MS5002C and D “Power Crystal™ Kit” Heavy Duty Gas Turbine Development and Operating Experience

2012 ◽  
Author(s):  
Paolo Del Turco ◽  
Michele D’Ercole ◽  
Ahmed Ossama Fouad ◽  
Riccardo Carta ◽  
Alessandro Russo ◽  
...  
Keyword(s):  
High Pressure ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Energy Demand ◽  
Operating Experience ◽  
Development Program ◽  
Heavy Duty ◽  
High Pressure Turbine ◽  
Initial Field ◽  
Turbine Wheel

Given the constant increase in world energy demand, gas turbine operators are continuously looking for turbo-machinery improvements, both in terms of increased power and extended maintenance intervals, limiting, as much as possible, the downtime for upgrading. In 2006, GE Oil & Gas engineers launched the Power Crystal™ development program to enhance the output power or extend the maintenance interval of the MS5002C and D heavy duty gas turbines. This effort resulted in an upgrade kit potentially to be installed during a standard major inspection, which include a single crystal material 1st stage high pressure turbine blade and additional improvements, such as new coatings for combustor hardware and improved cooling of the 1st stage high pressure turbine nozzle and 1st stage high pressure turbine wheel. The upgrade kit was validated through an extensive test campaign, which included test-rig component tests in advance of the First Engine to Test (FETT). All critical-to-quality parameters of the gas turbine were investigated, such as turbine gas path component temperatures and stresses, performance and operability. This paper describes the background for the upgrade, discusses the new kit features, how the test program was built and conducted, and reports the experience accumulated on the gas turbine during the initial field operation.

Development and Testing of the Upgraded High Pressure Turbine Section for an Industrial Gas Turbine

2008 ◽  
Author(s):  
E. Aschenbruck ◽  
D. Frank ◽  
T. Korte ◽  
R. Mu¨ller ◽  
U. Orth
Keyword(s):  
High Pressure ◽  
Gas Turbine ◽  
Cooling System ◽  
Mechanical Design ◽  
Development Program ◽  
Tip Clearance ◽  
Test Facility ◽  
High Pressure Turbine ◽  
Online Data ◽  
Clearance Control

As part of an ongoing development program to increase power output and efficiency of the THM 1304 gas turbine, modifications were made to the high pressure turbine. The modifications include but are not limited to blade and vane aerodynamics, cooling system and clearance control, mechanical design and materials. The development was to achieve the following goals: • Intensified blade and vane cooling to permit higher turbine inlet temperatures and to further extend service lifetime; • Improved aerodynamic performance; • Blades with pre-loaded tip shrouds to achieve low vibration amplitudes in a broad operating speed range; • Rotor design modifications to simplify assembly and disassembly; • Modified vane carrier and casing designs for optimal tip clearance control and turbine performance. The improved high pressure turbine was extensively tested in MAN TURBO’s full-load gas turbine test facility. Test results verified that component temperatures were within the expected range and design targets have been achieved. The first production gas turbine equipped with the upgraded high pressure turbine was installed in May 2004 as a gas compressor driver. To date a total of 11 units have gone into operation including units for power generation. Dry low emission technology is used on all engines. Every unit is monitored by an online data monitoring system and visually inspected in shorter intervals to verify the behavior in the field. Operation of the fleet is flawless at this time.

Aerodynamic Optimization of High Pressure Turbine and Interstage Duct in a Two-Stage Air System for a Heavy-Duty Diesel Engine

2017 ◽  
Author(s):  
Uswah Khairuddin ◽  
Aaron W. Costall
Keyword(s):  
High Pressure ◽  
Diesel Engine ◽  
Operating Point ◽  
Heavy Duty ◽  
Aerodynamic Optimization ◽  
High Pressure Turbine ◽  
Two Stage ◽  
Turbine Wheel ◽  
Heavy Duty Diesel Engine ◽  
Heavy Duty Diesel

