An Advanced Extreme-Environment Wireless Telemetry System for Turbine Blade Instrumentation

2017 ◽  
Vol 14 (4) ◽  
pp. 158-165 ◽  
Author(s):  
John R. Fraley ◽  
Brett Sparkman ◽  
Stephen Minden ◽  
Anand Kulkarni ◽  
Joshua McConkey
Keyword(s):  
High Temperature ◽  
Natural Gas ◽  
System Integration ◽  
Gas Turbines ◽  
Power Plants ◽  
Mechanical Design ◽  
Extreme Environment ◽  
Department Of Energy ◽  
Future Direction ◽  
High Level

As advanced natural gas power generation systems evolve, the thrust for increased efficiencies and reduced emissions results in increasingly harsh conditions inside the turbine environment. These high temperatures, pressures, and corrosive atmospheres result in accelerated rates of degradation, leading to failure of turbine materials and components. Wolfspeed, A Cree Company, Siemens Energy, and Siemens Corporate Technology, in collaboration with the Department of Energy (DOE)'s National Energy Technology Laboratory, are developing a reliable and long-term monitoring capability in the turbine hot gas path in the form of novel ceramic-based thermocouples and wide bandgap instrumentation electronics that will contribute to the overall reliability of gas turbines. When equipped with better monitoring and controls, power plants can operate with increased fuel-burning efficiency, improved process dynamics and gas concentrations, and increased overall longevity of the power plant components. This will result in increased turbine availability and a reduction in outages and maintenance costs. The technology being developed in this program is based on advanced techniques and innovations in nearly every aspect of high-temperature electronics, including materials, semiconductor devices, subcomponents, electronic packaging, and system integration. The environment in which this wireless system must operate has continuous centrifugal loads with a gravitation force on the order of 16,000 times the force of gravity (16,000 g) and temperatures exceeding 400°C. This article will specifically discuss the background and motivation for the high-temperature instrumentation system and will explain the high-level electrical system, the construction of the instrumentation package, the techniques used for integration onto rotating components, as well as the wireless power and data transmission systems. In addition to the electrical and mechanical design, this article will also discuss results from laboratory bench testing as well as heated spin rig testing. Finally, this article will highlight the future direction of the instrumentation system evolution, with a final objective of insertion into Siemens natural gas turbine power plants.

An Advanced Extreme Environment Wireless Telemetry System for Turbine Blade Instrumentation

2017 ◽  
Vol 2017 (HiTEN) ◽  
pp. 000001-000010
Author(s):  
John R. Fraley ◽  
Brett Sparkman ◽  
Stephen Minden ◽  
Joshua McConkey
Keyword(s):  
High Temperature ◽  
Natural Gas ◽  
System Integration ◽  
Gas Turbines ◽  
Power Plants ◽  
Mechanical Design ◽  
Wide Band ◽  
Extreme Environment ◽  
Future Direction ◽  
High Level

ABSTRACT As advanced natural gas power generation systems evolve, the thrust for increased efficiencies and reduced emissions results in increasingly harsh conditions inside the turbine environment. These high temperatures, pressures, and corrosive atmospheres result in accelerated rates of degradation, leading to failure of turbine materials and components. Wolfspeed, A Cree Company, Siemens Energy and Siemens Corporate Technology, in collaboration with the DoE's National Energy Technology Laboratory (NETL), are developing a reliable and long-term monitoring capability in the turbine hot gas path in the form of novel ceramic based thermocouples and wide band gap instrumentation electronics that will contribute to the overall reliability of gas turbines. When equipped with better monitoring and controls, power plants can operate with increased fuel-burning efficiency, improved process dynamics and gas concentrations, and increased overall longevity of the power plant components. This will result in increased turbine availability and a reduction in outages and maintenance costs. The technology being developed in this program is based upon advanced techniques and innovations in nearly every aspect of high temperature electronics, including materials, subcomponents, semiconductors, electronic packaging, and system integration. The environment in which this wireless system must operate has continuous g-loads on the order of 16,000g, and temperatures exceeding 400 °C. This paper will specifically discuss the background and motivation for the high temperature instrumentation system, and will explain the high-level electrical system, the construction of the instrumentation package, the techniques utilized for integration onto rotating components, as well as the wireless power and data transmission systems. In addition to the electrical and mechanical design, this paper will also discuss results from laboratory bench testing as well as heated spin rig testing. Finally, this paper will highlight the future direction of the instrumentation system evolution, with a final objective of insertion into Siemens natural gas turbine power plants.

