Comparison Between Two-Shaft Simple and Single-Shaft Recuperated Brayton Cycles Using Different Types of Gaseous Fuels

Geopolitical issues give rise to problems in the smooth and continuous flow of oil and natural gas from the production countries to the consumers’ development countries. In addition, severe environmental issues such as greenhouse gas emissions, eventually guide the consumers to fuels more suitable to the present situation. Alternative fuels such as biogas and coal gas have recently become more attractive because of their benefits, especially for electricity generation. On the other hand, the use of relatively low heating value fuels has a significant effect to the performance parameters of gas turbines. In this paper, the impact of using four fuels with different heating value in the gas turbine performance is simulated. Based on the high efficiency and commercialization criteria, two types of engines are chosen to be simulated: two-shaft simple and single-shaft recuperated cycle gas turbines. The heating values of the four gases investigated, correspond to natural gas and to a series of three gases with gradually lower heating values than that of natural gas. The main conclusions drawn from this design point (DP) and off-design (OD) analysis is that, for a given TET, efficiency increases for both engines when gases with low heating value are used. On the contrary, when power output is kept constant, the use of gases with low heating value will result in a decrease of thermal efficiency. A number of parametric studies are carried out and the effect of operating parameters on performance is assessed. The analysis is performed with customized software, which has been developed for this purpose.

Fast CFD Simulation of Horizontal Axis Wind Turbines

The numerical simulation of horizontal axis wind turbines (HAWT) has been analysed using computational fluid dynamics (CFD) with the aim of obtaining reliable but at the same time affordable wind turbine simulations, while significantly reducing required overall resources (time, computational power, user skills), for example in an optimization perspective. Starting from mesh generation, time required to extract preliminary aerodynamic predictions of a wind turbine blade has been shortened by means of some simplifications, i.e.: fully unstructured mesh topology, reduced grid size, incompressible flow assumption, use of wall functions, commercial available CFD package employment. Ansys Fluent software package has been employed to solve Reynolds Averaged Navier Stokes (RANS) equations, and results obtained have been compared against NREL Phase VI campaign data. The whole CFD process (pre-processing, processing, postprocessing) has been analysed and the chosen final settings are the result of a trade-off between numerical accuracy and required resources. Besides the introduced simplifications, numerical predictions of shaft torque, forces and flow distribution are in good agreement with experimental data and as accurate as those calcuted by other more sophisticated works.

Study of Fault Self-Recovery and Seal Improvement for Centrifugal Compressor

For centrifugal compressor, discharge or suction pressure variations due to process fluctuations or balance drum seal degradation can result in rotor thrust increasing which may jeopardize thrust bearing and compressor’s reliability. Also, the leakage flow through balance drum seal can seriously affect the efficiency of compressor. Summarizing the characteristic of axial displacement fault about centrifugal compressor and analyzing the mechanical performance of tilt pads thrust bearing, theory of axial displacement fault self-recovery is presented and realized through experimental study. The method presented in this paper monitors the stiffness of oil film and identifies the reason of axial displacement increasing. Also the low leakage feature of Dry-Gas-Seal (DGS), high reliability of labyrinth, and the feasibility of upgrading existing structure are taken into account at the same time to design a combined labyrinth-dry gas seal system on the balancing drum. Based on the combined seal system, a Fault Self-Recovering (FSR) mechanism for the fault of rotor axial displacement is introduced to assure the minimum oil film thickness was ensured in real time. The modern Computational Fluid Dynamics (CFD) and experimental study were used to validate this concept. The result and relevant information indicate that the method can realize axial displacement fault self-recovering effectively and the combined sealing system could improve the efficiency of the centrifugal compressor about four percent.

Optimizing Maintenance for Multi-Unit Industrial Gas Turbine Installations

High levels of availability and reliability are essential in many industries where production is subject to high costs due to downtime. Examples where gas turbines are used include the mechanical drive in natural gas pipelines and power generation on oil platforms, where it is common to use redundant gas turbines to mitigate the effects of service outage. In this paper, component-level maintenance of parallel multi-unit systems is considered, allowing production at a reduced level when some of the units are not operational. Units are themselves assumed to be composed out of components in a serial configuration; maintenance of one component implies shutdown of the unit. Parallel installations allow maintenance to be performed on one or a few gas turbines without taking down the entire installation. This allows maintenance to be optimized even further than in a serial system. However, the maintenance optimization process is made more complicated, since there now exist both positive and negative grouping effects. The positive grouping effects come from shared setup activities and costs, and the negative effects come from resource limitations, in this case the limited number of gas turbines which can be maintained at the same time. In the approach presented in this paper, each component has its individual preventive maintenance schedule, which is updated at inspections, changes in production and when indicated using remote condition monitoring. A minimal repair model for noncritical routine inspections and service tasks is assumed, which does not affect component state. In addition, previously developed procedures for estimating and measuring residual component lifetime for individual components during operation are used. The procedures are based on a Retirement For Cause (RFC) approach where components are not replaced until a potential failure has been detected. To maximize revenues for an operator, the available information is evaluated using software where scenario analysis and optimization is performed. To show the possible economic effects, gas turbine operation data is used together with maintenance and operator requirements as input for optimization of a production line consisting of a natural-gas compressor station having three SGT-600 gas turbines. Savings can be substantial compared to a traditional preventive maintenance plan.

