Component Tests With a Model V84.3A Gas Turbine in the Siemens Test Facility in Berlin

Author(s):  
Christof Lechner ◽  
Bernward Mertens ◽  
Dieter Warnack ◽  
Dirk Weltersbach ◽  
Herwart Ho¨nen

In its Gas Turbine Development and Manufacturing Center in Berlin Siemens runs a test bed for gas turbine prototypes. Since the end of 1998, the new model V84.3A gas turbine has been undergoing tests at this facility. One focus of last year’s tests was on flow field measurements with pneumatic probes in the exit flow duct of the turbine at various load levels to characterize the flow in the diffuser and provide a data base. Another item was the further investigation of the compressor surge margin and the validation of a newly-developed on-line surge prediction system.

Author(s):  
G. A. Zess ◽  
K. A. Thole

With the desire for increased power output for a gas turbine engine comes the continual push to achieve higher turbine inlet temperatures. Higher temperatures result in large thermal and mechanical stresses particularly along the nozzle guide vane. One critical region along a vane is the leading edge-endwall juncture. Based on the assumption that the approaching flow to this juncture is similar to a two-dimensional boundary layer, previous studies have shown that a horseshoe vortex forms. This vortex forms because of a radial total pressure gradient from the approaching boundary layer. This paper documents the computational design and experimental validation of a fillet placed at the leading edge-endwall juncture of a guide vane to eliminate the horseshoe vortex. The fillet design effectively accelerated the incoming boundary layer thereby mitigating the effect of the total pressure gradient. To verify the CFD studies used to design the leading edge fillet, flow field measurements were performed in a large-scale, linear, vane cascade. The flow field measurements were performed with a laser Doppler velocimeter in four planes orientated orthogonal to the vane. Good agreement between the CFD predictions and the experimental measurements verified the effectiveness of the leading edge fillet at eliminating the horseshoe vortex. The flowfield results showed that the turbulent kinetic energy levels were significantly reduced in the endwall region because of the absence of the unsteady horseshoe vortex.


Author(s):  
Keishaly Cabrera Cruz ◽  
Paolo Pezzini ◽  
Lawrence Shadle ◽  
Kenneth M. Bryden

Abstract Compressor dynamics were studied in a gas turbine – fuel cell hybrid power system having a larger compressor volume than traditionally found in gas turbine systems. This larger compressor volume adversely affects the surge margin of the gas turbine. Industrial acoustic sensors were placed near the compressor to identify when the equipment was getting close to the surge line. Fast Fourier transform (FFT) mathematical analysis was used to obtain spectra representing the probability density across the frequency range (0–5000 Hz). Comparison between FFT spectra for nominal and transient operations revealed that higher amplitude spikes were observed during incipient stall at three different frequencies, 900, 1020, and 1800 Hz. These frequencies were compared to the natural frequencies of the equipment and the frequency for the rotating turbomachinery to identify more general nature of the acoustic signal typical of the onset of compressor surge. The primary goal of this acoustic analysis was to establish an online methodology to monitor compressor stability that can be anticipated and avoided.


Author(s):  
Alessandra Cuneo ◽  
Alberto Traverso ◽  
Aristide F. Massardo

The dynamic modeling of energy systems can be used for different purposes, obtaining important information both for the design phase and control system strategies, increasing the confidence during experimental phase. Such analysis in dynamic conditions is generally performed considering fixed values for both geometrical and operational parameters such as volumes, orifices, but also initial temperatures, pressure. However, such characteristics are often subject to uncertainty, either because they are not known accurately or because they may depend on the operating conditions at the beginning of the relevant transient. With focus on a gas turbine fuel cell hybrid system (HS), compressor surge may or may not occur during transients, depending on the aforementioned cycle characteristics; hence, compressor surge events are affected by uncertainty. In this paper, a stochastic analysis was performed taking into account an emergency shut-down (ESD) in a fuel cell gas turbine HS, modeled with TRANSEO, a deterministic tool for the dynamic simulations. The aim of the paper is to identify the main parameters that impact on compressor surge margin. The stochastic analysis was performed through the response sensitivity analysis (RSA) method, a sensitivity-based approximation approach that overcomes the computational burden of sampling methods. The results show that the minimum surge margin occurs in two different ranges of rotational speed: a high-speed range and a low-speed range. The temperature and geometrical characteristics of the pressure vessel, where the fuel cell is installed, are the two main parameters that affect the surge margin during an emergency shut down.


Author(s):  
Alex Tsai ◽  
Larry Banta ◽  
David Tucker ◽  
Randall Gemmen

This paper presents a Relative Gain Array (RGA) analysis of a simulated SOFC/Gas Turbine plant based on a multivariate empirical formulation of a 300kW hybrid system. The HyPer test facility at the National Energy Technology Laboratory, served as the test bed for deriving frequency response data and subsequent multivariable model of a direct fired, recuperated hybrid cycle plant. Through the modulation of various airflow bypass-valves, magnitude and phase data is used to formulate Transfer Function {TF} equations that describe input/output system interaction. A frequency dependent RGA calculation of the empirical Transfer Function matrix provides a means of quantifying the degree of coupling between system inputs and outputs for the configuration studied. Various input/output interaction time scales are obtained to identify frequencies where fully developed system coupling occur. Analysis of the RGA matrix leads to a better understanding of the inherent properties the hybrid configuration, and can serve as a validating tool to existing analytical RGA calculations of similar types of hybrids.


