Development of High Efficient 30MW Class Gas Turbine: The Kawasaki L30A

2012 ◽  
Author(s):  
Ryozo Tanaka ◽  
Take Koji ◽  
Masanori Ryu ◽  
Akinori Matsuoka ◽  
Atsushi Okuto
Keyword(s):  
Gas Turbine ◽  
Pressure Ratio ◽  
Test Facility ◽  
Gas Generator ◽  
Pressure Losses ◽  
Power Turbine ◽  
High Efficient ◽  
Cooling Design ◽  
Power Application ◽  
Technical Features

Kawasaki Heavy Industries (KHI) will launch the first unit of the L30A gas turbine, rated output of 30.9MW, and 41.2% of thermal efficiency. The L30A is a twin-shaft gas turbine designed for combined heat and power application (CHP) with lower emissions. The newly developed 14-stage compressor has a pressure ratio of 24.5 with an air flow of 86.5 kg/sec. KHI’s proven dry low emission (DLE) technologies are adapted to the combustion design, and NOx emission of 15 ppm (15% = O2) has been achieved. Also, the newly designed 2-stage gas generator turbine (GGT) employs the proven cooling design with conjugate heat transfer and flow (CHT) analysis, and 3-stage power turbine (PT) has the inter-locking type tip shroud which reduces vibration level for wide operating range of PT with lower pressure losses. The in-house verification tests have been conducted since 2010, to confirm design targets such as performance, emission, vibrations and temperatures were verified in exclusive test facility for the L30A. This paper describes the technical features of the L30A, the development activities and some verification test results.

Off-Design Performance Investigation of a Low Calorific Gas Fired Two-Shaft Gas Turbine

2009 ◽  
Author(s):  
Pontus Eriksson ◽  
Magnus Genrup ◽  
Klas Jonshagen ◽  
Jens Klingmann
Keyword(s):  
Gas Turbine ◽  
Pressure Ratio ◽  
Gas Generator ◽  
Dimensional Parameter ◽  
Gaseous Fuels ◽  
Surge Margin ◽  
Power Turbine ◽  
Lean Premixed ◽  
Wobbe Index ◽  
Compressor Map

Gas turbine systems are predominantly designed to be fuelled with gaseous fuels within a limited Wobbe index range (typically HHV = 45–55 MJ/Nm3 or 1200–1480 Btu/scf). When low calorific fuel gases are fired, the engine will be forced to operate outside its design envelope. The added mass flow will typically raise the cycle pressure ratio and in two-shaft designs also raise the gas generator shaft speed. Typical constraints to be considered due to the altered fuel composition are pressure loads, shaft torques, shaft overspeeds, centrifugal overloading of disks and blades, combustor flameout, surge and flutter limits for the turbomachinery. This poses limitations to usable fuel choices. In this study, the response of a natural gas fired simple cycle two-shaft gas turbine is investigated. A lean premixed combustor is also included in the model. Emphasis has been put on predicting the turbomachinery and combustor behavior as different amounts of N2 or CO2 are added to the fuel path. These two inerts are typically found in large quantities in medium and low calorific fuels. The fuels lower heating value is thus gradually changed from 50 MJ/kg (21.5 kBtu/lb) to 5MJ/kg (2.15 kBtu/lb). A model, based on the Volvo Aero Corp. VT4400 gas turbine (originally Dresser Rand DR990) characterized by one compressor and two expander maps is considered. The free turbine is operated at fixed physical speed. The operating point is plotted in the compressor map and the turbine maps at three distinct firing temperatures representing turndown from full load to bleed opening point. Gas generator speed and shaft power are shown. Surge margin and power turbine power is plotted. Overall efficiency is computed. The behavior of the Volvo lean premixed combustor is also discussed. Air split, primary zone equivalence ratio and temperature is plotted. Combustor loading, combustion intensity and pressure drop is graphed. Results are, as far as possible, given as non-dimensional parameter groups for easy comparison with other machines.

scholarly journals Development and Field Experience of a New 29000 HP Gas Turbine

1980 ◽  
Author(s):  
J. K. Hubbard ◽  
C. Austin
Keyword(s):  
Gas Turbine ◽  
Field Experience ◽  
Performance Test ◽  
High Efficiency ◽  
Test Facility ◽  
Gas Generator ◽  
Initial Field ◽  
Power Turbine ◽  
Exhaust Heat ◽  
Gas Turbine Exhaust

