Development Approach to the Dry Low Emission Combustion System of MAN Diesel and Turbo Gas Turbines

2014 ◽  
Author(s):  
Holger Huitenga ◽  
Eric R. Norster
Keyword(s):  
High Pressure ◽  
Gas Turbines ◽  
Field Tests ◽  
Test Facility ◽  
Design Parameters ◽  
Combustion System ◽  
Low Emission ◽  
Lean Premixed ◽  
Industrial Gas Turbines ◽  
Gas Pumping

The THM series of industrial gas turbines covers a power range of 6 to 12.5 MW and has been improved and uprated over many years. The majority of turbines installed are still in commercial operation and they are mainly used for compressor drives but also find generator applications. In recent years the constraints of emission legislations for new and existing gas turbines has made a development programme for a dry low emission (DLE) combustion system essential. The combustion system apart from meeting latest emission targets of 75 mg/mN3 NOx and 100 mg/mN3 CO must be suitable for both, new and retrofit engine options and therefore compact for standard enclosure installation. In addition the design should be simple and robust with the same accessibility as the existing standard combustion system. The paper describes the design and development steps to provide a prototype lean premixed DLE combustion system. The basic approach for a simple lean premixed design together with aero-thermodynamic sizing for pressure loss, flow proportions, stability and cooling is described. The initial efforts were directed to a system for the 11 MW THM 1304-11AP machine, with combustor atmospheric testing to verify design parameters and operating limits. The development was continued by subsequent high pressure testing of the prototype, starting with suitable units in the MAN engine test facility, omitting any high pressure rig tests. Field tests were carried out on a compressor drive application on a gas pumping station to prove long term durability. Adaptations of the design are now engine-tested for other THM models, even recuperated ones. Also, the combustor technology and methods developed here provide the basis for the combustors on the new MAN MGT 6100 and 6200 engines [1].

Combustion System Development and Testing for MAN’s New Industrial Gas Turbines MGT 6100 and MGT 6200

2014 ◽  
Author(s):  
Frank Reiss ◽  
Sven-Hendrik Wiers ◽  
Ulrich Orth ◽  
Emil Aschenbruck ◽  
Martin Lauer ◽  
...  
Keyword(s):  
High Pressure ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Test Facility ◽  
Combustion System ◽  
Test Rig ◽  
Low Emission ◽  
Pressure Test ◽  
Industrial Gas Turbines ◽  
And Performance

This paper describes the development and test results of the low emission combustion system for the new industrial gas turbines in the 6–7 MW class from MAN Diesel & Turbo. The design of a robust combustion system and the achievement of very low emission targets were the most important design goals of the combustor development. During the design phase, the analysis of the combustor (i.e. burner design, air distribution, liner cooling design) was supported with different CFD tools. This advanced Dry Low Emission can combustion system (ACC) consists of 6 cans mounted externally on the gas turbine. The behavior and performance of a single can sector was tested over a wide load range and with different boundary conditions; first on an atmospheric test rig and later on a high pressure test rig with extensive instrumentation to ensure an efficient test campaign and accurate data. The atmospheric tests showed a very good performance for all combustor parts and promising results. The high pressure tests demonstrated very stable behavior at all operation modes and very low emissions to satisfy stringent environmental requirements. The whole operation concept of the combustion system was tested first on the single-can high pressure test bed and later on twin and single shaft gas turbines at MAN’s gas turbine test facility. During the engine tests, the can combustors demonstrated the expected combustion performance under real operation conditions. All emissions and performance targets were fully achieved. On the single shaft engine, the combustors were running with single digit ppm NOx levels between 50% and 100% load. The validation phase and further optimization of the gas turbines and the engine components are ongoing. The highlights of the development process and results of the combustor and engine tests will be presented and discussed within this paper.

Development of a Catalytic Combustor for Industrial Gas Turbines

1994 ◽  
Author(s):  
Luke H. Cowell ◽  
Matthew P. Larkin
Keyword(s):  
Gas Turbines ◽  
Catalytic Combustion ◽  
Nox Emissions ◽  
Combustion System ◽  
Single Digit ◽  
Design Elements ◽  
Part Load ◽  
Lean Premixed ◽  
Industrial Gas Turbines ◽  
Load Conditions

