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 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].

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).

Second-Generation Low-Emission Combustors for ABB Gas Turbines: Tests Under Full-Engine Conditions

1990 ◽  
Author(s):  
M. Aigner ◽  
A. Mayer ◽  
P. Schiessel ◽  
W. Strittmatter
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Second Generation ◽  
Test Facility ◽  
Low Emission ◽  
Preheating Temperature ◽  
Pressure Test ◽  
Flow Pressure ◽  
Stability Limits ◽  
Experimental Rig

An experimental rig was constructed which made it possible to research the influence of air mass flow, pressure, preheating temperature, and fuel/air ratio on the behavior of a full-scale burner. Because the investigations were carried out in the high pressure test facility at the DLR in Cologne, and not in a real gas turbine, the parameters could be varied independently of one another. Based on these systematic measurements, it is possible to predict flame stability limits and emissions for any gas turbine under any operating condition. For example, it can be shown that NOx emissions from the GT8 with ABB’s new second-generation premixing burners will not exceed 25 ppm (for 15% O2) and COwet will be less than 8 ppm at full load (16 bar, 420°C). In addition, the data measured were compared to results obtained from correlations frequently used, such as that NOx is proportional to p0.5. It was shown that this equation is too optimistic even if the flame type remains unchanged.

The Design and Performance of a Reverse Flow Combustion System for the TP 500 Gas Turbine Engine

1989 ◽  
Author(s):  
E. Carr ◽  
H. Todd
Keyword(s):  
Gas Turbine ◽  
Sea Level ◽  
Reverse Flow ◽  
General Aviation ◽  
Test Facility ◽  
Spray Combustion ◽  
Combustion System ◽  
Turbine Engine ◽  
Turboprop Engine ◽  
And Performance

The TP 500 is a 525 SHP turboprop engine being produced by Teledyne Continental Motors for general aviation use. This paper describes the design and performance of the reverse flow fan spray combustion system being supplied for this engine. The main features of the design are described in some detail, together with the performance of the system as established in the combustion test facility at AIT Ltd and covering light-up to Take-Off conditions and sea level to 6km altitude.

Dry, Low Emissions for the ‘H’ Heavy-Duty Industrial Gas Turbines: Full-Scale Combustion System Rig Test Results

2003 ◽  
Author(s):  
Geoff Myers ◽  
Dan Tegel ◽  
Markus Feigl ◽  
Fred Setzer ◽  
William Bechtel ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Pressure Ratio ◽  
Combined Cycle ◽  
Full Scale ◽  
Combustion System ◽  
Heavy Duty ◽  
Test Program ◽  
Industrial Gas Turbines ◽  
Inlet Conditions

The lean, premixed DLN2.5H combustion system was designed to deliver low NOx emissions from 50% to 100% load in both the Frame 7H (60 Hz) and Frame 9H (50 Hz) heavy-duty industrial gas turbines. The H machines employ steam cooling in the gas turbine, a 23:1 pressure ratio, and are fired at 1440 C (2600 F) to deliver over-all thermal efficiency for the combined-cycle system near 60%. The DLN2.5H combustor is a modular can-type design, with 14 identical chambers used on the 9H machine, and 12 used on the smaller 7H. On a 9H combined-cycle power plant, both the gas turbine and steam turbine are fired using the 14-chamber DLN2.5H combustion system. An extensive full-scale, full-pressure rig test program developed the fuel-staged dry, low emissions combustion system over a period of more than five years. Rig testing required test stand inlet conditions of over 50 kg/s at 500 C and 28 bar, while firing at up to 1440 C, to simulate combustor operation at base load. The combustion test rig simulated gas path geometry from the discharge of the annular tri-passage diffuser through the can-type combustion liner and transition piece, to the inlet of the first stage turbine nozzle. The present paper describes the combustion system, and reports emissions performance and operability results over the gas turbine load and ambient temperature operating range, as measured during the rig test program.