An Advanced Extreme Environment Wireless Telemetry System for Turbine Blade Instrumentation

2019 ◽  
Vol 2019 (HiTen) ◽  
pp. 000001-000006
Author(s):  
John R. Fraley ◽  
Alan Mantooth ◽  
Sajib Roy ◽  
Robert Murphree ◽  
Affan Abassi ◽  
...  
Keyword(s):  
High Temperature ◽  
Integrated Circuit ◽  
Gas Turbines ◽  
Power Plants ◽  
High Reliability ◽  
Wide Band ◽  
Extreme Environment ◽  
Condition Monitoring System ◽  
Key Aspects ◽  
The University

ABSTRACT As advanced natural gas power generation systems evolve, the thrust for increased efficiencies and reduced emissions results in increasingly harsh conditions inside the turbine environment. These high temperatures, pressures, and corrosive atmospheres result in accelerated rates of degradation, leading to failure of turbine materials and components. The University of Arkansas (UA) and Siemens, in collaboration with the DoE's National Energy Technology Laboratory (NETL), are developing a reliable and long-term monitoring capability in the turbine hot gas path in the form of novel ceramic-based thermocouples and integrated wide band gap instrumentation electronics that will contribute to the overall reliability of gas turbines. When equipped with better monitoring and controls, power plants can operate with increased fuel-burning efficiency, improved process dynamics and gas concentrations, and increased overall longevity of the power plant components. This will result in increased turbine availability and a reduction in outages and maintenance costs. One of the key aspects to driving forward turbine monitoring capability is the development of high temperature capable integrated circuit (IC) electronics. Previous papers have described 500 °C + electronics that were developed primarily from a combination of discrete single transistors combined with supporting high temperature passive components. While these circuits have been tested successfully in high temperature spin test environments, the move to an IC approach will greatly increase the performance and reliability of turbine monitoring systems. This program is developing such capability through the implementation of silicon carbide (SiC) based ICs, and this paper details the initial approach and early testing of the developed devices. This research represents an important step towards the realization of a field deployable high reliability turbine condition monitoring system.

Adapting Gas Turbines to Zero Emission Oxy-Fuel Power Plants

2008 ◽  
Author(s):  
Roger E. Anderson ◽  
Scott MacAdam ◽  
Fermin Viteri ◽  
Daniel O. Davies ◽  
James P. Downs ◽  
...  
Keyword(s):  
High Pressure ◽  
High Temperature ◽  
Natural Gas ◽  
Steam Turbine ◽  
Output Power ◽  
Gas Turbines ◽  
Power Plants ◽  
Low Pressure ◽  
Inlet Temperature ◽  
Zero Emission

Future power plants will require some type of carbon capture and storage (CCS) system to mitigate carbon dioxide (CO2) emissions. The most promising technologies for CCS are: oxy-fuel (O-F) combustion, pre-combustion capture, and post-combustion capture. This paper discusses the recent work conducted by Siemens Power Generation, Florida Turbine Technologies, Inc. (FTT) and Clean Energy Systems, Inc. (CES) in adapting high temperature gas turbines to use CES’s drive gases in high-efficiency O-F zero emission power plants (ZEPPs). CES’s O-F cycle features high-pressure combustion of fuel with oxygen (O2) in the presence of recycled coolant (water, steam or CO2) to produce drive gases composed predominantly of steam and CO2. This cycle provides the unique capability to capture nearly pure CO2 and trace by-products by simple condensation of the steam. An attractive O-F power cycle uses high, intermediate and low pressure turbines (HPT, IPT and LPT, respectively). The HPT may be based on either current commercial or advanced steam turbine technology. Low pressure steam turbine technology is readily applicable to the LPT. To achieve high efficiencies, an IPT is necessary and efficiency increases with inlet temperature. The high-temperature IPT’s necessitate advanced turbine materials and cooling technology. O-F plants have an abundance of water, cool steam ∼200°C (400°F) and CO2 that can be used as cooling fluids within the combustor and IPT systems. For the “First Generation” ZEPP, a General Electric J79 turbine, minus the compressor, to be driven directly by CES’s 170 MWt high-pressure oxy-fuel combustor (gas generator), has been adapted. A modest inlet gas temperature of 760°C (1400°F) was selected to eliminate the need for turbine cooling. The J79 turbine operating on natural gas delivers 32 MWe and incorporates a single-stage free-turbine that generates an additional 11 MWe. When an HPT and an LPT are added, the net output power (accounting for losses) becomes 60 MWe at 30% efficiency based on lower heating value (LHV), including the parasitic loads for O2 separation and compression and for CO2 capture and compression to 151.5 bar (2200 psia). For an inlet temperature of 927°C (1700°F), the nominal value, the net output power is 70 MWe at 34% efficiency (LHV). FTT and CES are evaluating a “Second Generation” IPT with a gas inlet temperature of 1260°C (2300°F). Predicted performance values for these plants incorporating the HPT, IPT and the LPT are: output power of approximately 100–200 MWe with an efficiency of 40 to 45%. The “Third Generation” IPT for 2015+ power plants will be based on the development of very high temperature turbines having an inlet temperature goal of 1760°C (3200°F). Recent DOE/CES studies project such plants will have LHV efficiencies in the 50% range for natural gas and HHV efficiencies near 40% for gasified coal.