Turbochargers are a key technology for reducing the fuel consumption and CO2 emissions of heavy-duty internal combustion engines by enabling greater power density, which is essential for engine downsizing and downspeeding. This in turn raises turbine expansion ratio levels and drives the shift to air systems with multiple stages, which also implies the need for interconnecting ducting, all of which is subject to tight packaging constraints. This paper considers the challenges in the aerodynamic optimization of the exhaust side of a two-stage air system for a Caterpillar 4.4-litre heavy-duty diesel engine, focusing on the high pressure turbine wheel and interstage duct. Using the current production designs as a baseline, a genetic algorithm-based aerodynamic optimization process was carried out separately for the wheel and duct components in order to minimize the computational effort required to evaluate seven key operating points. While efficiency was a clear choice for the cost function for turbine wheel optimization, the most appropriate objective for interstage duct optimization was less certain, and so this paper also explores the resulting effect of optimizing the duct design for different objectives. Results of the optimization generated differing turbine wheel and interstage duct designs depending on the corresponding operating point, thus it was important to check the performance of these components at every other operating point, in order to determine the most appropriate designs to carry forward. Once the best compromise high pressure turbine wheel and interstage duct designs were chosen, prototypes of both were manufactured and then tested together against the baseline designs to validate the CFD predictions. The best performing high pressure turbine design, wheel A, was predicted to show an efficiency improvement of 2.15 percentage points, for on-design operation. Meanwhile, the optimized interstage duct contributed a 0.2 and 0.5 percentage-point efficiency increase for the high and low pressure turbines, respectively.

Operating Experience in Refinery Application of the 13MW-Class Heavy Duty MF-111 Gas Turbine Engine

1990 ◽  
Author(s):  
J. Masada ◽  
I. Fukue
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Operating Experience ◽  
Combined Cycle ◽  
Outlet Temperature ◽  
Heavy Duty ◽  
Turbine Engine ◽  
Industrial Gas Turbines ◽  
Heavy Duty Gas Turbine ◽  
Temperature Levels

A new, 13MW class, heavy duty gas turbine, the “MF-111” was developed for use as a prime mover for cogeneration, combined cycle and repowering applications. The use of such equipment in refineries presents special challenges as regards the combustion of nonstandard fuels, tolerance of industrial environments, and accomodation of site-specific design requirements. Such circumstances add substantially to the tasks of proving and adjusting the design of a new gas turbine, meeting stringent emissions requirements and introducing to the world of industrial gas turbines the benefits of F-class (1250°C burner outlet temperature) levels of thermodynamic performance. This paper describes how these challenges have successfully been met during the three calendar years and ten machine-years of MF-111 refinery-application experience accumulated to-late.

Combustion Hardware Extendor Kit III Enhancement Kit for MS5002C and D Heavy Duty Gas Turbine for Oil and Gas Applications

2011 ◽  
Author(s):  
Gianni Ceccherini ◽  
Eugenio Del Puglia ◽  
Michele Provenzale ◽  
Francesco Mastromatteo ◽  
Filippo Cappuccini ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Design Process ◽  
Gas Turbines ◽  
Energy Demand ◽  
Failure Modes ◽  
Oil And Gas ◽  
Production Costs ◽  
Strong Impact ◽  
Heavy Duty ◽  
Continuous Increase

The continuous increase of both energy demand and oil and gas prices has driven gas turbine operators to seek improvements in both the durability and performances of their machines. The maintenance interval still represents one of the most critical issues related to durability and has a strong impact on production costs, especially in oil and gas applications. To address this issue, specific development programs were introduced by GE Oil & Gas, aimed at extending the mean time between maintenance (MTBM) of its entire heavy-duty fleet. These programs basically consist of identifying the most probable failure modes, strategies to remedy problems and finally delivering new technology. The success of such programs starts with the introduction of the new product, after it has gone through a rigorous and well-proven design process which includes conceptual, preliminary and detailed design reviews. Due to both high temperature environment and combustion dynamic frequencies, the combustor hardware is prone to different failure modes, limiting, in some cases, the MTBM to a relatively small number of hours. This paper describes the design process followed to deliver Extendortm III, which is a modification kit for the LHE (Lean Head End) combustion system of the MS5002C & D heavy duty gas turbines, aimed at enhancing MTBM. The development strategy is described in detail and the results of numerical dynamic analyses and validation testing are shown.