Development and Application of Industrial Gas Turbines for Medium-Btu Gaseous Fuels

1986 ◽  
Vol 108 (1) ◽  
pp. 182-190 ◽  
Author(s):  
J. G. Meier ◽  
W. S. Y. Hung ◽  
V. M. Sood
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Combustion Process ◽  
Point Of View ◽  
Combustion System ◽  
Successful Development ◽  
Gaseous Fuels ◽  
Sanitary Landfills ◽  
Industrial Gas Turbines ◽  
Alternate Fuels

This paper describes the successful development and application of industrial gas turbines using medium-Btu gaseous fuels, including those derived from biodegradation of organic matters found in sanitary landfills and liquid sewage. The effects on the gas turbine and its combustion system of burning these alternate fuels compared to burning high-Btu fuels, along with the gas turbine development required to use alternate fuels from the point of view of combustion process, control system, gas turbine durability, maintainability and safety, are discussed.

Staged Combustion System for Improved Emissions Operability and Flexibility for 7HA Class Heavy Duty Gas Turbine Engine

2017 ◽  
Author(s):  
Hasan Karim ◽  
Jayaprakash Natarajan ◽  
Venkat Narra ◽  
Jun Cai ◽  
Shreekrishna Rao ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Firing Temperature ◽  
Gas Turbines ◽  
Test Facility ◽  
Engine Test ◽  
Combustion System ◽  
Operational Flexibility ◽  
Staged Combustion ◽  
Combustion Dynamics ◽  
Gas Turbine Combustion

Driven by global warming, a relentless march towards increased fuel efficiency has resulted in increased firing temperature for HA-class engines without an increase in baseload emissions. Moreover, emissions compliance for CO, NOx, and unburned hydrocarbons are desired over increased range in gas turbine load. In addition, exceptional gas turbine operational flexibility is desired to address potential intermittency due to the penetration of renewables in the electrical grid. Staged/sequential combustion is a state of the technology to provide operational flexibility and reduced emissions in power generation gas turbines. GE Power’s 7HA-class gas turbine combustion system combines GE’s proven DLN-2.6+ combustion technology, that has run reliably for over 1.3 million fired hours across more than eighty 9FA.03, 9F.05 & 7FA gas turbine engines, with an axially fuel staged system (AFS). Axially staging combustion to two zones allows for increased firing temperature at baseload (while maintaining the same NOx level) by operating the later/second stage hotter than the first/primary stage. During low load operation as the gas turbine firing temperature is reduced, percentage fuel split in the staged fuel system can either be reduced significantly or turned off and thereby keeping the overall combustion system into emissions compliance over a wider range of firing temperatures. This paper presents both the development testing of the staged combustion in the FA and HA class gas turbine combustion system rigs at GE Power’s Gas Turbine Technology Laboratory and the validation testing of staged combustion system for the 7HA.01 engine completed during Spring 2016 at GE Power’s engine test facility in Greenville, SC. The paper also discusses the significant simplification of operational principle and flexibility of startup, loading and baseload operation of the 7HA combustion system. Discussion of engine test results will show how axial fuel staging was utilized to demonstrate emissions compliance ( NOx (15% O2) < 25 ppm; CO < 9 ppm), operation from 14% load to 100% load with low combustion dynamics and also to enable wide wobbe capability, which is a normalized measure of fuel flexibility.

Field Test Validation of the DLN2.5H Combustion System on the 9H Gas Turbine at Baglan Bay Power Station

2005 ◽  
Author(s):  
Markus Feigl ◽  
Fred Setzer ◽  
Rebecca Feigl-Varela ◽  
Geoff Myers ◽  
Bryan Sweet
Keyword(s):  
Gas Turbine ◽  
Field Test ◽  
Test Performance ◽  
Gas Turbines ◽  
Combined Cycle ◽  
Combustion System ◽  
Test Program ◽  
Power Station ◽  
Industrial Gas Turbines ◽  
Characterization Test

The lean, premixed H combustion system was targeted to deliver low NOx and CO emissions from 50% to 100% combined cycle load in both the Frame 7H (60 Hz) and Frame 9H (50 Hz) heavy-duty industrial gas turbines. The H System™ is the first gas turbine combined-cycle technology capable of achieving 60% thermal efficiency. The present paper describes field test performance of the combustion system during the launch and operation of the initial MS9001H installation at Baglan Bay power station near Port Talbot, Wales. The 480 MW 9H combined cycle, fired using the 14-chamber DLN2.5H combustion system, was comprehensively evaluated during the gas turbine Characterization Test program over a period of several months in late 2002 and 2003. Results are reported for exhaust emissions, combustor component durability, operability, and other key combustion system performance parameters over the full gas turbine operating range. The present paper also describes the operability of the H combustion system throughout a rigorous validation of the power plant system, including National Grid Council testing, load rejections, and other key system transients.

