Baseline Airfoil Cooling Designs for a 5-10 MW Combined Heat and Power Turbine Application

2021 ◽  
Author(s):  
Doug Straub ◽  
Sridharan Ramesh ◽  
Matthew Searle ◽  
Arnab Roy ◽  
James Black
Keyword(s):  
Gas Turbines ◽  
Leading Edge ◽  
Combined Heat And Power ◽  
Economic Benefits ◽  
Department Of Energy ◽  
Internal Cooling ◽  
Power Turbine ◽  
Industrial Gas Turbines ◽  
Primary Focus ◽  
Conventional Cooling

Abstract Industrial gas turbines are commonly used in steam combined heat and power (CHP) applications. Combined heat and power applications have significant environmental and economic benefits that are consistent with the goals of the U.S. Department of Energy. One area that is currently being studied includes the potential benefits of CHP turbine operation at higher turbine inlet temperatures. Although these benefits will be described briefly in this paper, the primary focus will address a means to achieve these performance benefits through improvements in airfoil cooling. Specifically, internal cooling concepts enabled by additive and hybrid manufacturing are of primary interest. This paper will describe the conventional cooling technologies that have been identified after a thorough review of public literature as a baseline for more detailed analysis and future testing. This effort is unique because the cooling features (i.e., leading edge, mid-chord, and trailing edge) are integrated together within an airfoil of realistic scale. The engineering models that have been developed to characterize the cooling performance for these baseline configurations will be described. It is believed that the cooling designs described in this paper are representative of gas turbines in the 5–10 MWe size range, but not identical to any commercial product. The present effort to establish a state-of-the-art cooling scheme is a first, and necessary, step in an on-going project to identify and test more advanced cooling concepts for CHP systems that are enabled by additive manufacturing.

Comparing Turbine Gaspath Component Alternatives

2004 ◽  
Author(s):  
Fred T. Willett ◽  
Rodger O. Anderson ◽  
Michael R. Pothier
Keyword(s):  
Gas Turbines ◽  
Economic Benefits ◽  
Risk Tolerance ◽  
Engineering Process ◽  
Plant Operator ◽  
Engineering Approach ◽  
Industrial Gas Turbines ◽  
Potential Benefits ◽  
Power Plant Operator ◽  
Base Load

The large installed base of large frame industrial gas turbines has prompted a number of replacement part offerings, in addition to the replacement parts offered by the OEM. The quality and rigor of the offerings varies considerably. The replacement parts can be broken down into three categories: replicated parts, reverse-engineered parts, and re-engineered parts. The processes of replication, reverse engineering, and re-engineering are examined in detail. Specific differences between the three approaches are identified and discussed. The economic model presented by Willett and Pothier [2003] is used to examine the potential economic benefits of replacement parts and quantify differences in potential benefits as a function of engineering approach. The benefits of each approach depend not only on the engineering process, but also on the customer (power plant operator) profile. Base load, cyclic duty, and peaking operation, along with risk tolerance, influence the predicted benefit and determine the most effective engineering approach.

Advanced Thermochemical Cleaning Procedures for Structural Braze Repair Techniques

2002 ◽  
Author(s):  
Alexander Stankowski
Keyword(s):  
High Temperature ◽  
Gas Turbines ◽  
Complete Removal ◽  
Salt Bath ◽  
Economic Benefits ◽  
Multiple Cracks ◽  
Deregulated Markets ◽  
Hot Gas ◽  
Processing Times ◽  
Industrial Gas Turbines

