Computational and Experimental Analysis of an Industrial Gas Turbine Compressor

2011 ◽  
Author(s):  
Alexander Wiedermann ◽  
Dirk Frank ◽  
Ulrich Orth ◽  
Markus Beukenberg
Keyword(s):  
Gas Turbine ◽  
Mechanical Design ◽  
Phase 1 ◽  
Tip Clearance ◽  
Vibration Modes ◽  
Blade Vibration ◽  
Flow Solver ◽  
Pressure Profiles ◽  
Wide Range ◽  
Industrial Gas Turbine

Test rig results and their comparison with computational analyses of a highly-loaded 11-stage compressor for a newly developed industrial gas turbine will be presented in this paper. The scope of the tests has been validation of aerodynamic and mechanical features of the bladed flow path to meet both the demands for single- and dual-shaft operation of the gas turbine. The test was carried out in three phases using extensive instrumentation. In phase 1 the front stages have been tested, and in phase 2 the test of the full 11-stage compressor was performed including numerous aerodynamic and structural check-outs. Vane and blade vibration modes were measured in all rows with numerous strain gauges using a telemetry system and Tip Timing, which additionally was applied to the front stage rotors. Concerning the mechanical design, finite element predictions of the vibration modes of all blades and vanes were carried out in the design phase to guarantee safe and resonance-free operation for a wide range of operational speeds which could be verified by the test data up to higher modes. Flow field computations were carried out with both a through flow solver and full 3-D viscous multistage solver based on Denton’s TBLOCK, where all rotor and stator flow fields had been solved simultaneously and compared with experiments. The effects of tip clearance and stator cavities on compressor performance have been taken into account by the computational analysis. Effects of inlet distortion were examined in phase 3. Comprehensive comparisons of computed and measured results will be presented. The extensive instrumentation gave also insight into flow details as vane pressure distributions and total pressure profiles in span wise direction. It will be shown that the agreements of predicted and measured data were excellent.

scholarly journals A New 4500-HP Gas Turbine for Pipeline Industrial Service

1970 ◽  
Author(s):  
R. R. Oliver ◽  
F. Fraschetti
Keyword(s):  
Gas Turbine ◽  
Mechanical Design ◽  
Maximum Efficiency ◽  
Heavy Duty ◽  
Cooperative Effort ◽  
Package Design ◽  
Wide Range ◽  
Industrial Service ◽  
Design Options ◽  
Regenerative Cycle

This paper describes the performance and mechanical design of a 4500-hp, two shaft heavy duty simple or regenerative cycle gas turbine. This machine resulted from an international cooperative effort of the joint authors’ respective companies. Initially planned for gas pipelines and process applications, a line of load compressors has been integrated into the single package design. Options include indoor or outdoor models and geared or direct mechanical output for applications not served by the integral compressor models. A variable area load turbine nozzle assures maximum efficiency over a wide range of load, speed, and amibient conditions.

Correlation Analysis of Multiple Sensors for Industrial Gas Turbine Compressor Blade Health Monitoring

2015 ◽  
Vol 137 (11) ◽  
Author(s):  
Brian Kestner ◽  
Tim Lieuwen ◽  
Chris Hill ◽  
Leonard Angello ◽  
Josh Barron ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Acoustic Pressure ◽  
Dynamic Pressure ◽  
Pressure Sensors ◽  
Rotating Stall ◽  
Compressor Blade ◽  
Blade Vibration ◽  
Multiple Sensors ◽  
Dynamic Pressure Measurements ◽  
Industrial Gas Turbine

This paper summarizes an analysis of data obtained from an instrumented compressor of an operational, heavy duty industrial gas turbine; the goal of the aforementioned analysis is to understand some of the fundamental drivers, which may lead to compressor blade vibration. Methodologies are needed to (1) understand the fundamental drivers of compressor blade vibration, (2) quantify the severity of “events,” which accelerate the likelihood of failure and reduce the remaining life of the blade, and (3) proactively detect when these issues are occurring so that the operator can take corrective action. The motivation for this analysis lies in understanding the correlations between different sensors, which may be used to measure the fundamental drivers and blade vibrations. In this study, a variety of dynamic data was acquired from an operating engine, including acoustic pressure, bearing vibration, tip timing, and traditional gas path measurements. The acoustic pressure sensors were installed on the first four compressor stages, while the tip timing was installed on the first stage only. These data show the presence of rotating stall instabilities in the front stages of the compressor, occurring during every startup and shutdown, and manifesting itself as increased amplitude oscillations in the dynamic pressure measurements, which are manifested in blade and bearing vibrations. The data that lead to these observations were acquired during several startup and shutdown events, and clearly show that the amplitude of these instabilities and the rpm at which they occur can vary substantially.

