to improve the performance of stationary gas turbines in cogeneration through the selective replacement of hot section components with ceramic parts. Preliminary design evaluation and life assessment results are presented here for the following components: (1) Stage 1 turbine blade, (2) Stage 1 turbine nozzle, and (3) combustor inner liner. From the results of the analysis, recommendations are made for improving the life and reliability of the components. All designs were developed in Phase I (preliminary design) of the CSGT program and will be optimized in Phase II (detail design) of the program.

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