Author(s):  
Y. S. Kim ◽  
J. J. Lee ◽  
K. S. Cha ◽  
T. S. Kim ◽  
J. L. Sohn ◽  
...  

An IGCC (integrated gasification combined cycle) plant couples a power block to a gasification block. The method of integrating a gas turbine with a gasification process is the major design option. Matching between the gas turbine and the air separation unit is especially important. This study analyzes the influences of IGCC design options on the operability and performance of the gas turbine. Another research focus is given to the estimation of the change of turbine metal temperature in the IGCC operating environment. For this purpose, a full off-design analysis of the gas turbine is used with the turbine blade cooling model. Four different syngas fuels are considered. As the integration degree becomes lower, the gas turbine power and efficiency increase. However, a lower integration degree causes a reduction of the compressor surge margin and overheating of the turbine metal. Only near 100% integration degree designs are almost free of those two problems. The syngas property also affects the gas turbine operation. As the heating value gets lower, the problems of surge margin reduction and metal overheating become more severe. Modifications of the compressor (adding a couple of stages) and the turbine (increasing gas path area) could solve the compressor surge problem. However, the turbine overheating problem still exists. In particular, the turbine modification is predicted to overheat turbine metal considerably.


Author(s):  
Sasha M. Savic ◽  
Katharina E. Rostek ◽  
Daniel K. Klaesson

High fogging (wet compression, spray inter-cooling) is a technology used for gas turbine (GT) power augmentation. By evaporative spray inter-cooling of the air during compression, which is the main physical effect associated with the HF, a 5–7% power boost of the GT (for each percent of injected water per mass of air) is achieved. HF of a gas turbine can be accomplished using different spray technologies. In this study three different, commercially available spray technologies — pressure-swirl, hot water injection and air-assisted atomization — are compared regarding both technical and economical benefits and risks. The comparison is based on droplet sizing results, system complexity, the feasibility of system integration into the GT’s control and plant operation concept, GT performance and operational and additional O&M costs. It is also known that high fogging carries certain risks to the safe operation of a GT, such as compressor blades erosion, reduction in compressor surge margin and cooling airflows. To minimize the negative impact of high fogging, it is therefore important to select the most appropriate high fogging system as well as to provide for its full engine integration.


Author(s):  
Jeffrey S. Patterson ◽  
Howard Harris

The TF40B Gas Turbine Test Facility is the only dedicated Landing Craft, Air Cushion main propulsion engine test complex available to the U.S. Navy. This facility, located at the Naval Surface Warfare Center, Carderock Division (NSWCCD) in Philadelphia, PA, began operation in August, 1992. Since then, the test engine has logged approximately 230 starts and 350 operating hours. This paper will present the installation, testing and lessons learned of the TF40B test facility. The installation section will discuss the modifications made to the existing test facility to accept the TF40B engine. The test section will include the Foreign Object Damage (FOD) screen evaluation, both on-line and crank wash detergent fluid evaluations, cold weather fuel testing, engine vent line testing and Aerojet 5 oil evaluation. The lessons learned section will include problems related to the electric starter, waterbrake, inlet and exhaust systems, data acquisition system, instrumentation control panel and the test cell equipment arrangement.


Author(s):  
Sandipan Chatterjee ◽  
Christopher Halmo ◽  
Ömer L. Gülder

Turbulent non-premixed swirl flames were investigated in a gas turbine model combustor with optical access. Velocity and soot concentration fields for ethylene/air combustion at three overall fuel-air equivalence ratios, 0.222, 0.209 and 0.198, were studied. Stereoscopic particle image velocimetry measurements were used to study the flow field in the combustor, and time-averaged soot volume fractions were obtained using laser induced incandescence. The flow field and soot measurements were performed separately, but under identical conditions. The flow field measurements captured the inner and outer recirculation zones, the boundaries of which showed high turbulence intensity. This high intensity turbulence implies a rapid mixing of the cold reactants with the recirculating hot combustion products and chemically active radicals near the recirculation zone boundaries. The soot volume fractions showed a strong dependence on the overall fuel-air equivalence ratio. Regions of maximum soot had a conical shape and grew radially outward with downstream locations.


2014 ◽  
Vol 2014 ◽  
pp. 1-17
Author(s):  
M. Sivapragasam ◽  
S. Ramamurthy ◽  
M. D. Deshpande ◽  
P. White

An air jet distortion generation system is developed to simulate the distorted flow field ahead of gas turbine engines in ground test facility. The flow field of a system of four jets arranged circumferentially and issuing into a confined counterflow was studied experimentally and numerically. The total pressure distortion parameters were evaluated at the Aerodynamic Interface Plane (AIP) for several values of mass flow ratios. Since the total pressure loss distribution at theAIPis characteristically “V” shaped, the number of jets was increased to obtain total pressure distributions as required for gas turbine engine testing. With this understanding, a methodology has been developed to generate a target total pressure distortion pattern at theAIP. Turbulent flow computations are used to iteratively progress towards the target distribution. This methodology was demonstrated for a distortion flow pattern typical of use in gas turbine engine testing using twenty jets, which is a smaller number than reported in the literature. The procedure converges with a root-mean-square error of 3.836% and is able to reproduce the target pattern and other distortion parameters.


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