Hot gas path components of modern Industrial Gas Turbines (IGT) are exposed to extreme thermal, mechanical and chemical loading that ultimately leads to their deterioration. Modern GT designs provide for safe operation for a certain operation period. Higher firing temperatures and changing machine loads as a result of the deregulated markets call for highly sophisticated part designs and the use of cost-intensive superalloys. As the lifetime of critical parts is not infinite, they are reconditioned periodically or replaced to regain efficiency losses and to mitigate the risk of unscheduled outages due to hot gas path (HGP) failures. This paper presents advanced thermochemical preparation treatments that form the basis for the subsequent structural repairs, such as high temperature brazing. Before executing any repair step, coated components must be stripped of the consumed and degenerated coatings. Not all of the many techniques that are commonly used can guarantee reproducible and complete removal without damaging the substrate. Recently improved thermochemical techniques, such as a combination of advanced Chemical Stripping and Salt Bath Cleaning, enables the OEM to obtain clean components at low unit costs and for short processing times. In previous approaches, CrF2- and PTFE-based processes were used to clean surfaces and, principally, cracks from oxide scales before welding or brazing was carried out. These preparation techniques were indispensable for reworking superalloys, which cannot be cleaned sufficiently using conventional methods such as exposure under reducing atmospheres at high temperatures. Today, the high versatility of the “Dynamic Subatmospheric Fluoride Ion Cleaning” process (FIC) enables the OEM to run precisely tailored processes, allowing complete freedom to adjust the chemical activity of the gas phase and in so doing fulfil the specific conditions for any superalloy being reworked, even taking into account the varying grade of degradation sustained during service exposure. Weld repairs on superalloys are very sensitive to hot cracking, and high temperature brazing has established itself as a successful method for overcoming this problem. Furthermore, the intensively FIC cleaned surfaces can be regarded as the most important condition to enable a high quality bonding. Other key advantages of braze repairs are the uniform heat input that is possible, the high shape tolerance and the fact that multiple cracks can be simultaneously repaired. In addition, the brazing heat treatment allows controlled adjustment of the microstructural properties. Besides the economic benefits of the treatment, the brazed parts show excellent results in respect of their mechanical integrity. A schematic presentation of the repair sequence described in this paper is shown in the appendix (Fig. 17).

Biomass Gasification — Commercialization and Development: The Combined Heat and Power (CHP) Option

1997 ◽  
Author(s):  
Richard L. Bain ◽  
Kevin C. Craig ◽  
Ralph P. Overend
Keyword(s):  
Gas Turbines ◽  
Forest Products ◽  
The United States ◽  
Combined Heat And Power ◽  
Department Of Energy ◽  
Liquid Fuels ◽  
The Public ◽  
Generation Capacity ◽  
Dedicated Energy Crops ◽  
Electrical Generation

World-wide, biomass is the most used nonfossil fuel and is expanding from its traditional thermal applications to more usage for liquid fuels and electricity. More than 9 gigawatts of biomass electrical generation capacity have been installed in the United States, primarily by forest products industries, since the Public Utilities Regulatory Policy Act (PURPA) was passed. Combined heat and power (CHP) technologies promise to improve power-to-heat efficiencies to strengthen the economic viability of these electrical generating methods. These technologies, which are now being tested and demonstrated, employ industrial and aeroderivative gas turbines; use a variety of feedstocks including agricultural wastes, residues, and dedicated energy crops; and range in size from 8 MW to 75 MW. Specific demonstrations with the U.S. Department of Energy Biomass Power Program and partners in Vermont and Hawaii are discussed.

Evaluation of Advanced Combustors for Dry NOx Suppression With Nitrogen Bearing Fuels in Utility and Industrial Gas Turbines

1982 ◽  
Vol 104 (2) ◽  
pp. 429-438 ◽  
Author(s):  
M. B. Cutrone ◽  
M. B. Hilt ◽  
A. Goyal ◽  
E. E. Ekstedt ◽  
J. Notardonato
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Pressure Ratio ◽  
Water Injection ◽  
Operating Conditions ◽  
Department Of Energy ◽  
Technical Program ◽  
Wide Range ◽  
Industrial Gas Turbines ◽  
Low Levels

The work described in this paper is part of the DOE/LeRC Advanced Conversion-Technology Project (ACT). The program is a multiple contract effort with funding provided by the Department of Energy, and technical program management provided by NASA LeRC. Combustion tests are in progress to evaluate the potential of seven advanced combustor concepts for achieving low NOx emissions for utility gas turbine engines without the use of water injection. Emphasis was on the development of the required combustor aerothermodynamic features for burning high nitrogen fuels. Testing was conducted over a wide range of operating conditions for a 12:1 pressure ratio heavy-duty gas turbine. Combustors were evaluated with distillate fuel, SRC-II coal-derived fuel, residual fuel, and blends. Test results indicate that low levels of NOx and fuel-bound nitrogen conversion can be achieved with rich-lean combustors for fuels with high fuel-bound nitrogen. In addition, ultra-low levels of NOx can be achieved with lean-lean combustors for fuels with low fuel-bound nitrogen.