scholarly journals Analysis, Design, and Testing of a Low Profile Deflection Pad™ Thrust Bearing in an Industrial Gas Turbine

1994 ◽  
Author(s):  
Dilip Jain ◽  
Fouad Zeidan ◽  
Michael Wittmeyer
Keyword(s):  
Gas Turbine ◽  
Thrust Bearing ◽  
Element Analysis ◽  
Low Profile ◽  
Wide Range ◽  
Analysis Design ◽  
Thrust Pad ◽  
Industrial Gas Turbine ◽  
Design And Testing ◽  
Thrust Load

This paper describes the analysis, design, and testing of a low profile thrust bearing in a DR 990 industrial gas turbine. High unit loads and speeds, and the need to maintain low frictional power loss presented many challenges. The thrust pad design utilizes a flexure pivot, which allow near optimum performance for a wide range of speeds and loads in comparison to a fixed geometry taper land design. The use of high conductivity material for the thrust pads and directed lubrication allowed operation at lower temperatures. Finite element analysis was used to model the pad structure and pivot support. This analysis was confirmed by measuring the pad tilt using an eddy current probe. The test was conducted in a controlled thrust rig allowing accurate application and measurement of the thrust load. Precision manufacturing of the spherical seat and the application of a proprietary coating allowed better aligning capability under load. The bearing was tested in an engine at a range of speeds and loading conditions. The results are presented and compared with the existing fixed geometry bearing design. The bearing is currently running in an engine in the field and has accumulated 2,400 hours of operation with no forced outages.

Design Flexibility Permits a 35000 HP Industrial Gas Turbine to Meet a Wide Range of Application Requirements

1983 ◽  
Author(s):  
P. W. Kuly
Keyword(s):  
Ambient Temperature ◽  
Gas Turbine ◽  
Gas Flow ◽  
Steam Injection ◽  
High Ambient Temperature ◽  
Engine Operation ◽  
Temperature Conditions ◽  
Exhaust Heat ◽  
Wide Range ◽  
Industrial Gas Turbine

Two recent applications for a heavy duty industrial gas turbine engine are discussed. The principal design requirements for both cases are compared and the design changes necessary to meet the requirements are illustrated. In the case of a main pipeline compressor driver, the need for high thermal efficiency over a wide range of loads is met by use of a regenerative cycle and by reprogramming the loading sequence. Long term step increases in engine capability were provided by incorporating a unique engine convertability feature. In the case of a process air compressor driver with exhaust heat recovery, the engine exhaust temperature and gas flow imposed constraints on engine capability during high ambient temperature operation and on engine operation at low ambient temperature conditions. The constraints were met by the use of steam injection to augment power at high ambient temperature conditions and by the use of variable inlet guide vanes to control exhaust flow at the low temperatures.

25MW Class Modern Industrial Gas Turbine Suitable for Wide Range of Applications in CoGen/CC Power Plants

1996 ◽  
Author(s):  
Chuck Stankiewicz ◽  
Septimus van der Linden
Keyword(s):  
Gas Turbine ◽  
Power Plants ◽  
Developing Economies ◽  
District Heating ◽  
Advanced Technology ◽  
South East Asia ◽  
Wide Range ◽  
Turbine Component ◽  
Industrial Gas Turbine ◽  
Petrochemical Industries

The GT10 25MW class industrial gas turbine from ABB has seen a rapid success in power as well as heat generation for utilities, district heating plants, refineries, communities, universities, paper & food, cement and petrochemical industries. This broad application attests to the versatility of a modern gas turbine benefiting from advanced technology concepts in combustion, as well as turbine component efficiencies. The paper will review these developments and some interesting applications that could benefit dispersed industrial power plants in the fast developing economies of South East Asia.