A catalytic combustion system for advanced industrial gas turbines is under long tern development employing recent advances in catalyst and materials technologies. Catalytic combustion is a proven means of burning fuel with single digit NOx emissions levels. However, this technology has yet to be considered for production in an industrial gas turbine for a number of reasons including: limited catalyst durability, demonstration of a system that can operate over all loads and ambient conditions, and market and cost factors. The catalytic combustion system will require extensive modifications to production gas turbines including fuel staging and variable geometry. The combustion system is composed of five elements: a preheat combustor, premixer, catalyst bed, part load injector and post-catalyst combustor. The preheat combustor operates in a lean premixed mode and is used to elevate catalyst inlet air and fuel to operating temperature. The premixer combines fuel and air into a uniform mixture before entering the catalyst. The catalyst bed initiates the fuel-air reactions, elevating the mixture temperature and partially oxidizing the fuel. The part load injector is a lean premixed combustor system that provides fuel and air to the post-catalyst combustor. The post-catalyst combustor is the volume downstream of the catalyst bed where the combustion reactions are completed. At part load conditions a conventional flame bums in this zone. Combustion testing is on-going in a subscale rig to optimize the system and define operating limits. Short duration rig testing has been completed to 9 atmospheres pressure with stable catalytic combustion and NOx emissions down to the 5 ppmv level. Testing was intended to prove-out design elements at representative full load engine conditions. Subscale combustion testing is planned to document performance at part-load conditions. Preliminary full-scale engine design studies are underway.

scholarly journals Combustion-System Design for Industrial Gas Turbines

1964 ◽  
Author(s):  
R. E. Strong ◽  
C. E. Hussey
Keyword(s):  
System Design ◽  
Gas Turbines ◽  
Field Tests ◽  
Combustion System ◽  
Discharge Temperature ◽  
Industrial Gas Turbines

Some of the problems encountered in combustion-system design are discussed with particular attention to combustor discharge-temperature patterns. The results of extensive laboratory and field tests that culminated in improved temperature patterns are presented.

Low NOx SEV Lean Premix Reheat Combustion in Alstom GT24 Gas Turbines

2015 ◽  
Author(s):  
Daniel Guyot ◽  
Gabrielle Tea ◽  
Christoph Appel
Keyword(s):  
High Pressure ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Fuel Injection ◽  
Test Facility ◽  
Inlet Temperature ◽  
Combustion System ◽  
Operational Flexibility ◽  
Term Operation ◽  
Fuel Flexibility

Reducing gas turbine emissions and increasing their operational flexibility are key targets in today’s gas turbine market. In order to further reduce emissions and increase the operational flexibility of its GT24 (60Hz) and GT26 (50Hz), Alstom has introduced an improved SEV burner and fuel lance into its GT24 upgrade 2011 and GT26 upgrade 2011 sequential reheat combustion system. Sequential combustion is a key differentiator of Alstom GT24 engines in the F-class gas turbine market. The inlet temperature for the GT24 SEV combustor is around 1000 degC and reaction of the fuel/oxidant mixture is initiated through auto-ignition. The recent development of the Alstom sequential combustion system is a perfect example of evolutionary design optimizations and technology transfer between Alstom GT24 and GT26 engines. Better overall performance is achieved through improved SEV burner aerodynamics and fuel injection, while keeping the main features of the sequential burner technology. The improved SEV burner/lance concept has been optimized towards rapid fuel/oxidant mixing for low emissions, improved fuel flexibility with regards to highly reactive fuels (higher C2+ and hydrogen content), and to sustain a wide operation window. In addition, the burner front panel features an improved cooling concept based on near-wall cooling as well as integrated acoustics damping devices designed to reduce combustion pulsations thus extending the SEV combustor’s operation window even further. After having been validated extensively in the Alstom high pressure sector rig test facility, the improved GT24 SEV burner has been retrofitted into a commercial GT24 field engine for full engine validation during long-term operation. This paper presents the obtained high pressure sector rig and engine validation results for the GT24 (2011) SEV burner/lance hardware with a focus on reduced NOX and CO emissions and improved operational behavior of the SEV combustor. The high pressure tests demonstrated robust SEV burner/lance operation with up to 50% lower NOX formation and a more than 70K higher SEV burner inlet temperature compared to the GT24 (2006) hardware. For the GT24 engine with retrofitted upgrade 2011 SEV burner/lance all validation targets were achieved including an extremely robust operation behavior, up to 40% lower GT NOX emissions, significantly lower CO emissions at partload and baseload, a very broad operation window (up to 100K width in SEV combustor inlet temperature) and all measured SEV burner/lance temperatures in the expected range. Sector rig and engine validation results have confirmed the expected SEV burner fuel flexibility (up to 18%-vol. C2+ and up to 5%-vol. hydrogen as standard).

