FTT Aerothermal Research in Support of DOE …...Title Microsoft PowerPoint - UTSR Aerothermal 2012...
Transcript of FTT Aerothermal Research in Support of DOE …...Title Microsoft PowerPoint - UTSR Aerothermal 2012...
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Jim DownsManager – Thermal Systems Design
Florida Turbine Technologies, Inc.561-427-6250
FTT Aerothermal Research in Support of DOE Initiatives/Goals
4 October 2012
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.
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OutlineOutline
• Oxy-fuel turbomachinery development (with Clean Energy Systems & Siemens)
• Demonstration of enabling Spar-Shell cooling technology in gas turbines
• Sealing and leakage control technology
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012 2
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Oxy-Fuel Turbomachinery DevelopmentOxy-Fuel Turbomachinery Development
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012 3
Program goals and objectives
• Objective: Design, manufacture & test a commercial-scale oxy-fuel turbine (OFT) for use in industrial O-F plants that:– Capture and sequester 99% of produced CO2
– Operate at competitive cycle efficiencies
– Utilize diverse fuels
• Schedule: 48 months– FY2011 thru FY2014
• Development partners– Clean Energy Systems, Siemens Energy, Inc., Florida Turbine
Technologies, Inc. and Integrated Engineers and Contractors Co.
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Oxy-Fuel Turbomachinery DevelopmentOxy-Fuel Turbomachinery Development
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012 4
Oxy-fuel cycle – Zero emission power plant
Recycle Water
C.W.
Cond.
FuelProcessing
Plant
CrudeFuel
AirSeparation
PlantAir
N2
Coal, RefineryResidues, or
Biomass
NG, Oil orLandfill Gas
HP IP LP
O2
Fuel*
CO2Recovery
* CH4, CO, H2, etc.
ExcessWater
EOR, ECBM, orSequestration
DirectSales
HX
ElectGen.
Multi-stageTurbines
Gas Generator
CO2
RH
Recycle Water
C.W.
Cond.
FuelProcessing
Plant
CrudeFuel
FuelProcessing
Plant
CrudeFuel
AirSeparation
PlantAir
N2
AirSeparation
PlantAir
N2
AirSeparation
PlantAir
N2
Coal, RefineryResidues, or
Biomass
NG, Oil orLandfill Gas
HP IP LP
O2
Fuel*
CO2Recovery
CO2Recovery
* CH4, CO, H2, etc.
ExcessWater
EOR, ECBM, orSequestration
DirectSales
HX
ElectGen.
Multi-stageTurbines
Gas Generator
CO2
RH
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Oxy-Fuel Turbomachinery DevelopmentOxy-Fuel Turbomachinery Development
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012 5
Adaptation of existing turbomachinery for IPT
• Originally a W251 (SGT-900) gas turbine• Remove compressor, convert combustors to O-F reheaters• Converted to a 150 MW oxy-turbine• CO2 by-product is a revenue stream
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Oxy-Fuel Turbomachinery DevelopmentOxy-Fuel Turbomachinery Development
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012 6
Transformation of SGT-900 to OFT-900/SXT-150SGT-900 air-breathing gas turbine
OFT-900/SXT-150 oxy-fuel intermediate pressure turbine
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Oxy-Fuel Turbomachinery DevelopmentOxy-Fuel Turbomachinery Development
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012 7
FTT reheat combustor manufacture
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Oxy-Fuel Turbomachinery DevelopmentOxy-Fuel Turbomachinery Development
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012 8
Assembled reheat combustor received from FTT
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Oxy-Fuel Turbomachinery DevelopmentOxy-Fuel Turbomachinery Development
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012 9
Secondary flow system routing/modeling
OFT-900/SXT-150
HeatExchanger
HeatExchanger
SGT-900
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Oxy-Fuel Turbomachinery DevelopmentOxy-Fuel Turbomachinery Development
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012 10
Whole engine thermal/structural modelingVerify structural integrity• Component lifing• Blade tip and seal clearance
Temperature
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Oxy-Fuel Turbomachinery DevelopmentOxy-Fuel Turbomachinery Development
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012 11
Status
The program: • CES has partnered with Siemens Oil & Gas and FTT to
retrofit an SGT-900 to a highly efficient OFT under the DOE-CES program.