Siemens Westinghouse Advanced Turbine Systems Program Final Summary

2002 ◽  
Author(s):  
Ihor S. Diakunchak ◽  
Greg R. Gaul ◽  
Gerry McQuiggan ◽  
Leslie R. Southall
Keyword(s):  
High Temperature ◽  
High Efficiency ◽  
Technology Development ◽  
Mechanical Design ◽  
System Development ◽  
Department Of Energy ◽  
Combustion Heat ◽  
Alloy Casting ◽  
Generation Plant ◽  
Power Generation Plant

This paper summarises achievements in the Siemens Westinghouse Advanced Turbine Systems (ATS) Program. The ATS Program, co-funded by the U.S. Department of Energy, Office of Fossil Energy, was a very successful multi-year (from 1992 to 2001) collaborative effort between government, industry and participating universities. The program goals were to develop technologies necessary for achieving significant gains in natural gas-fired power generation plant efficiency, a reduction in emissions, and a decrease in cost of electricity, while maintaining current state-of-the-art electricity generation systems’ reliability, availability, and maintainability levels. Siemens Westinghouse technology development concentrated on the following areas: aerodynamic design, combustion, heat transfer/cooling design, engine mechanical design, advanced alloys, advanced coating systems, and single crystal (SC) alloy casting development. Success was achieved in designing and full scale verification testing of a high pressure high efficiency compressor, airfoil clocking concept verification on a two stage turbine rig test, high temperature bond coat/TBC system development, and demonstrating feasibility of large SC turbine airfoil castings. The ATS program included successful completion of W501G engine development testing. This engine is the first step in the W501ATS engine introduction and incorporates many ATS technologies, such as closed-loop steam cooling, advanced compressor design, advanced sealing and high temperature materials and coatings.

Assessment of the Potential of Combined Micro Gas Turbine and High Temperature Fuel Cell Systems

2002 ◽  
Author(s):  
Dieter Bohn ◽  
Nathalie Po¨ppe ◽  
Joachim Lepers
Keyword(s):  
Fuel Cells ◽  
High Temperature ◽  
Fuel Cell ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Power Plants ◽  
Advanced Materials ◽  
Cell Systems ◽  
Micro Gas Turbine ◽  
Technological Assessment

The present paper reports a detailed technological assessment of two concepts of integrated micro gas turbine and high temperature (SOFC) fuel cell systems. The first concept is the coupling of micro gas turbines and fuel cells with heat exchangers, maximising availability of each component by the option for easy stand-alone operation. The second concept considers a direct coupling of both components and a pressurised operation of the fuel cell, yielding additional efficiency augmentation. Based on state-of-the-art technology of micro gas turbines and solid oxide fuel cells, the paper analyses effects of advanced cycle parameters based on future material improvements on the performance of 300–400 kW combined micro gas turbine and fuel cell power plants. Results show a major potential for future increase of net efficiencies of such power plants utilising advanced materials yet to be developed. For small sized plants under consideration, potential net efficiencies around 70% were determined. This implies possible power-to-heat-ratios around 9.1 being a basis for efficient utilisation of this technology in decentralised CHP applications.

The Effect of Alternative Turbine Cooling Schemes on the Performance of Utility Gas Turbine Powerplants

1982 ◽  
Author(s):  
Arthur Cohn ◽  
Mark Waters
Keyword(s):  
High Temperature ◽  
Gas Turbines ◽  
Power Plants ◽  
Heat Rate ◽  
Combined Cycle ◽  
Specific Power ◽  
Cooling Effectiveness ◽  
Turbine Cooling ◽  
The Impact ◽  
Systems Studies

It is important that the requirements and cycle penalties related to the cooling of high temperature turbines be thoroughly understood and accurately factored into cycle analyses and power plant systems studies. Various methods used for the cooling of high temperature gas turbines are considered and cooling effectiveness curves established for each. These methods include convection, film and transpiration cooling using compressor bleed and/or discharge air. In addition, the effects of chilling the compressor discharge cooling gas are considered. Performance is developed to demonstrate the impact of the turbine cooling schemes on the heat rate and specific power of Combined–Cycle power plants.