Condition Monitoring of Combustion System on Industrial Gas Turbines Based on Trend and Noise Analysis

2017 ◽  
Author(s):  
Yu Zhang ◽  
Miguel Martínez-García ◽  
Mike Garlick ◽  
Anthony Latimer ◽  
Samuel Cruz-Manzo
Keyword(s):  
Condition Monitoring ◽  
Gas Turbines ◽  
Noise Analysis ◽  
Warning System ◽  
The Other ◽  
Training Data ◽  
Combustion System ◽  
Industrial Gas Turbines ◽  
Industrial Level ◽  
Experimental Trials

In this paper, a scheme of an ‘early warning’ system is developed for the combustion system of Industrial Gas Turbines (IGTs), which attains low computational workload and simple programming requirements, being therefore employable at an industrial level. The methodology includes trend analysis, which examines when the measurement shows different trends from the other measurements in the sensor group, and noise analysis, which examines when the measurement is displaying higher levels of noise compared to those of the other sensors. In this research, difficulties encountered by other data-driven methods due to temperature varying with load conditions of the IGT’s have also been overcome by the proposed approach. Furthermore, it brings other advantages, for instance, no historic training data is needed, and there is no requirement to set thresholds for each sensor in the system. The efficacy and effectiveness of the proposed approach has been demonstrated through experimental trials of previous pre-chamber burnout cases. And the resulting outcomes of the scheme will be of interest to IGT companies, especially in condition monitoring of the combustion system. Future work and possible improvements are also discussed at the end of the paper.

Experimental and Numerical Investigation of Fuel–Air Mixing in a Radial Swirler Slot of a Dry Low Emission Gas Turbine Combustor

2015 ◽  
Vol 138 (6) ◽  
Author(s):  
Festus Eghe Agbonzikilo ◽  
Ieuan Owen ◽  
Jill Stewart ◽  
Suresh Kumar Sadasivuni ◽  
Mike Riley ◽  
...  
Keyword(s):  
Experimental Data ◽  
Large Scale ◽  
Experimental Studies ◽  
Flux Ratio ◽  
Turbulence Models ◽  
Test Facility ◽  
Combustion System ◽  
Fuel Gas ◽  
Low Emission ◽  
Air Mixing

This paper presents the results of an investigation in which the fuel/air mixing process in a single slot within the radial swirler of a dry low emission (DLE) combustion system is explored using air/air mixing. Experimental studies have been carried out on an atmospheric test facility in which the test domain is a large-scale representation of a swirler slot from a Siemens proprietary DLE combustion system. Hot air with a temperature of 300 °C is supplied to the slot, while the injected fuel gas is simulated using air jets with temperatures of about 25 °C. Temperature has been used as a scalar to measure the mixing of the jets with the cross-flow. The mixture temperatures were measured using thermocouples while Pitot probes were used to obtain local velocity measurements. The experimental data have been used to validate a computational fluid dynamics (CFD) mixing model. Numerical simulations were carried out using CFD software ansys-cfx. Due to the complex three-dimensional flow structure inside the swirler slot, different Reynolds-averaged Navier–Stokes (RANS) turbulence models were tested. The shear stress transport (SST) turbulence model was observed to give best agreement with the experimental data. The momentum flux ratio between the main air flow and the injected fuel jet, and the aerodynamics inside the slot were both identified by this study as major factors in determining the mixing characteristics. It has been shown that mixing in the swirler can be significantly improved by exploiting the aerodynamic characteristics of the flow inside the slot. The validated CFD model provides a tool which will be used in future studies to explore fuel/air mixing at engine conditions.

7H™ Combustion System Performance With Fuel Moisturization

2006 ◽  
Author(s):  
Markus Feigl ◽  
Geoff Myers ◽  
Stephen R. Thomas ◽  
Raub Smith
Keyword(s):  
Gas Turbines ◽  
Combined Cycle ◽  
Combustion System ◽  
Heavy Duty ◽  
Single Digit ◽  
Efficiency Performance ◽  
Industrial Gas Turbines ◽  
Industrial Gas Turbine ◽  
Cycle Efficiency ◽  
Full Pressure

This paper describes the concept and benefits of the fuel moisturization system for the GE H System™ steam-cooled industrial gas turbine. The DLN2.5H combustion system and fuel moisturization system are both described, along with the influence of fuel moisture on combustor performance as measured during full-scale, full-pressure rig testing of the DLN2.5H combustion system. The lean, premixed DLN2.5H combustion system was targeted to deliver single-digit NOx and CO emissions from 40% to 100% combined cycle load in both the Frame 7H (60 Hz) and Frame 9H (50 Hz) heavy-duty industrial gas turbines. These machines are also designed to yield a potential combined-cycle efficiency of 60 percent or higher. Fuel moisturization contributes to the attainment of both the NOx and the combined-cycle efficiency performance goals, as discussed in this paper.

scholarly journals Variable Geometry Fuel Injector for Low Emissions Gas Turbines