The paper describes the development and initial field experience with a new high efficiency 26,000/30,000 hp gas turbine. Exhaust heat from the power turbine was used to boost the installation thermal efficiency and provide icing protection for the inlet. Wherever possible, proven power turbine design concepts were combined with the advances of a “second generation” aircraft derivative gas generator to produce a reliable machine which was introduced with a minimum of development time. To assure field success, a special test facility was constructed and the unit subjected to a full load mechanical and performance test under simulated field condition.

scholarly journals Design and Development of a 12,500-Hp Gas Turbine

1971 ◽  
Author(s):  
C. Austin
Keyword(s):  
Gas Turbine ◽  
Electrical Power ◽  
Load Test ◽  
Test Facility ◽  
Gas Generator ◽  
Design Concepts ◽  
Power Turbine ◽  
Gas Generators ◽  
Design Speed ◽  
Simulated Field

This paper outlines the major design considerations and development experience of a 12,500-hp dual-shaft gas turbine. The unit uses an aircraft derivative gas turbine as the gas generator and is designed to operate in an attended or unattended station without external electrical power above 60 per cent of design speed. Proven power turbine design concepts were combined with the advantages of a variety of highly developed gas generators to produce a reliable machine which could be introduced with a minimum of development time. A special test facility was constructed to subject the unit to a full load test under conditions which simulated field operation.

Numerical Modeling of Heat Transfer and Pressure Losses for Uncooled Gas Turbine Blade Tip: Effect of Tip Clearance and Tip Geometry

2007 ◽  
Author(s):  
Lamyaa A. El-Gabry
Keyword(s):  
Heat Transfer ◽  
Mach Number ◽  
Gas Turbine ◽  
Computational Study ◽  
Numerical Models ◽  
Pressure Ratio ◽  
Tip Clearance ◽  
Pressure Losses ◽  
Blade Tip ◽  
Exit Mach Number

A computational study has been performed to predict the heat transfer distribution on the blade tip surface for a representative gas turbine first stage blade. CFD predictions of blade tip heat transfer are compared to test measurements taken in a linear cascade, when available. The blade geometry has an inlet Mach number of 0.3 and an exit Mach number of 0.75, pressure ratio of 1.5, exit Reynolds number based on axial chord of 2.57×106, and total turning of 110 deg. Three blade tip configurations were considered; they are flat tip, a full perimeter squealer, and an offset squealer where the rim is offset to the interior of the tip perimeter. These three tip geometries were modeled at three tip clearances of 1.25, 2.0, and 2.75% of blade span. The tip heat transfer results of the numerical models agree fairly well with the data and are comparable to other CFD predictions in the open literature.

Experimental Evaluation of a Metal Mesh Bearing Damper

2000 ◽  
Vol 122 (2) ◽  
pp. 326-329 ◽  
Author(s):  
Mark Zarzour ◽  
John Vance
Keyword(s):  
Elevated Temperatures ◽  
Test Facility ◽  
Squeeze Film ◽  
Gas Generator ◽  
Metal Mesh ◽  
Previous Investigator ◽  
Spreadsheet Program ◽  
Squirrel Cage ◽  
Power Turbine ◽  
Squeeze Film Dampers

Metal mesh is a commercially available material used in many applications including seals, heat shields, filters, gaskets, aircraft engine mounts, and vibration absorbers. This material has been tested by the authors as a bearing damper in a rotordynamic test rig. The test facility was originally used to support the design of a turboprop engine, developing squirrel cages and squeeze film dampers for both the gas generator and power turbine rotors. To design the metal mesh damper, static stiffness and dynamic rap test measurements were first made on metal mesh samples in a specially designed nonrotating test fixture. These property tests were performed on samples of various densities and press fits. One sample was also tested in an Instron machine as an ancillary and redundant way to determine the stiffness. Using the stiffness test results and equations derived by a previous investigator, a spreadsheet program was written and used to size metal mesh donuts that have the radial stiffness value required to replace the squirrel cage in the power turbine. The squirrel cage and squeeze film bearing damper developed for the power turbine rotor was then replaced by a metal mesh donut sized by the computer code. Coast down tests were conducted through the first critical speed of the power turbine. The results of the metal mesh tests are compared with those obtained from previous testing with the squeeze film damper and show that the metal mesh damper has the same damping as the squeeze film at room temperature but does not lose its damping at elevated temperatures up to 103°C. Experiments were run under several different conditions, including balanced rotor, unbalanced rotor, heated metal mesh, and wet (with oil) metal mesh. The creep, or sag, of the metal mesh supporting the rotor weight was also measured over a period of several weeks and found to be very small. Based on these tests, metal mesh dampers appear to be a viable and attractive substitute for squeeze film dampers in gas turbine engines. The advantages shown by these tests include less variation of damping with temperature, ability to handle large rotor unbalance, and the ability (if required) to operate effectively in an oil free environment. Additional testing is required to determine the endurance properties, the effect of high impact or maneuver loads, and the ability to sustain blade loss loads (which squeeze films cannot handle). [S0742-4795(00)01002-4]

