Gas Turbine Seminar -17 Lund University
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1 Gas Turbine Seminar -17 Lund University
2 Farligaste djuret? Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 2
3 Farligaste djuret? Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 3
4 Additive Manufacturing - AM Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 4
5 Almost 100% renewable in Germany W616 Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 5
6 The European issue Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 6
7 Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 7 Cost of Electricity (CoE) vs. OH 4 2 Design Courtesy of VGB Powertech t0.961CoEtCoE
8 The Duck-Curve Sweden California 4.3 GW/h Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 8
9 Grid codes Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 9
10 Flexibility Load Courtesy of Siemens LF Start Steady state Active generation control Spinning reserve off-peak turndown SS Shutdown Load Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 10
11 Flexibility Start-up Air attemperation Sky venting Cascaded steam bypass with attemperation Ramping Turn-down MECL Lock-out Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 11
12 GT start-up Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 12
13 Emissions vs. firing level Flame temperature vs air/fuel Temperature influence on NO x and CO Stoichiometric T max Increasing Temperature Increasing CO NO x Rich Lean NO x formation rate AFR = FAR Combustion temp, C Typical optimum for design at AFR 30 (i.e. λ 2) Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 13
14 Min Emission Compliance Load MECL Maximum EGT III II I Exhaust temperature, C CO NOx MECL EGT Emissions, mass/unit time GT load, percent Staging to prevent from: Lean blow out (LBO) Combustion dynamics Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 14
15 Ansaldo sequential (SEV) Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 15
16 Ansaldo (Alstom) GT36 Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 16
17 Exhaust loss Δh a N.B. The figure is based on a certain exhaust size a general figure should be based on the annulus velocity (V AN =Q/A) since: Loss ~ rating or flow Loss ~ 1/pressure Loss ~ 1/area ~ 1/ stress Turn-up region Optimum design Supersonic w 2 u c 2 c 2 Δh a c Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 17 V m 3 s
18 Fatigue low or high? Wöhler- or σ,n curve Stress amplitude, [σ a ] Low-cycle fatigue Failure Stress σ Time σ a σ a Fatigue limit No failure no crack initiation High-cycle fatigue Life cycles, [n] Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 18
19 Rotor stress temperature gradients T Steam T T Surface T Average T Center ΔT Temperature induced stresses (radial and hoop): σ σ r θ r r 2 2 ry r α E r r i T r dr T r dr μ r r r y i r i 2 2 ry r α E r r i 2 T r dr T r dr Tr μ r r r y i r i Simplified equations for a case without a bore: r i r i Example α = C -1 E = MPa ΔT = 55 C = 46 MPa r σ σ r θ 1 rim r α E T r dr T r dr rrim r 3 r 0 0 rim 1 r 1 r α E ΔT rim r α E T r dr T r dr T rrim r 3 r 0 0 rim r 1 r α E ΔT r r Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 19
20 Compressor blade failure Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 20
21 Siemens SGT5-8000H Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 21
22 Turbine flow path typical 3-spool aero Rolls-Royce: The Jet Engine Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 22
23 State-of-the-art combined cycle GTCC ~ kg/mws ~ 600 C (+) steam admission ~ 20% SCR ~ 0.02 bar(a) Combustor 100% ~ C ~ 40% Compressor Turbine COT ~ 1,500 C (+) PR ~ η CC η GT η SC η HRSG 1η GT Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 23
24 Siemens HL-class 42% efficiency 85 MW/min 1000 kg/s 680 C EGT Courtesy of Siemens Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 24
25 Siemens HL-class rotor #1 Courtesy of Siemens Convective heat transfer Nu Conductive heat transfer hl k f Re,Pr,... h ~ 1 L Nu Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 25
26 Siemens SGT-800 Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 26
27 GE LM9000 Simple Cycle CC & CHP Mechanical Drive Free power turbine ( rpm) 4 stage HPT ISO Performance Maintenance Emissions 65 MW power output 43% simple-cycle efficiency 99% availability >80% cogeneration efficiency 33:1 pressure ratio 12,000 hours: inspections 36,000 hours: hot section replacement 72,000 hours: overhaul Package design allows engine swap in 24 hours 15 ppm DLE NOx & 25 ppm CO DLE 1.5 dual fuel (natural gas and liquid fuel) 4 stage LPC 9 stage HPC 2 stage HPT 1 stage HPT Fuel flex MWI gas Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 27
28 SGT-A45 TR Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 28
29 P&W FT4000 Performance 140 MW nominal output in twin-engine configuration Wet compression for improved performance above ISO conditions Single or dual engine operation (common alternator) 50 or 60 Hz performance with no penalty 41% (+) thermal efficiency without external cooling Operational Less than 10 minutes start-up time 30 MW/min ramp rate Synchronous condensation with spinning PT, a FT has a windage loss of 500 1,000 kw NO maintenance penalty for start/stop! Fleet has 17,500 OH s and 1400 cycles P&W has substantial experience in synchronous condensation without SSS-clutch! >900 engines >20 years >40 MOH Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 29