1999 ◽  
Author(s):  
K. Smith ◽  
R. Steele ◽  
J. Rogers
Keyword(s):  
Gas Turbines ◽  
Field Tests ◽  
Flow Distribution ◽  
Operating Conditions ◽  
Variable Geometry ◽  
Fuel Injector ◽  
System Variable ◽  
Lean Premixed Combustion ◽  
Stable Operating ◽  
Lean Premixed

To extend the stable operating range of a lean premixed combustion system, variable geometry can be used to adjust the combustor air flow distribution as gas turbine operating conditions vary. This paper describes the design and preliminary testing of a lean premixed fuel injector that provides the variable geometry function. Test results from both rig and engine evaluations using natural gas are presented. The variable geometry injector has proven successful in the short-term testing conducted to date. Longer term field tests are planned to demonstrate durability.

scholarly journals Impact of a Cooled Cooling Air System on the External Aerodynamics of a Gas Turbine Combustion System

2017 ◽  
Vol 139 (5) ◽  
Author(s):  
A. Duncan Walker ◽  
Bharat Koli ◽  
Liang Guo ◽  
Peter Beecroft ◽  
Marco Zedda
Keyword(s):  
Gas Turbines ◽  
Pressure Loss ◽  
Total Pressure ◽  
Outer Wall ◽  
Total Pressure Loss ◽  
Test Facility ◽  
Combustion System ◽  
Air System ◽  
External Aerodynamics ◽  
Cooling Air

To manage the increasing turbine temperatures of future gas turbines a cooled cooling air system has been proposed. In such a system some of the compressor efflux is diverted for additional cooling in a heat exchanger (HX) located in the bypass duct. The cooled air must then be returned, across the main gas path, to the engine core for use in component cooling. One option is do this within the combustor module and two methods are examined in the current paper; via simple transfer pipes within the dump region or via radial struts in the prediffuser. This paper presents an experimental investigation to examine the aerodynamic impact these have on the combustion system external aerodynamics. This included the use of a fully annular, isothermal test facility incorporating a bespoke 1.5 stage axial compressor, engine representative outlet guide vanes (OGVs), prediffuser, and combustor geometry. Area traverses of a miniature five-hole probe were conducted at various locations within the combustion system providing information on both flow uniformity and total pressure loss. The results show that, compared to a datum configuration, the addition of transfer pipes had minimal aerodynamic impact in terms of flow structure, distribution, and total pressure loss. However, the inclusion of prediffuser struts had a notable impact increasing the prediffuser loss by a third and consequently the overall system loss by an unacceptable 40%. Inclusion of a hybrid prediffuser with the cooled cooling air (CCA) bleed located on the prediffuser outer wall enabled an increase of the prediffuser area ratio with the result that the system loss could be returned to that of the datum level.

Development of a Three-Staged Low Emissions Combustor for Industrial Small-Size Gas Turbines

1999 ◽  
Author(s):  
Hiroshi Sato ◽  
Toshiji Amano ◽  
Yoshihiro Iiyama ◽  
Masaaki Mori ◽  
Tsuneaki Nakamura
Keyword(s):  
Gas Turbines ◽  
Gas Flow ◽  
Superior Performance ◽  
Staged Combustion ◽  
Engine Operation ◽  
Fuel Gas ◽  
Low Emission ◽  
Lean Premixed ◽  
Development Temperature ◽  
Combustor Liner

This paper describes the development of an ultra-low emission single-can combustor applicable to 200 kW to 3 MW size natural gas-driven gas turbines for cogeneration systems. The combustor, called a three-staged combustor, was designed by applying the theory of lean premixed staged combustion. The combustor comprises two sets of premixing injector tubes located around the combustor liner downstream of the premixing nozzle equipped with a pilot diffusion nozzle in the center. The combustor controls engine output solely by varying the fuel gas flow without the need for complex variable geometry, such as inlet guide vanes, for combustion airflow control. Reliability, response to load variation and retrofit capability have been greatly improved along with wide low-emission operating range. As the result of the atmospheric rig tests, the three-staged combustor has demonstrated superior performance of 3.5 ppm NOx (O2 = 15%) and 7 ppm CO (O2 = 15%) at full load. Assuming the relationship between NOx emission and pressure and taking into account sequential CO oxidation occurring in the scroll, the performance of the combustor at engine operation is expected to be less than 9 ppm NOx (O2 = 15%) and 50 ppm CO (O2 = 15%) emissions between 25% and 100% engine load. During the development, temperature distribution in the atmospheric combustion was measured in detail to gain comprehensive understanding of the low emissions combustion phenomena. The results of the measurement were compared with the theory of lean premixed staged combustion. Employing the concept of effective mixing ratio, the theory of lean premixed staged combustion has proved to be a powerful method to design a lean premixed staged combustor.

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