Oxy-Fuel Gas Turbine, Gas Generator and Reheat Combustor Technology Development and Demonstration

2010 ◽  
Author(s):  
Roger Anderson ◽  
Fermin Viteri ◽  
Rebecca Hollis ◽  
Ashley Keating ◽  
Jonathan Shipper ◽  
...  
Keyword(s):  
Power Plant ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Clean Energy ◽  
Test Facility ◽  
Working Fluid ◽  
Capital Costs ◽  
2Nd Generation ◽  
Wide Range ◽  
And Performance

Future fossil-fueled power generation systems will require carbon capture and sequestration to comply with government green house gas regulations. The three prime candidate technologies that capture carbon dioxide (CO2) are pre-combustion, post-combustion and oxy-fuel combustion techniques. Clean Energy Systems, Inc. (CES) has recently demonstrated oxy-fuel technology applicable to gas turbines, gas generators, and reheat combustors at their 50MWth research test facility located near Bakersfield, California. CES, in conjunction with Siemens Energy, Inc. and Florida Turbine Technologies, Inc. (FTT) have been working to develop and demonstrate turbomachinery systems that accommodate the inherent characteristics of oxy-fuel (O-F) working fluids. The team adopted an aggressive, but economical development approach to advance turbine technology towards early product realization; goals include incremental advances in power plant output and efficiency while minimizing capital costs and cost of electricity [1]. Proof-of-concept testing was completed via a 20MWth oxy-fuel combustor at CES’s Kimberlina prototype power plant. Operability and performance limits were explored by burning a variety of fuels, including natural gas and (simulated) synthesis gas, over a wide range of conditions to generate a steam/CO2 working fluid that was used to drive a turbo-generator. Successful demonstration led to the development of first generation zero-emission power plants (ZEPP). Fabrication and preliminary testing of 1st generation ZEPP equipment has been completed at Kimberlina power plant (KPP) including two main system components, a large combustor (170MWth) and a modified aeroderivative turbine (GE J79 turbine). Also, a reheat combustion system is being designed to improve plant efficiency. This will incorporate the combustion cans from the J79 engine, modified to accept the system’s steam/CO2 working fluid. A single-can reheat combustor has been designed and tested to verify the viability and performance of an O-F reheater can. After several successful tests of the 1st generation equipment, development started on 2nd generation power plant systems. In this program, a Siemens SGT-900 gas turbine engine will be modified and utilized in a 200MWe power plant. Like the 1st generation system, the expander section of the engine will be used as an advanced intermediate pressure turbine and the can-annular combustor will be modified into a O-F reheat combustor. Design studies are being performed to define the modifications necessary to adapt the hardware to the thermal and structural demands of a steam/CO2 drive gas including testing to characterize the materials behavior when exposed to the deleterious working environment. The results and challenges of 1st and 2nd generation oxy-fuel power plant system development are presented.

Low NOx Lean Premix Reheat Combustion in Alstom GT24 Gas Turbines

2015 ◽  
Vol 138 (5) ◽  
Author(s):  
Daniel Guyot ◽  
Gabrielle Tea ◽  
Christoph Appel
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Fuel Injection ◽  
Test Facility ◽  
Inlet Temperature ◽  
Combustion System ◽  
Operational Flexibility ◽  
Nox Formation ◽  
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 (60 Hz) and GT26 (50 Hz), Alstom has introduced an improved sequential environmental (SEV) burner and fuel lance into its GT24 and GT26 upgrades 2011 sequential reheat combustion system. Sequential combustion is a key differentiator of Alstom GT24/GT26 engines in the F-class gas turbine market. The inlet temperature for the SEV combustor is around 1000 °C 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 toward rapid fuel/oxidant mixing for low emissions, improved fuel flexibility with regard to highly reactive fuels (higher C2+ and hydrogen content), and to sustain a wide operation window. 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 Alstom's high pressure (HP) 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 HP 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 HP tests demonstrated robust SEV burner/lance operation with up to 50% lower NOx formation and a more than 70 K 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 100 K 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).

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