30 Ventilation work spinning PT The spinning power turbine will feed work into the entrapped air by increasing the angular momentum It is standard to assess the work with the equation from the book by Traupel: 3 P C 1 D l u V P P ~ 2 3 8!!! The preceding equation shows why only non-geared PTs can be operated at nominal speed in ventilation Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 30
31 Firing level Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 31
32 Firing temperature the misery factor Creep follows an Arrhenius type of expression The Larson-Miller parameter: P P LM LM c T K M K 1 20 K Taper 2 3 log t 10 ln K ln c AN 10 ~ AN 3 c 2 A more convenient and practical approach is to introduce a maintenance factor MF (consumed life per hour of operation) Firing Lifing MF MF e COT Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 32
33 Creep Larson-Miller parameter C.R.S Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 33
34 Lifing It may be argued that creep-induced damage will reduce the fatigue life of a metal, and that fatigue-induced damage will reduce the metals creep life One approach is to use the linear damage summation (DS) model (also called the linear life fraction, or linear cumulative damage) for assessing creep-fatigue-life: D fatigue + D creep = D total By combining the Robinson Rule (1952) for creep and Miner for fatigue, one gets the cumulative damage index (failure at unity): N N f t t r D This is the rationale behind the concept of equivalent operating hours Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 34
35 The expensive way equivalent hours EOH OH 1 Ffuel Ffiring 1 creep and oxidation n starts 1 Fstarts Fload rate 1 FTrips 1 1 LCF n trips Where: EOH OH F fuel F fuel n starts F starts F load rate equivalent operating hours actual operating hours factor depending on fuel factor depending on firing level number of fired starts number of hours per start load rate factor Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 35
36 Lifing Miner-Palmgren Robinson N N f t N r D Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 36
37 Operational hours Maintenance interval Factored Hours Actual Hours hours Factored Hours = (K + M I) (G D + A f H + 10 P) Actual Hours = (G + D + H + P) G = Annual Base Load Operating hours on Gas Fuel D = Annual Base Load Operating hours on Distillate Fuel H = Annual Operating Hours on Heavy Fuel A f = Heavy Fuel Severity Factor (Residual = 3 to 4, Crude = 2 to 3) P = Annual Peak Load Operating Hours I = Percent Water/Steam Injection Referenced to Inlet Air Flow M&K = Water/Steam Injection Constants (see GE documentation) Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 37
38 Noff cycles Maintenance 900 interval Factored Starts Actual Starts Starts Factored Starts 0.5N A N B 1.6N P 20E 2F η ati 1 i1 T i Actual Starts = (N A + N B + N P ) S = Maximum Starts-Based Maintenance Interval (Model Size Dependent) N A = Annual Number of Part Load Start/Stop Cycles (<60% Load) N B = Annual Number of Base Load Start/Stop Cycles N P = Annual Number of Peak Load Start/Stop Cycles (>100% Load) E = Annual Number of Emergency Starts F = Annual Number of Fast Load Starts T = Annual Number of Trips a Ti = Trip Severity Factor = fcn(load, Trip during accel. = 2, Peak = 10) η = Number of Trip Categories (i.e. Full Load, Part Load, etc.) Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 38
39 Turbine governor twin-shaft EGT control f COT Nom,PR,n,... T P 4 T T 4x 5 p p 4 5 η γ1 p γ p p 4 5 n1 n 5 P 5 s Courtesy of Siemens Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 39
![.8 4 8 12 16 20 24 28 32 36 40 Mass Flow W25RSTD [kg/s] LPT 2.5 N=0.8 N=0.9 N=1 N=1.1 N=1.2 0.94 0.93 N=0.7 0.90 0.92 0.85 0.88 0.80 1.](/docs-images/78/76909911/images/40-3.jpg "5 P48q5 Power Turbine Pressure Ratio N=0.6 Not converged points are marked with a red symbol.")
40 Performance modelling HPC N=1.05 N=1 N= N= N=0.85 N=0.8 N=0.75 N= P3q25 HPC Pressure Ratio 0.70 N=0.6 N=0.5 Not converged points are marked with a red symbol Mass Flow W25RSTD [kg/s] LPT 2.5 N=0.8 N=0.9 N=1 N=1.1 N= N= P48q5 Power Turbine Pressure Ratio N=0.6 Not converged points are marked with a red symbol W48*sqrt(T48)/(P48/Pstd) [Kg/s] Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 40
41 Some results Burner Temperature ZT4 = [C] Electric Power [kw] * Rel. HP Spool Speed Relative Torque [%] ^(0.0693*(ZT4-850)) Burner Exit Temperature T4 [C] Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 41
42 Impact on output from firing and ambient Burner Temperature ZT4 = [C] Ambient Temperature Ts0 = [C] Inlet Temperature T2 [C] = * Electric Power [kw] Burner Exit Temperature T4 [C] 8 ZT4 = 850 ZT4 = 855 ZT4 = 860 ZT4 = 865 ZT4 = 870 ZT4 = 875 ZT4 = 880 Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 42
43 Flat MW Ambient Temperature Ts0 = [C] ^(0.0693*(ZT4-850)) Thermal Efficiency Burner Exit Temperature T4 [C] Inlet Temperature T2 [C] Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 43
44 Emulsionseldning Lund University / LTH / Energy Sciences / TPE / Magnus Genrup / Page 44
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