Ceramic Stationary Gas Turbine Development Program: Sixth Annual Summary

1999 ◽  
Author(s):  
Jeffrey R. Price ◽  
Oscar Jimenez ◽  
Vijay Parthasarathy ◽  
Narendernath Miriyala
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Material Selection ◽  
Field Testing ◽  
Phase Iii ◽  
Engine Test ◽  
Component Design ◽  
Ceramic Components ◽  
Wall Ceramic ◽  
Engine Testing

The Ceramic Stationary Gas Turbine (CSGT) program is being performed under the sponsorship of the United States Department of Energy, Office of Industrial Technologies. The objective of the program is to improve the performance of stationary gas turbines in cogeneration through the selective replacement of cooled metallic hot section components with uncooled ceramic parts. This review summarizes the progress on Phase III of the program which involves field testing of the ceramic components at a cogeneration end user site and characterization of the ceramic components following the field test exposure. The Solar Centaur 50S engine, which operates a turbine rotor inlet temperature (TRIT) of 1010°C (1850°F), was selected for the developmental program. The program goals include an increase in the TRIT to 1121°C (2050 °F), accompanied by increases in thermal efficiency and output power. This will be accomplished by the incorporation of uncooled ceramic first stage blades and nozzles, and a “hot wall” ceramic combustor liner. The performance improvements are attributable to the increase in TRIT and the reduction in cooling air requirements for the ceramic parts. The “hot wall” ceramic liners also enable a reduction in gas turbine emissions of NOx and CO. The component design and material selection have been definitized for the ceramic blades, nozzles and combustor liners. Each of these ceramic component designs were successfully tested in short term engine tests in the Centaur 50S engine test cell facility at Solar. Based on the results of the engine testing of the ceramic components, minor redesigns of the ceramic/metallic attachments were conducted where necessary. Based on their performance in a 100 hour cyclic in-house engine test, the ceramic components are approved for field testing. To date, four field installations of the CSGT Centaur 50S engine totaling over 4000 hours of operation have been initiated under the program at an industrial cogeneration site. This paper discusses the component design and material selection, in house engine testing, field testing, and component characterization.

Ceramic Stationary Gas Turbine Development Program: Eighth Annual Summary

2001 ◽  
Author(s):  
Jeffrey Price ◽  
Oscar Jimenez ◽  
Narendernath Miriyala ◽  
Josh B. Kimmel ◽  
Don R. Leroux ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Output Power ◽  
Thermal Efficiency ◽  
Gas Turbines ◽  
Field Testing ◽  
The United States ◽  
Phase Iii ◽  
Engine Test ◽  
Ceramic Components ◽  
Wall Ceramic

The Ceramic Stationary Gas Turbine (CSGT) program has been performed under the sponsorship of the United States Department of Energy, Office of Industrial Technologies and Office of Power Technologies. The objective of the program was to improve the performance of stationary gas turbines in cogeneration by retrofitting uncooled ceramic components into the hot section of the engine. The replacement of previously cooled metallic hot section components with the uncooled ceramics enables improved thermal efficiency, increased output power, and reduced gas turbine emissions. This review summarizes the latest progress on Phase III of the program, which involves 1) preparation for the final in-house CSGT engine test of ceramic blades, nozzles and CFCC liners, and 2) field testing of the CFCC combustor liners at two cogeneration end user sites. The field testing of CFCC combustor liners is now being performed under the Advanced Materials Program, sponsored by DOE, Office of Power Technologies. The Solar Centaur 50S engine, which operates at a turbine rotor inlet temperature (TRIT) of 1010°C, was selected for the developmental program. The program goals include an increase in the TRIT to 1121°C, accompanied by increases in thermal efficiency and output power. This is to be accomplished by the incorporation of ceramic first stage blades and nozzles, and a “hot wall” ceramic combustor liner. The performance improvements are attributable to the increase in TRIT and the reduction in cooling air requirements for the ceramic parts. The “hot wall” ceramic liners also enable a reduction in gas turbine emissions of NOx and CO. This 1121°C TRIT engine test of the ceramic hot section is planned for the first quarter of 2001. The component design and material selection have been previously definitized for the ceramic blades, nozzles and combustor liners. Each of these ceramic component designs was successfully evaluated in short-term engine tests in the Centaur 50S engine test cell facility at Solar. Environmental barrier coatings for the ceramic components are also being optimized. To date, seven field installations of the CSGT Centaur 50S engine totaling over 30,000 hours of operation have been initiated under the program at two industrial cogeneration sites. This paper briefly discusses the recent developmental efforts for the upcoming 1121°C TRIT engine test, but focuses on the various field demonstrations of CFCC combustor liners.