Experimental Evaluation of a Metal Mesh Bearing Damper

1999 ◽  
Author(s):  
Mark Zarzour ◽  
John Vance
Keyword(s):  
Elevated Temperatures ◽  
Test Facility ◽  
Squeeze Film ◽  
Gas Generator ◽  
Metal Mesh ◽  
Previous Investigator ◽  
Spreadsheet Program ◽  
Squirrel Cage ◽  
Power Turbine ◽  
Squeeze Film Dampers

Metal mesh is a commercially available material used in many applications including seals, heat shields, filters, gaskets, aircraft engine mounts, and vibration absorbers. This material has been tested by the authors as a bearing damper in a rotordynamic test rig. The test facility was originally used to support the design of a turboprop engine, developing squirrel cages and squeeze film dampers for both the gas generator and power turbine rotors. To design the metal mesh damper, static stiffness and dynamic rap test measurements were first made on metal mesh samples in a specially designed nonrotating test fixture. These property tests were performed on samples of various densities and press fits. One sample was also tested in an Instron machine as an ancillary and redundant way to determine the stiffness. Using the stiffness test results and equations derived by a previous investigator, a spreadsheet program was written and used to size metal mesh donuts that have the radial stiffness value required to replace the squirrel cage in the power turbine. The squirrel cage and squeeze film bearing damper developed for the power turbine rotor was then replaced by a metal mesh donut sized by the computer code. Coast down tests were conducted through the first critical speed of the power turbine. The results of the metal mesh tests are compared with those obtained from previous testing with the squeeze film damper and Show that the metal mesh damper has the same damping as the squeeze film at room temperature but does not lose its damping at elevated temperatures up to 103 °C. Experiments were run under several different conditions, including balanced rotor, unbalanced rotor, heated metal mesh, and wet (with oil) metal mesh. The creep, or sag, of the metal mesh supporting the rotor weight was also measured over a period of several weeks and found to be very small. Based on these tests, metal mesh dampers appear to be a viable and attractive substitute for squeeze film dampers in gas turbine engines. The advantages shown by these tests include less variation of damping with temperature, ability to handle large rotor unbalance, and the ability (if required) to operate effectively in an oil free environment. Additional testing is required to determine the endurance properties, the effect of high impact or maneuver loads, and the ability to sustain blade loss loads (which squeeze films cannot handle).

Emission and Performance of a Lean-Premixed Gas Fuel Injection System for Aeroderivative Gas Turbine Engines

1994 ◽  
Author(s):  
Timothy S. Snyder ◽  
Thomas J. Rosfjord ◽  
John B. McVey ◽  
Aaron S. Hu ◽  
Barry C. Schlein
Keyword(s):  
Gas Turbine ◽  
Fuel Injection ◽  
Pressure Ratio ◽  
Combustion Efficiency ◽  
Injection System ◽  
Test Facility ◽  
Fuel Injection System ◽  
Moderate Pressure ◽  
Single Digit ◽  
Lean Premixed

A dry-low-NOx, high-airflow-capacity fuel injection system for a lean-premixed combustor has been developed for a moderate pressure ratio (20:1) aeroderivative gas turbine engine. Engine requirements for combustor pressure drop, emissions, and operability have been met. Combustion performance was evaluated at high power conditions in a high-pressure, single-nozzle test facility which operates at full baseload conditions. Single digit NOx levels and high combustion efficiency were achieved A wide operability range with no signs of flashback, autoignition, or thermal problems was demonsuated. NOx sensitivities 10 pressure and residence time were found to be small at flame temperatures below 1850 K (2870 F). Above 1850 K some NOx sensitivity to pressure and residence Lime was observed and was associated with the increased role of the thermal NOx production mechanism at elevated flame temperatures.