Low NOx Combustion Systems for Burning Heavy Residual Fuels and High-Fuel-Bound Nitrogen Fuels

1982 ◽  
Vol 104 (2) ◽  
pp. 377-385 ◽  
Author(s):  
D. J. White ◽  
A. Batakis ◽  
R. T. LeCren ◽  
H. G. Yacobucci
Keyword(s):  
Gas Turbines ◽  
Department Of Energy ◽  
Technical Program ◽  
Turbine Engine ◽  
Industrial Gas Turbines ◽  
Low Nox Combustion ◽  
Thermal Nox ◽  
Nox Control ◽  
Industrial Gas Turbine ◽  
And Control

The work described in this paper is a part of the Department of Energy/Lewis Research Center (DOE/LeRC) “Advanced Conversion Technology” (ACT) project. The program is a multiple contract effort with funding provided by the Department of Energy and technical program management provided by NASA LeRC. The increasingly critical situation concerning the world’s petroleum supply necessitates the investigation of alternate fuels for use in industrial gas turbines. Environmentally acceptable operation with minimally processed petroleum based heavy residual and coal derived synthetic fuels requires advanced combustor technology. The technology described in this paper was developed under the DOE/NASA Low NOx Heavy Fuel Combustor Concept Program (Contract DEN3-145). Novel combustor concepts were designed for dry reduction of thermal NOx, control of NOx from fuels containing high levels of organic nitrogen, and control of smoke from low hydrogen content fuels. These combustor concepts were tested by burning a wide variety of fuels including a middle distillate (ERBS), a petroleum based heavy residual, a coal derived synthetic (SRC-II), and various ratios of blends of these fuels which included nitrogen doping with pyridine. The results of these tests show promise that low NOx emissions and high efficiencies can be obtained over most of the operating range of a typical industrial gas turbine engine.

Overview of Creep Strength and Oxidation of Heat-Resistant Alloy Sheets and Foils for Compact Heat-Exchangers

2005 ◽  
Author(s):  
Philip J. Maziasz ◽  
John P. Shingledecker ◽  
Bruce A. Pint ◽  
Neal D. Evans ◽  
Yukinori Yamamoto ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Heat Exchangers ◽  
Gas Turbines ◽  
High Efficiency ◽  
National Laboratory ◽  
Department Of Energy ◽  
Oak Ridge ◽  
Heat Resistant Alloy ◽  
Heat Resistant ◽  
Industrial Gas Turbines

The Oak Ridge National Laboratory (ORNL) has been involved in research and development related to improved performance of recuperators for industrial gas turbines since about 1996, and in improving recuperators for advanced microturbines since 2000. Recuperators are compact, high efficiency heat-exchangers that improve the efficiency of smaller gas turbines and microturbines. Recuperators were traditionally made from 347 stainless steel and operated below or close to 650°C, but today are being designed for reliable operation above 700°C. The Department of Energy (DOE) sponsored programs at ORNL have helped defined the failure mechanisms in stainless steel foils, including creep due to fine grain size, accelerated oxidation due to moisture in the hot exhaust gas, and loss of ductility due to aging. ORNL has also been involved in selecting and characterizing commercial heat-resistant stainless alloys, like HR120 or the new AL20-25+Nb, that should offer dramatically improved recuperator capability and performance at a reasonable cost. This paper summarizes research on sheets and foils of such alloys over the last few years, and suggests the next likely stages for manufacturing recuperators with upgraded performance for the next generation of larger 200–250 kW advanced microturbines.

Selection, Development and Testing of Stainless Steels and Alloys for High-Temperature Recuperator Applications

2003 ◽  
Author(s):  
Philip J. Maziasz ◽  
Bruce A. Pint ◽  
Robert W. Swindeman ◽  
Karren L. More ◽  
Edgar Lara-Curzio
Keyword(s):  
High Temperature ◽  
Stainless Steels ◽  
Gas Turbines ◽  
National Laboratory ◽  
Cost Effective ◽  
Department Of Energy ◽  
Oak Ridge ◽  
Industrial Gas Turbines ◽  
Improved Performance ◽  
Alternate Fuels

Compact recuperators/heat-exchangers are essential hardware that increases the efficiency of microturbines and smaller industrial gas turbines. There are several different kinds of recuperator technology (primary surface, plate and fin, spiral, and others), but they all have several common materials needs. Most commercial recuperators today are made from 347 stainless steel sheet or foil. Increased engine size, higher exhaust temperatures and alternate fuels all require greater performance (strength, corrosion resistance) and reliability than 347 steel, especially as temperatures approach or exceed 750°C. To meet these needs, the Department of Energy (DOE) has sponsored programs at the Oak Ridge National Laboratory (ORNL) to measure properties of commercial sheet and foil materials, to analyze recuperator components, and to identify or develop materials with improved performance and reliability, but which also are cost-effective. This paper summarizes high-temperature creep and corrosion testing of commercial 347 used for current recuperators, testing of HR 120 and modified 803 alloys, and development of modified 347 stainless steels.