Ceramic Stationary Gas Turbine Development Program — Seventh Annual Summary

2000 ◽  
Author(s):  
Jeffrey Price ◽  
Oscar Jimenez ◽  
Vijay Parthasarathy ◽  
Narendernath Miriyala ◽  
Don Leroux
Keyword(s):  
Gas Turbine ◽  
Output Power ◽  
Thermal Efficiency ◽  
Gas Turbines ◽  
Field Testing ◽  
The United States ◽  
Phase Iii ◽  
Engine Test ◽  
Ceramic Components ◽  
Wall Ceramic

The Ceramic Stationary Gas Turbine (CSGT) program is being performed under the sponsorship of the United States Department of Energy, Office of Industrial Technologies. The objective of the program is to improve the performance of stationary gas turbines in cogeneration by retrofitting uncooled ceramic components into the hot section of the engine. The replacement of previously cooled metallic hot section components with the uncooled ceramics enables improved thermal efficiency, increased output power, and reduced gas turbine emissions. This review summarizes the progress on Phase III of the program, which involves field testing of the ceramic components at cogeneration end user sites. The Solar Centaur 50S engine, which operates a turbine rotor inlet temperature (TRIT) of 1010°C (1850°F), was selected for the developmental program. The program goals include an increase in the TRIT to 1121°C (2050°F), accompanied by increases in thermal efficiency and output power. This will be accomplished by the incorporation of ceramic first stage blades and nozzles, and a “hot wall” ceramic combustor liner. The performance improvements are attributable to the increase in TRIT and the reduction in cooling air requirements for the ceramic parts. The “hot wall” ceramic liners also enable a reduction in gas turbine emissions of NOx and CO. The component design and material selection have been definitized for the ceramic blades, nozzles and combustor liners. Each of these ceramic component designs was successfully tested in short term engine tests in the Centaur 50S engine test cell facility at Solar. Based on their performance in a 100 hour cyclic in-house engine test, the ceramic components were approved for field testing. Oxidation of the ceramic components in the gas turbine environment dictated the need for environmental barrier coatings, which were optimized under the program. To date, six field installations of the CSGT Centaur 50S engine totaling over 14,000 hours of operation have been initiated under the program at two industrial cogeneration sites. An 8000 hour field demonstration of a low emission ceramic combustion system was initiated in August 1999. This paper briefly discusses the recent developmental efforts for the ceramic components, but focuses on the various field demonstrations.

Ceramic Stationary Gas Turbine Development Program: Third Annual Summary

1996 ◽  
Author(s):  
Mark van Roode ◽  
William D. Brentnall ◽  
Kenneth O. Smith ◽  
Bryan D. Edwards ◽  
Leslie J. Faulder ◽  
...  
Keyword(s):  
Silicon Nitride ◽  
Gas Turbine ◽  
Phase Ii ◽  
Development Program ◽  
Full Scale ◽  
Phase Iii ◽  
Ceramic Component ◽  
Ceramic Components ◽  
Engine Testing