Capacity Matching of Aeroderivative Gas Generator With Free Power Turbine: Challenges, Uncertainties, and Opportunities

2019 ◽  
Author(s):  
Deepak Thirumurthy ◽  
Jose Carlos Casado Coca ◽  
Kanishka Suraweera
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Systems Approach ◽  
Gas Generator ◽  
Performance Guarantees ◽  
Design Variables ◽  
Performance Trends ◽  
Power Turbine ◽  
Parameter Matching ◽  
Turbine Capacity

Abstract For gas turbines with free power turbines, the capacity or flow parameter matching is of prime importance. Accurately matched capacity enables the gas turbine to run at its optimum conditions. This ensures maximum component efficiencies, and optimum shaft speeds within mechanical limits. This paper presents the challenges, uncertainties, and opportunities associated with an accurate matching of a generic two-shaft aeroderivative HP-LP gas generator with the free power turbine. Additionally, generic performance trends, uncertainty quantification, and results from the verification program are also discussed. These results are necessary to ensure that the final free power turbine capacity is within the allowable range and hence the product meets the performance guarantees. The sensitivity of free power turbine capacity to various design variables such as the vane throat area, vane trailing edge size, and manufacturing tolerance is presented. In addition, issues that may arise due to not meeting the target capacity are also discussed. To conclude, in addition to design, analysis, and statistical studies, a system-of-systems approach is mandatory to meet the allowed variation in the free power turbine capacity and hence the desired gas turbine performance.

Advanced Multi-Cup Fuel Injector Technology for Environmentally Responsible Aviation Gas Turbine Engines

2015 ◽  
Author(s):  
Erlendur Steinthorsson ◽  
Adel Mansour ◽  
Brian Hollon ◽  
Michael Teter ◽  
Clarence Chang
Keyword(s):  
Gas Turbine ◽  
Direct Injection ◽  
Pressure Ratio ◽  
Test Facility ◽  
Turbine Engines ◽  
Practical Implementation ◽  
Gas Turbine Engines ◽  
Fuel Injector ◽  
Ambient Conditions ◽  
Environmentally Responsible

Participating in NASA’s Environmentally Responsible Aviation (ERA) Project, Parker Hannifin built and tested multipoint Lean Direct Injection (LDI) fuel injectors designed for NASA’s N+2 55:1 Overall Pressure-Ratio (OPR) gas turbine engine cycles. The injectors are based on Parker’s earlier three-zone injector (3ZI) which was conceived to enable practical implementation of multipoint LDI schemes in conventional aviation gas turbine engines. The new injectors offer significant aerodynamic design flexibility, excellent thermal performance, and scalability to various engine sizes. The injectors built for this project contain 15 injection points and incorporate staging to enable operation at low power conditions. Ignition and flame stability were demonstrated at ambient conditions with ignition air pressure drop as low as 0.3% and fuel-to-air ratio (FAR) as low as 0.011. Lean Blowout (LBO) occurred at FAR as low as 0.005 with air at 460 K and atmospheric pressure. A high pressure combustion testing campaign was conducted in the CE-5 test facility at NASA Glenn Research Center at pressures up to 250 psi and combustor exit temperatures up to 2,033 K (3,200 °F). The tests demonstrated estimated LTO cycle emissions that are about 30% of CAEP/6 for a reference 60,000 lbf thrust, 54.8-OPR engine. This paper presents some details of the injector design along with results from ignition, LBO and emissions testing.

The Reheat Gas Turbine With Steam-Blade Cooling—A Means of Increasing Reheat Pressure, Output, and Combined Cycle Efficiency

1982 ◽  
Vol 104 (1) ◽  
pp. 9-22 ◽  
Author(s):  
I. G. Rice
Keyword(s):  
Gas Turbine ◽  
Pressure Ratio ◽  
Pressure Rise ◽  
Expansion Ratio ◽  
Combined Cycle ◽  
Gas Generator ◽  
Exhaust Temperature ◽  
Blade Cooling ◽  
Cycle Efficiency ◽  
Turbine Blading

The reheat (RH) pressure can be appreciably increased by applying steam cooling to the gas-generator (GG) turbine blading which in turn allows a higher RH firing temperature for a fixed exhaust temperature. These factors increase gas turbine output and raise combined-cycle efficiency. The GG turbine blading will approach “uncooled expansion efficiency”. Eliminating cooling air increases the gas turbine RH pressure by 10.6 percent. When steam is used (injected) as the blade coolant, additional GG work is also developed which further increases the RH pressure by another 12.0 percent to yield a total increase of approximately 22.6 percent. The 38-cycle pressure ratio 2400° F (1316° C) TIT GG studied produces a respectable 6.5 power turbine expansion ratio. The higher pressure also noticeably reduces the physical size of the RH combustor. This paper presents an analysis of the RH pressure rise when applying steam to blade cooling.

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