A Higher Turndown Flexibility on AE64.3A Gas Turbine: Design and Operating Experience

2011 ◽  
Author(s):  
Federico Bonzani ◽  
Luca Bozzi ◽  
Alessia Bulli ◽  
Andrea Silingardi ◽  
Domenico Zito
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Energy Demand ◽  
Power Plants ◽  
Operating Experience ◽  
Maintenance Cost ◽  
Power Demand ◽  
Service Market ◽  
Low Load ◽  
Base Load

Italian power generation market is living today a period of substantial changes due to the liberalization process, climate issues, natural gas price fluctuation and the uncertain future of nuclear and coal. In this framework, many gas turbine power plants, originally designed to operate mainly at base load, feel the necessity to be flexibly and profitably operated into the dispatch and ancillary energy service market. In particular, many operators ask for the possibility to operate their gas turbines intermittently, frequently cycling and quickly ramping up and down to satisfy energy demand. Such using drafts new trade off between profitability and maintenance cost. From this point of view it’s not unusual to shut down the engine when the power demand is low if the unit cannot be cost effectively parked at a suitable low load and then quickly ramped up to base load when the power demand is higher. The main barrier against lowering the minimum load of the gas turbines is the increase of the CO emission. When the engine operates close to its turndown load the compressor airflow is such that the heat released by the flame cannot properly support the conversion of CO into CO2. In such a condition, the power plant will not comply with the environmental legislation and must be operated at a higher load or, worse, shut down. An operating strategy has been devised to face up such problem. It is based on the adjustment of compressor IGV (Inlet Guide Vanes) and the optimisation of cooling air consumption in order to keep the proper amount of combustion air close to the turndown load. This paper shows the feasibility check, the installation and final field tests of the low load turndown upgrade on a AE64.3A gas turbine which allowed to operate the unit in a more cost effective way even when the power demand is low.

Marine Gas Turbines in the Royal Navy 1978–1979

1980 ◽  
Author(s):  
J. M. Kingsland
Keyword(s):  
Gas Turbine ◽  
Health Monitoring ◽  
Gas Turbines ◽  
Operating Experience ◽  
Development Program ◽  
Life Extension ◽  
Royal Navy

The gas turbine is rapidly becoming the dominant means of propulsion in surface ships of the Royal Navy, as more ships of existing classes are built and as new gas turbine ships come into service. The paper describes recent operating experience, and the introduction of the uprated RM1 C Tyne engine to service. The principles of upkeep, engine health monitoring, and life extension being followed by the Royal Navy are discussed. The paper includes a review of the progress of the development program for the SM1 A Marine Spey engine for ships of the Royal Navy in the 1980s.

Aerodynamic Optimization of the High Pressure Turbine and Interstage Duct in a Two-Stage Air System for a Heavy-Duty Diesel Engine

2017 ◽  
Vol 140 (5) ◽  
Author(s):  
Uswah B. Khairuddin ◽  
Aaron W. Costall
Keyword(s):  
High Pressure ◽  
Diesel Engine ◽  
Heavy Duty ◽  
Aerodynamic Optimization ◽  
High Pressure Turbine ◽  
Two Stage ◽  
Turbine Wheel ◽  
Heavy Duty Diesel Engine ◽  
Heavy Duty Diesel ◽  
Engine Operating Point

Turbochargers reduce fuel consumption and CO2 emissions from heavy-duty internal combustion engines by enabling downsizing and downspeeding through greater power density. This requires greater pressure ratios and thus air systems with multiple stages and interconnecting ducting, all subject to tight packaging constraints. This paper considers the aerodynamic optimization of the exhaust side of a two-stage air system for a Caterpillar 4.4 l heavy-duty diesel engine, focusing on the high pressure turbine (HPT) wheel and interstage duct (ISD). Using current production designs as a baseline, a genetic algorithm (GA)-based aerodynamic optimization process was carried out separately for the wheel and duct components to evaluate seven key operating points. While efficiency was a clear choice of cost function for turbine wheel optimization, different objectives were explored for ISD optimization to assess their impact. Optimized designs are influenced by the engine operating point, so each design was evaluated at every other engine operating point, to determine which should be carried forward. Prototypes of the best compromise high pressure turbine wheel and ISD designs were manufactured and tested against the baseline to validate computational fluid dynamics (CFD) predictions. The best performing high pressure turbine design was predicted to show an efficiency improvement of 2.15% points, for on-design operation. Meanwhile, the optimized ISD contributed a 0.2% and 0.5% point efficiency increase for the HPT and low pressure turbine (LPT), respectively.