Improved µ-Scale Turbine Expander for Energy Recovery

Micro power converters for energy recovery are increasingly important for a number of future applications. The Austrian Institute of Technology (AIT) is presently developing an innovative μ-scale turbine expander for work recovery in transcritical CO2 heat pumps. The main drawback of a lower COP (coefficient of performance) of transcritical CO2 heat pumps compared to conventional heat pump systems can be compensated by utilizing the pressure difference between the high pressure and low pressure part of the pump for work recovery. Work recovery can be realized by substituting the expansion valve between the high and low pressure side by a Pelton turbine with specific two phase flow turbine blades. In order to increase the power output, the generator was integrated into the turbine to reduce the friction losses and hence increase the overall efficiency. An important aspect is that the generator is directly connected with the high pressure part of the turbine. One part of the project is the optimization of the turbine geometry via simulation tools. The paper will give an overview about our microturbine development as well as a comparison of the power output of each turbine generation. Furthermore the present paper discusses a concept that utilizes our microturbine together with a micro combustion module that enables a micro power generator with very high power-to-weight ratios based on green fuels.

Wet Gas Impeller Test Facility

The development of wet gas compressors will enable increased oil and gas production rates and enhanced profitable operation by subsea well-stream boosting. A more fundamental knowledge of the impact of liquid is essential with regard to the understanding of thermodynamic and fluid dynamic compressor behavior. An open-loop impeller test facility was designed to investigate the wet gas performance, aerodynamic stability, and operation range. The facility was made adaptable for different impeller and diffuser geometries. In this paper, the wet gas test facility and experimental work concerning the impact of wet gas on a representative full-scale industrial impeller are presented. The centrifugal compressor performance was examined at high gas volume fractions and atmospheric inlet conditions. Air and water were used as experimental fluids. Dry and wet gas performance was experimentally verified and analyzed. The results were in accordance with previous test data and indicated a stringent influence of the liquid phase. Air/water tests at atmospheric conditions were capable of reproducing the general performance trend of hydrocarbon wet gas compressor tests at high pressure.

Transient Pressure Loss in Compressor Station Piping Systems

“Dynamic pressure loss” is often used to describe the added loss associated with the time varying components of an unsteady flow through a piping system in centrifugal and reciprocating compressor stations. Conventionally, dynamic pressure losses are determined by assuming a periodically pulsating 1-D flow profile and calculating the transient pipe friction losses by multiplying a friction factor by the average flow dynamic pressure component. In reality, the dynamic pressure loss is more complex and is not a single component but consists of several different physical effects, which are affected by the piping arrangement, structural supports, piping diameter, and the level of unsteadiness in the flow stream. The pressure losses due to fluid-structure interactions represent one of these physical loss mechanisms and are presently the most misrepresented loss term. The dynamic pressure losses, dominated at times by the fluid-structure interactions, have not been previously quantified for transient flows in compressor piping systems. A number of experiments were performed by SwRI utilizing an instrumented piping system in a compressor closed loop facility to determine this loss component. Steady and dynamic pressure transducers and on-pipe accelerometers were utilized to study the dynamic pressure loss. This paper describes findings from reciprocating compressor experiments and the various fluid modeling studies undertaken for the same piping system. The objective of the research was to quantitatively assess the individual pressure loss components which contribute to dynamic pressure (non-steady) loss based on their physical basis as described by the momentum equation. Results from these experiments were compared to steady state and dynamic pressure loss predictions from 1-D and 3-D fluid models (utilizing both steady and transient flow conditions to quantify the associated loss terms). Comparisons between the fluid model predictions and experiments revealed that pressure losses associated with the piping fluid-structure interactions can be significant and may be unaccounted for by advanced 3-D fluid models. These fluid-to-structure losses should not be ignored when predicting dynamic pressure loss. The results also indicated the ability of an advanced 1-D Navier Stokes solution at predicting inertial momentum losses. Correspondingly, the three-dimensional fluid models were able to capture boundary layer losses affected by 3-D geometries.

Effect of Blade Inclination Angle on a Darrieus Wind Turbine

This paper presents a model for the evaluation of energy performance and aerodynamic forces acting on a small helical Darrieus vertical axis wind turbine depending on blade inclination angle. It consists of an analytical code coupled to a solid modeling software, capable of generating the desired blade geometry depending on the desired design geometric parameters, which is linked to a finite volume CFD code for the calculation of rotor performance. After describing and validating the model with experimental data, the results of numerical simulations are proposed on the bases of five machine architectures, which are characterized by an inclination of the blades with respect to the horizontal plane in order to generate a phase shift angle between lower and upper blade sections of 0°, 30°, 60°, 90° and 120° for a rotor having an aspect ratio of 1.5. The effects of blade inclination on tangential and axial forces are first discussed and then the overall rotor torque is considered as a function of azimuthal position of the blades. Finally, the downstream tip recirculation zone due to the finite blade extension is analyzed for each blade inclination angle, achieving a numerical quantification of the influence of induced drag on rotor performance, as a function of both blade element longitudinal and azimuthal positions of the blade itself.

A Performance Autopsy of Three Centrifugal Compressors for a Small Gas Turbine

Three 140mm tip diameter centrifugal compressors were designed and tested to determine the one exhibiting the best performance most suitable for eventual application to a small 60KW radial flow type gas turbine. The design features, and stage test results of these three moderately high pressure ratio impellers are presented, together with a comparison of their respective test and CFD computed performance maps.

Heat Accumulator in Large District Heating Systems: Simulation and Optimisation

Heat accumulators in large district heating systems are used to buffer heat production. Their main purpose is to make heat production as independent as possible from district heating system demand. To do this effectively a heat accumulator of appropriate capacity must be selected. In large district heating systems, heat accumulators can be used for equalising production over periods lasting a few hours. Accumulators can be used for optimising electricity and heat production to achieve possible highest income. It may be important in situations where on-line prices change. An optimising algorithm for heat accumulator use is shown and commented. Typical working situations are simulated and results presented.