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. The program, currently in Phase II focuses on detailed engine and component design, ceramic component fabrication and testing, establishment of a long term materials property data base, the development of supporting nondestructive evaluation (NDE) technologies, and the application of ceramic component life prediction. A 4000 hr engine field test is planned for Phase III of the program. This paper summarizes progress from January 1995 through January 1996. First generation designs of the primary ceramic components (first stage blades and nozzles, combustor liners) for the program engine, the Solar Centaur 50S, and of the secondary metallic components interfacing with the ceramic parts were completed. The fabrication of several components has been completed as well. These components were evaluated in rigs and the Centaur 50S test engine. NTI64 (Norton Advanced Ceramics) and GN-10 (AlliedSignal Ceramic Components) silicon nitride dovetail blades were cold and hot spin tested and engine tested at the baseline nominal turbine rotor inlet temperature (TRIT) of 1010°C. Full scale SiC/SiC continuous fiber-reinforced ceramic matrix composite (CFCC) liners (B.F. Goodrich Aerospace) were also rig tested and engine tested at the nominal baseline TRIT of 1010°C. One of the engine tests, incorporating both the GN-10 blades and the full scale SiC/SiC CFCC liners, was performed for 21.5 hrs (16 hrs at 100% load) with six start/stop cycles. A cumulative 24.5 hrs of engine testing was performed at the end of January, 1996. The ceramic components were in good condition following completion of the testing. Subscale Hexoloy® SA silicon carbide (Carborundum) and enhanced SiC/SiC CFCC (DuPont Lanxide Composites) and Al2O3/Al2O3 CFCC (Babcock & Wilcox) combustor liners were tested to evaluate mechanical attachment, durability and/or emissions reduction potential. The enhanced SiC/SiC CFCC of DuPont Lanxide Composites demonstrated superior durability in subscale combustor testing and this material was subsequently selected for the fabrication of full scale combustor liners for final engine rig testing in Phase II and field testing in Phase III of the program. Enhanced SiC/SiC CFCC liners also showed significantly reduced emissions of NOx and CO when compared with conventionally cooled subscale metallic liners. This observation is believed to apply generally to “hot wall” combustor substrates. The emissions results for the enhanced SiC/SiC CFCC liners were paralleled by similar emissions levels of NOx and CO monitored during engine testing with B.F. Goodrich Aerospace SiC/SiC CFCC combustor liners. NOx levels below 25 ppmv and CO levels below 10 ppmv were measured during the engine testing. Short term (1,000 hrs) creep testing of candidate ceramic materials under approximate nozzle “hot spot” conditions was completed and long term (5000–10,000 hrs) creep testing is in progress. The selected nozzle material, SN-88 silicon nitride, has survived over 5,500 hrs at 1288°C and 186 MPa stress at the end of January, 1996.

scholarly journals Ceramic Gas Turbine Technology Development

1998 ◽  
Author(s):  
Michael L. Easley ◽  
Bjoern Schenk ◽  
Hongda Cai
Keyword(s):  
Gas Turbines ◽  
Technology Development ◽  
Scale Up ◽  
Carbon Particle ◽  
Field Testing ◽  
Impact Testing ◽  
Model Verification ◽  
Test Bed ◽  
Ceramic Components ◽  
Engine Testing

AlliedSignal Engines is addressing critical concerns slowing commercialization of structural ceramics in gas turbines. The AlliedSignal 331-200[CT] APU test bed features ceramic first-stage nozzles and blades. Fabrication of ceramic components provides manufacturing process demonstration scale-up to minimum levels for commercial viability. Endurance tests and field testing in commercial aircraft will demonstrate component reliability. Manufacturing scale-up activities showed significant progress in 1997. Subcontractors AlliedSignal Ceramic Components (CC, Torrance, CA) and Kyocera Industrial Ceramics Corporation (KICC, Vancouver, WA), transitioned process refinements to demonstration. CC initiated trial production of 100 nozzles/month. These suppliers are also developing fixed processes to fabricate ceramic integrally-bladed turbine rotors (“blisks”). Ceramic design technology advanced with carbon particle impact testing supporting impact model verification, and 300 hours successful engine testing of longer-life inserted blade attachment compliant layers. Ceramic turbine nozzles were readied for planned field demonstrations with 473 hours of engine testing. This work was funded as part of the Turbine Engine Technologies Program by the DoE Office of Transportation Technologies under Contract No. DE-AC02-96EE50454.