The ultra-high efficiency gas turbine engine, UHEGT, part I: Design and numerical analysis of the multistage system

2020 ◽  
pp. 095765092095166
Author(s):  
Seyed M Ghoreyshi ◽  
Meinhard T Schobeiri
Keyword(s):  
High Pressure ◽  
Gas Turbine ◽  
Gas Turbines ◽  
High Efficiency ◽  
Combustion Process ◽  
Gas Turbine Engine ◽  
High Pressure Turbine ◽  
Turbine Engine ◽  
Gaseous Fuels ◽  
Multi Stage

The Ultra-High Efficiency Gas Turbine Engine (UHEGT) was introduced in our previous studies. In UHEGT, the combustion process is no longer contained in isolation between the compressor and turbine. It is rather distributed in multiple stages and integrated within the high-pressure turbine stator rows. Compared to the current most advanced conventional gas turbines, UHEGT considerably improves the efficiency and output power of the engine while reducing its emissions and size. In this study, a six-stage UHEGT turbine with three stages of stator internal combustion is designed and analyzed. The design represents a single spool turboshaft system for power generation using gaseous fuels. The preliminary flow path for each turbine stage is designed by the meanline approach and modified using Computational Fluid Dynamics (CFD). Unsteady CFD calculation (via commercial software ANSYS CFX) is used to simulate and optimize the flow and combustion process through high-pressure turbine stages. The results show a base thermal efficiency of above 45% is achieved. It shows a successful integration of the multi-stage combustion process into the high-pressure turbine stages and a highly uniform temperature distribution at the inlet of each rotor row. High temperatures in some areas on the stator blade surfaces are controlled using indexing of fuel injectors and stator blades.

scholarly journals Investigation of Failure in Gas Turbines: Part 2 — Engineering and Metallographic Aspects of Failure Investigation

1993 ◽  
Author(s):  
Robert E. Dundas
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Heavy Duty ◽  
Metallographic Examination ◽  
Fracture Surfaces ◽  
Failure Investigation ◽  
Materials Used ◽  
Component Failures

This paper opens with a discussion of the various mechanisms of cracking and fracture encountered in gas turbine failures, and discusses the use of metallographic examination of crack and fracture surfaces. The various types of materials used in the major components of heavy-duty industrial and aeroderivative gas turbines are tabulated. A collection of macroscopic and microscopic fractographs of the various mechanisms of failure in gas turbine components is then presented for reference in failure investigation. A discussion of compressor damage due to surge, as well as some overall observations on component failures, follows. Finally, a listing of the most likely types of failure of the various major components is given.

A Comparison Between ORC and Supercritical CO2 Bottoming Cycles For Energy Recovery From Industrial Gas Turbines Exhaust Gas

2021 ◽  
Author(s):  
M. A. Ancona ◽  
M. Bianchi ◽  
L. Branchini ◽  
A. De Pascale ◽  
F. Melino ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Thermal Efficiency ◽  
Gas Turbines ◽  
Supercritical Co2 ◽  
Energy Demand ◽  
Oil And Gas ◽  
Gas Production ◽  
Medium Size ◽  
Oil And Gas Production ◽  
Industrial Gas Turbines

Abstract Gas turbines are often employed in the industrial field, especially for remote generation, typically required by oil and gas production and transport facilities. The huge amount of discharged heat could be profitably recovered in bottoming cycles, producing electric power to help satisfying the onerous on-site energy demand. The present work aims at systematically evaluating thermodynamic performance of ORC and supercritical CO2 energy systems as bottomer cycles of different small/medium size industrial gas turbine models, with different power rating. The Thermoflex software, providing the GT PRO gas turbine library, has been used to model the machines performance. ORC and CO2 systems specifics have been chosen in line with industrial products, experience and technological limits. In the case of pure electric production, the results highlight that the ORC configuration shows the highest plant net electric efficiency. The average increment in the overall net electric efficiency is promising for both the configurations (7 and 11 percentage points, respectively if considering supercritical CO2 or ORC as bottoming solution). Concerning the cogenerative performance, the CO2 system exhibits at the same time higher electric efficiency and thermal efficiency, if compared to ORC system, being equal the installed topper gas turbine model. The ORC scarce performance is due to the high condensing pressure, imposed by the temperature required by the thermal user. CO2 configuration presents instead very good cogenerative performance with thermal efficiency comprehended between 35 % and 46 % and the PES value range between 10 % and 22 %. Finally, analyzing the relationship between capital cost and components size, it is estimated that the ORC configuration could introduce an economical saving with respect to the CO2 configuration.

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