Closed Cycle Gas Turbines: An ECAS Update — Part 1

1979 ◽  
Author(s):  
H. C. Daudet ◽  
C. A. Kinney
Keyword(s):  
Heat Exchanger ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Power Plants ◽  
System Analysis ◽  
Public Utility ◽  
Department Of Energy ◽  
Closed Cycle ◽  
Study Program ◽  
Study Results

This paper presents a discussion of the significant results of a study program conducted for the Department of Energy to evaluate the potential for closed cycle gas turbines and the associated combustion heater systems for use in coal fired public utility power plants. Two specific problem areas were addressed: (a) the identification and analysis of system concepts which offer high overall plant efficiency consistent with low cost of electricity (COE) from coal-pile-to-bus-bar, and (b) the identification and conceptual design of combustor/heat exchanger concepts compatible for use as the cycle gas primary heater for those plant systems. The study guidelines were based directly upon the ground rules established for the ECAS studies to facilitate comparison of study results. Included is a discussion of a unique computer model approach to accomplish the system analysis and parametric studies performed to evaluate entire closed cycle gas turbine utility power plants with and without Rankine bottoming cycles. Both atmospheric fluidized bed and radiant/convective combustor /heat exchanger systems were addressed. Each incorporated metallic or ceramic heat exchanger technology. The work culminated in conceptual designs of complete coal fired, closed cycle gas turbine power plants. Critical component technology assessment and cost and performance estimates for the plants are also discussed.

Turning NGCC Into IGCC: Cycle Retrofitting Issues

2006 ◽  
Author(s):  
Juan Pablo Gutierrez ◽  
Terry B. Sullivan ◽  
Gerald J. Feller
Keyword(s):  
Natural Gas ◽  
Gas Turbines ◽  
Power Plants ◽  
Combined Cycle ◽  
Integrated Gasification Combined Cycle ◽  
Water Steam ◽  
Power Block ◽  
Starting Point ◽  
Natural Gas Combined Cycle ◽  
Gas Plants

The increase in price of natural gas and the need for a cleaner technology to generate electricity has motivated the power industry to move towards Integrated Gasification Combined Cycle (IGCC) plants. The system uses a low heating value fuel such as coal or biomass that is gasified to produce a mixture of hydrogen and carbon monoxide. The potential for efficiency improvement and the decrease in emissions resulting from this process compared to coal-fired power plants are strong evidence to the argument that IGCC technology will be a key player in the future of power generation. In addition to new IGCC plants, and as a result of new emissions regulations, industry is looking at possibilities for retrofitting existing natural gas plants. This paper studies the feasibility of retrofitting existing gas turbines of Natural Gas Combined Cycle (NGCC) power plants to burn syngas, with a focus on the water/steam cycle design limitations and necessary changes. It shows how the gasification island processes can be treated independently and then integrated with the power block to make retrofitting possible. This paper provides a starting point to incorporate the gasification technology to current natural gas plants with minor redesigns.

Cost Optimal Strategies of High Temperature Thermal Energy Storage Systems in Combined Heat and Power Applications

2016 ◽  
Author(s):  
Parker Wells ◽  
Karthik Nithyanandam ◽  
Richard Wirz
Keyword(s):  
High Temperature ◽  
Energy Storage ◽  
Los Angeles ◽  
Natural Gas ◽  
Thermal Energy ◽  
Thermal Energy Storage ◽  
Power Plants ◽  
Combined Heat And Power ◽  
Time Of Day ◽  
Recycled Paper

As variable generation electricity sources, namely wind and solar, increase market penetration, the variability in the value of electricity by time of day has increased dramatically. In response to increase in electricity demand, natural gas “peaker plants” are being added to the grid, and the need for spinning and nonspinning reserves have increased. Many natural gas, and other heat source based, power plants exist as combined heat and power (CHP), or cogeneration, plants. When built for industrial use, these plants are sized and run based on heat needs of an industrial facility, and are not optimized for the value of electricity generated. With the inclusion of new, less expensive thermal energy storage (TES) systems, the heating and electricity usage can be separated and the system can be optimized separately. The use of thermal energy storage with CHP improves system economics by improving efficiency, reducing upfront capital expenditures, and reducing system wear. This paper examines the addition of thermal energy storage to industrial natural gas combined heat and power (CHP) plants. Here a case study is presented for a recycled paper mill near Los Angeles, CA. By implementing thermal energy storage, the mill could decouple electric and heat production. The mill could take advantage of time-of-day pricing while producing the constant heat required for paper processing. This paper focuses on plant economics in 2012 and 2015, and suggests that topping cycle industrial CHP plants could benefit from the addition of high temperature (400–550°C) energy storage. Even without accounting for the California incentives associated with implementing advanced energy storage technologies and distributed generation, the addition of energy storage to CHP plants can drastically reduce the payback period below the 25 year expected economic lifetime of a plant. Thus thermal energy storage can make more CHP plants economically viable to build.

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