Semi-Simplified Black-Box Dynamic Modeling of an Industrial Gas Turbine Based on Real Performance Characteristics

2017 ◽  
Vol 139 (12) ◽  
Author(s):  
Abdollah Mehrpanahi ◽  
Gholamhasan Payganeh ◽  
Mohammadreza Arbabtafti ◽  
Ali Hamidavi
Keyword(s):  
Gas Turbine ◽  
Dynamic Modeling ◽  
Gas Turbines ◽  
Time Lag ◽  
Black Box ◽  
Sensors And Actuators ◽  
Power Turbine ◽  
Real Performance ◽  
Industrial Gas Turbines ◽  
Lp Turbine

The use of multishaft industrial gas turbines is expanding in various industries because of variation in their structure, flexibility, and their appropriate power generation range. In this study, a semi-simplified black-box dynamic modeling has been done for the three-shaft gas turbine MGT-30. Modeling is done in such a way that all the important variables can be calculated and evaluated. One of the important parameters in dynamic modeling of gas turbine is the time lag relevant to the performance properties of sensors and actuators of the system. In this study, in order to measure the transfer function, physical and actual characteristics of the system were applied. Depending on the type of thermocouples (TCs) used, their activation time was eliminated using a lead compensator. In modeling of the system, the functions were related to the implementation of off-design conditions for compliance with the outputs of a real system model, and outputs were presented proportional to the rate and type of changes for each variable. Finally, validation was done by comparing the power-turbine generated power, exhaust gas temperatures downstream of low pressure (LP) turbine, and speeds of LP and high-pressure (HP) turbines with the real values of Qeshm turbogenerator power plant.

Overview of Creep Strength and Oxidation of Heat-Resistant Alloy Sheets and Foils for Compact Heat Exchangers

2005 ◽  
Vol 128 (4) ◽  
pp. 814-819 ◽  
Author(s):  
Philip J. Maziasz ◽  
John P. Shingledecker ◽  
Bruce A. Pint ◽  
Neal D. Evans ◽  
Yukinori Yamamoto ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Heat Exchangers ◽  
Gas Turbines ◽  
High Efficiency ◽  
National Laboratory ◽  
Department Of Energy ◽  
Oak Ridge ◽  
Heat Resistant Alloy ◽  
Heat Resistant ◽  
Industrial Gas Turbines

The Oak Ridge National Laboratory (ORNL) has been involved in research and development related to improved performance of recuperators for industrial gas turbines since about 1996, and in improving recuperators for advanced microturbines since 2000. Recuperators are compact, high efficiency heat-exchangers that improve the efficiency of smaller gas turbines and microturbines. Recuperators were traditionally made from 347 stainless steel and operated below or close to 650°C, but today are being designed for reliable operation above 700°C. The Department of Energy (DOE) sponsored programs at ORNL have helped defined the failure mechanisms in stainless steel foils, including creep due to fine grain size, accelerated oxidation due to moisture in the hot exhaust gas, and loss of ductility due to aging. ORNL has also been involved in selecting and characterizing commercial heat-resistant stainless alloys, like HR120 or the new AL20-25+Nb, that should offer dramatically improved recuperator capability and performance at a reasonable cost. This paper summarizes research on sheets and foils of such alloys over the last few years, and suggests the next likely stages for manufacturing recuperators with upgraded performance for the next generation of larger 200-250kW advanced microturbines.

Thermal Analysis of a Turbine Blade: Effect of Film Cooling and Internal Convective Cooling

2015 ◽  
Author(s):  
S. Sarkar ◽  
P. Gupta
Keyword(s):  
Heat Transfer ◽  
Film Cooling ◽  
Gas Turbines ◽  
Leading Edge ◽  
Inlet Temperature ◽  
Internal Cooling ◽  
Suction Surface ◽  
Transfer Condition ◽  
Convective Cooling ◽  
Cooling Passage

Advanced gas turbines are designed to operate at increasingly higher inlet temperature that poses a greater challenge to the designer for more effective blade cooling strategies. In this paper, a generic high-pressure turbine (HPT) blade of a gas turbine, which is cooled by film cooling in conjunction with internal convective cooling, has been analysed by solving Navier-Stokes and energy equations. The intricate internal cooling passages and a series of holes on the suction surface are considered for the simulations. Large numbers of cell in different zones are used to truly replace the blade with cooling holes and the internal cooling passage. The CFD analysis with conjugate heat transfer condition is accomplished by Fluent, version 6.3. A detailed discussion has been made regarding the aerodynamics and heat transfer. In brief, the suction surface is well protected by film cooling, whereas, the pressure surface demands some additional protection for a longer life. The leading edge is under the metallurgical limit because of internal cooling for the present configuration.

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