scholarly journals Ceramic Gas Turbine Technology Development

1999 ◽  
Author(s):  
Bjoern Schenk
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Technology Development ◽  
Scale Up ◽  
Field Testing ◽  
Turbine Rotor ◽  
Test Bed ◽  
Ceramic Components ◽  
Endurance Testing ◽  
Endurance Tests

AlliedSignal Engines is addressing the critical concerns that are slowing commercialization of structural ceramics in gas turbines. The 331-200[CT] auxiliary power unit (APU) test bed features ceramic first-stage nozzles and blades. Fabrication of ceramic components provides manufacturing process demonstration scale-up to the minimum levels needed for commercial viability. On-site endurance tests are demonstrating component reliability, and additional field testing in APUs onboard commercial aircraft and stationary industrial engines is planned. Manufacturing scale-up activities showed significant progress during 1998. Subcontractors AlliedSignal Ceramic Components (Torrance, CA) and Kyocera Industrial Ceramics Corporation (Vancouver, WA) transitioned process refinements to full demonstration. Both suppliers achieved demonstration capability of ceramic nozzle production at the rate of 100 pieces/month. These suppliers are also developing fixed processes to fabricate ceramic integrally-bladed turbine rotor disks (“blisks”). Ceramic design technology advanced, and 776 hours engine operational testing of a ceramic blisk were successfully completed. Ceramic turbine nozzles were readied for planned field demonstrations, with 2.213 hours of engine endurance testing completed. High-temperature ceramic material tests in the cyclic oxidation test rigs were initiated, to establish functional operating temperature limits for current silicon nitride materials in gas turbine environments. This work was funded as part of the Turbine Engine Technologies Program by the U.S. Dept. of Energy Office of Transportation Technologies under Contract No. DE-AC02-96EE50454.

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 Gas Turbine Technology Development

1998 ◽  
Author(s):  
Michael L. Easley ◽  
Bjoern Schenk ◽  
Hongda Cai
Keyword(s):  
Gas Turbines ◽  
Technology Development ◽  
Scale Up ◽  
Carbon Particle ◽  
Field Testing ◽  
Impact Testing ◽  
Model Verification ◽  
Test Bed ◽  
Ceramic Components ◽  
Engine Testing

AlliedSignal Engines is addressing critical concerns slowing commercialization of structural ceramics in gas turbines. The AlliedSignal 331-200[CT] APU test bed features ceramic first-stage nozzles and blades. Fabrication of ceramic components provides manufacturing process demonstration scale-up to minimum levels for commercial viability. Endurance tests and field testing in commercial aircraft will demonstrate component reliability. Manufacturing scale-up activities showed significant progress in 1997. Subcontractors AlliedSignal Ceramic Components (CC, Torrance, CA) and Kyocera Industrial Ceramics Corporation (KICC, Vancouver, WA), transitioned process refinements to demonstration. CC initiated trial production of 100 nozzles/month. These suppliers are also developing fixed processes to fabricate ceramic integrally-bladed turbine rotors (“blisks”). Ceramic design technology advanced with carbon particle impact testing supporting impact model verification, and 300 hours successful engine testing of longer-life inserted blade attachment compliant layers. Ceramic turbine nozzles were readied for planned field demonstrations with 473 hours of engine testing. This work was funded as part of the Turbine Engine Technologies Program by the DoE Office of Transportation Technologies under Contract No. DE-AC02-96EE50454.

scholarly journals Feasibility of a Helium Closed-Cycle Gas Turbine for UAV Propulsion