Turbine Tip Clearance Measurement System Evaluation on an Industrial Gas Turbine

1997 ◽  
Author(s):  
S. J. Gill ◽  
M. D. Ingallinera ◽  
A. G. Sheard
Keyword(s):  
Gas Turbine ◽  
Measurement System ◽  
Gas Turbines ◽  
Turbine Blades ◽  
Tip Clearance ◽  
Real Time Measurement ◽  
Gap Measurement ◽  
Industrial Gas Turbines ◽  
Blade Tip ◽  
Industrial Gas Turbine

The continuing development of industrial gas turbines is resulting in machines of increasing power and efficiency. The need to continue this trend is focusing attention on minimizing all loss mechanisms within the machine, including those associated with turbine blade tip clearance. In order to study tip clearance in the turbine, real time measurement is required of clearance between turbine blades and the casing in which they run. This measurement is not routinely performed, due to the harsh nature of the turbine environment. On those occasions when turbine tip clearance is measured, it is typically in development vehicles, often using cooled probes that are somewhat unsuitable for use in production gas turbines. In this paper a program of work is reported that was undertaken with the purpose of identifying a promising turbine tip clearance measurement system that used the capacitive gap measurement technique. Issues surrounding the application of three systems to the turbine section of a GE MS6001FA gas turbine are identified and reported. Performance of the three evaluated systems is analyzed.

Development and Testing of the Upgraded High Pressure Turbine Section for an Industrial Gas Turbine

2008 ◽  
Author(s):  
E. Aschenbruck ◽  
D. Frank ◽  
T. Korte ◽  
R. Mu¨ller ◽  
U. Orth
Keyword(s):  
High Pressure ◽  
Gas Turbine ◽  
Cooling System ◽  
Mechanical Design ◽  
Development Program ◽  
Tip Clearance ◽  
Test Facility ◽  
High Pressure Turbine ◽  
Online Data ◽  
Clearance Control

As part of an ongoing development program to increase power output and efficiency of the THM 1304 gas turbine, modifications were made to the high pressure turbine. The modifications include but are not limited to blade and vane aerodynamics, cooling system and clearance control, mechanical design and materials. The development was to achieve the following goals: • Intensified blade and vane cooling to permit higher turbine inlet temperatures and to further extend service lifetime; • Improved aerodynamic performance; • Blades with pre-loaded tip shrouds to achieve low vibration amplitudes in a broad operating speed range; • Rotor design modifications to simplify assembly and disassembly; • Modified vane carrier and casing designs for optimal tip clearance control and turbine performance. The improved high pressure turbine was extensively tested in MAN TURBO’s full-load gas turbine test facility. Test results verified that component temperatures were within the expected range and design targets have been achieved. The first production gas turbine equipped with the upgraded high pressure turbine was installed in May 2004 as a gas compressor driver. To date a total of 11 units have gone into operation including units for power generation. Dry low emission technology is used on all engines. Every unit is monitored by an online data monitoring system and visually inspected in shorter intervals to verify the behavior in the field. Operation of the fleet is flawless at this time.

Application of Creativity Tools to Gas Turbine Engine Compressor Clearance Control

2013 ◽  
Author(s):  
Godwin I. Ekong ◽  
Christopher A. Long ◽  
Peter R. N. Childs
Keyword(s):  
Problem Solving ◽  
Gas Turbine ◽  
Divergent Thinking ◽  
Idea Generation ◽  
Problem Definition ◽  
Tip Clearance ◽  
Turbine Engine ◽  
Wide Range ◽  
Innovative Products ◽  
Clearance Control

Creativity tools are methods that can be used to promote innovative products and creative actions. There is a wide range of tools available for idea generation, employing divergent and convergent thinking for problem definition, exploration of problem features, generation of solution options, evaluation and implementation of ideas. Fundamental to their effective operation is to make use of a suitable creativity tool for a particular application and individual or team, to aid in the process of problem-solving, the refinement of old ideas, and the generation and implementation of new ideas. The principal creativity tool described in this paper is TRIZ which is the Russian acronym for Teoriya Resheniya Izobretatelskikh Zadatch meaning Theory of Inventive Problem Solving. This paper emphasizes the processes and specific TRIZ tools used in the implementation of TRIZ in the exploration of concepts for tip clearance control in gas turbine high pressure compressors in aircraft engines. The TRIZ process was used to categorize ideas generated through divergent thinking thus reducing the number of ideas carried forward for further engineering analysis.