2020 ◽  
Vol 11 (1) ◽  
pp. 28
Author(s):  
Emmanuel O. Osigwe ◽  
Arnold Gad-Briggs ◽  
Theoklis Nikolaidis
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Pressure Ratio ◽  
Low Noise ◽  
Closed Cycle ◽  
Propulsion Systems ◽  
Component Design ◽  
Readiness Level ◽  
Aerial Vehicle ◽  
Turbine Design

When selecting a design for an unmanned aerial vehicle, the choice of the propulsion system is vital in terms of mission requirements, sustainability, usability, noise, controllability, reliability and technology readiness level (TRL). This study analyses the various propulsion systems used in unmanned aerial vehicles (UAVs), paying particular focus on the closed-cycle propulsion systems. The study also investigates the feasibility of using helium closed-cycle gas turbines for UAV propulsion, highlighting the merits and demerits of helium closed-cycle gas turbines. Some of the advantages mentioned include high payload, low noise and high altitude mission ability; while the major drawbacks include a heat sink, nuclear hazard radiation and the shield weight. A preliminary assessment of the cycle showed that a pressure ratio of 4, turbine entry temperature (TET) of 800 °C and mass flow of 50 kg/s could be used to achieve a lightweight helium closed-cycle gas turbine design for UAV mission considering component design constraints.

Some Effects of Size on the Performances of Small Gas Turbines

2003 ◽  
Author(s):  
C. Rodgers
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Engine Performance ◽  
Lessons Learned ◽  
Rapid Expansion ◽  
Cycle Performance ◽  
Frictional Drag ◽  
Component Design ◽  
Turbine Component ◽  
Performance Development

By the new millennia gas turbine technology standards the size of the first gas turbines of Von Ohain and Whittle would be considered small. Since those first pioneer achievements the sizes of gas turbines have diverged to unbelievable extremes. Large aircraft turbofans delivering the equivalent of 150 megawatts, and research micro engines designed for 20 watts. Microturbine generator sets rated from 2 to 200kW are penetrating the market to satisfy a rapid expansion use of electronic equipment. Tiny turbojets the size of a coca cola can are being flown in model aircraft applications. Shirt button sized gas turbines are now being researched intended to develop output powers below 0.5kW at rotational speeds in excess of 200 Krpm, where it is discussed that parasitic frictional drag and component heat transfer effects can significantly impact cycle performance. The demarcation zone between small and large gas turbines arbitrarily chosen in this treatise is rotational speeds of the order 100 Krpm, and above. This resurgence of impetus in the small gas turbine, beyond that witnessed some forty years ago for potential automobile applications, fostered this timely review of the small gas turbine, and a re-address of the question, what are the effects of size and clearances gaps on the performances of small gas turbines?. The possible resolution of this question lies in autopsy of the many small gas turbine component design constraints, aided by lessons learned in small engine performance development, which are the major topics of this paper.

scholarly journals Dynamic Simulation of the FT8-2™ Gas Turbine

1995 ◽  
Author(s):  
Alan Metzger
Keyword(s):  
Control System ◽  
Gas Turbine ◽  
Dynamic Simulation ◽  
Gas Turbines ◽  
Test Procedure ◽  
Clean Air Act ◽  
Commercial Production ◽  
Engine Test ◽  
Low Emission ◽  
Clean Air

With the approach of the 1990 Clean Air Act compliance limits, the race is on to produce a functional, low-emission gas turbine. While most prototype Dry Low NOx (DLN) gas turbines are based on existing designs, the leap in technology required to meet NOx abatement levels is significant. To meet these goals, significant testing is required before low-emission turbines are ready for commercial production. This paper describes the test procedure that was used to verify control system and modulating valve technology for Turbo Power & Marine’s FT8-2™ Dry Low NOx prototype turbine. In particular, dynamic turbine simulation before the actual engine test will be discussed. The method and benefits of this test procedure will be presented.

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