Extension of Fuel Flexibility by Combining Intelligent Control Methods for Siemens SGT-400 Dry Low Emission Combustion System

2018 ◽  
Vol 141 (1) ◽  
Author(s):  
Kexin Liu ◽  
Phill Hubbard ◽  
Suresh Sadasivuni ◽  
Ghenadie Bulat
Keyword(s):  
Gas Turbine ◽  
Operating Conditions ◽  
Combustion System ◽  
Combustion Dynamics ◽  
Heating Value ◽  
Fuel Flexibility ◽  
Wide Range ◽  
Wobbe Index ◽  
Industrial Gas Turbine ◽  
The Impact

Extension of gas fuel flexibility of a current production SGT-400 industrial gas turbine combustor system is reported in this paper. A SGT-400 engine with hybrid combustion system configuration to meet a customer's specific requirements was string tested. This engine was tested with the gas turbine package driver unit and the gas compressor-driven unit to operate on and switch between three different fuels with temperature-corrected Wobbe index (TCWI) varying between 45 MJ/m3, 38 MJ/m3, and 30 MJ/m3. The alteration of fuel heating value was achieved by injection or withdrawal of N2 into or from the fuel system. The results show that the engine can maintain stable operation on and switching between these three different fuels with fast changeover rate of the heating value greater than 10% per minute without shutdown or change in load condition. High-pressure rig tests were carried out to demonstrate the capabilities of the combustion system at engine operating conditions across a wide range of ambient conditions. Variations of the fuel heating value, with Wobbe index (WI) of 30 MJ/Sm3, 33 MJ/Sm3, 35 MJ/Sm3, and 45 MJ/Sm3 (natural gas, NG) at standard conditions, were achieved by blending NG with CO2 as diluent. Emissions, combustion dynamics, fuel pressure, and flashback monitoring via measurement of burner metal temperatures, were the main parameters used to evaluate the impact of fuel flexibility on combustor performance. Test results show that NOx emissions decrease as the fuel heating value is reduced. Also note that a decreasing fuel heating value leads to a requirement to increase the fuel supply pressure. Effect of fuel heating value on combustion was investigated, and the reduction in adiabatic flame temperature and laminar flame speed was observed for lower heating value fuels. The successful development program has increased the capability of the SGT-400 standard production dry low emissions (DLE) burner configuration to operate with a range of fuels covering a WI corrected to the normal conditions from 30 MJ/N·m3 to 49 MJ/N·m3. The tests results obtained on the Siemens SGT-400 combustion system provide significant experience for industrial gas turbine burner design for fuel flexibility.

Transient Performance Analysis of an Industrial Gas Turbine Operating on Low-Calorific Fuels

2016 ◽  
Vol 139 (5) ◽  
Author(s):  
Vrishika Singh ◽  
Lars-Uno Axelsson ◽  
W.P.J. Visser
Keyword(s):  
Steady State ◽  
Energy Density ◽  
Gas Turbine ◽  
Alternative Fuels ◽  
Combustion Process ◽  
Transient Behavior ◽  
Performance Model ◽  
Transient Performance ◽  
Wide Range ◽  
Industrial Gas Turbine

The demand for more environmentally friendly and economic power production has led to an increasing interest to utilize alternative fuels. In the past, several investigations focusing on the effect of low-calorific fuels on the combustion process and steady-state performance have been published. However, it is also important to consider the transient behavior of the gas turbine when operating on nonconventional fuels. The alternative fuels contain very often a large amount of dilutants resulting in a low energy density. Therefore, a higher fuel flow rate is required, which can impact the dynamic behavior of the gas turbine. This paper will present an investigation of the transient behavior of the all-radial OP16 gas turbine. The OP16 is an industrial gas turbine rated at 1.9 MW, which has the capability to burn a wide range of fuels including ultra-low-calorific gaseous fuels. The transient behavior is simulated using the commercial software GSP including the recently added thermal network modeling functionality. The steady-state and transient performance model is thoroughly validated using real engine test data. The developed model is used to simulate and analyze the physical behavior of the gas turbine when performing load sheds. From the simulations, it is found that the energy density of the fuel has a noticeable effect on the rotor over-speed and must be considered when designing the fuel control.

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