• Will demonstrate a full-scale OFT at reduced loads, off the grid
• Is currently one year ahead of its 4-year development schedule
Once successful:• The OFT can be deployed in several applications - all
offering clean, reliable power without pollution
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Oxy-Fuel Turbomachinery DevelopmentOxy-Fuel Turbomachinery Development
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012 12
Equipment arrival in Bakersfield, CA August 27, 2012
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Oxy-Fuel Turbomachinery DevelopmentOxy-Fuel Turbomachinery Development
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012 13
Transport to Kimberlina via heavy hauler 8/27/12
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Oxy-Fuel Turbomachinery DevelopmentOxy-Fuel Turbomachinery Development
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012 14
OFT installed on foundation at KPP September 13th
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Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
OutlineOutline
• Oxy-fuel turbomachinery development (with Clean Energy Systems & Siemens)
• Demonstration of enabling Spar-Shell cooling technology in gas turbines
• Sealing and leakage control technology
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012 15
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Enabling Spar-Shell Cooling Tech.Enabling Spar-Shell Cooling Tech.
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012 16
Program goals and objectives
• Develop and test – commercial prototype:
• First-stage turbine airfoils requiring significantly less cooling flow than the current state-of-the-art (SOTA)
• Proposed cooling approach addresses durability concerns associated with turbine inlet pressure and temperature increases desired for future gas turbines
• Open door to commercialization of this new technology in both F-frame and other highly cooled turbine airfoil applications
Enabling technology for future gas turbine-based power systems
• DOE Office of Fossil Energy-sponsored hydrogen and oxy-fueled turbomachinery programs
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Philosophy/practice limits cooling potentialTypical impingement pressure ratioVane Pressures
17
Conventional cooling design
Enabling Spar-Shell Cooling Tech.Enabling Spar-Shell Cooling Tech.
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012
• Impingement pressure ratio typically near constant around airfoil
• Post-impingement pressure set high enough for coolant outflow to leading edge
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Enabling Spar-Shell Cooling Tech.Enabling Spar-Shell Cooling Tech.
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012 18
Ref: U.S. Patent #7080971, “Cooled Turbine Spar Shell Blade Construction, J. W. Wilson and W. Brown, July 25, 2006.
• FTT sequential-impingement cooling scheme based on new insert design improves cooling (reduces cooling flow 40%)
What is it? - Alternative to existing state-of-the-art
• Provides path for implementation of next generation materials
• Optimized thermal/structural arrangement allows increased firing temperatures and improved efficiency
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Commercialization program: DOE, FTT & Siemens
19
• Use existing (proven) 1st stage turbine vane casting as the shell– No rotating mass concerns
• Sequential-impingement cooling provided by FTT spar insert
• Demonstration will install 6-8 parts in a rainbow arrangement with bill-of-material parts
Enabling Spar-Shell Cooling Tech.Enabling Spar-Shell Cooling Tech.
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012
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20
3D thermal analysis results
Enabling Spar-Shell Cooling Tech.Enabling Spar-Shell Cooling Tech.
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012
Temperature
Average surface temperature increased less than 10C while cooling flow was reduced 35% (Relative to current hardware)
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3D structural analysis results
Enabling Spar-Shell Cooling Tech.Enabling Spar-Shell Cooling Tech.
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012
Von Mises Stress
Stresses and predicted cyclic capabilities are consistent with baseline design
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Enabling Spar-Shell Cooling Tech.Enabling Spar-Shell Cooling Tech.
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012
Design validation and verification activities Basic cooling flow and heat transfer performance evaluation via experimental test prior to engine installation
• Impingement heat transfer test (FTT/UCF)• Cold flow and pressure drop testing of actual engine hardware• Seal leakage test (FTT)
Health can be monitored during engine test to assure product integrity
• Temperature and pressure sensors• Frequent borescope (visual) inspection
Management of manufacturing/fabrication risk• Production of engineering mockups and models• Manufacturing, fabrication and assembly trials
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23
Purpose of heat transfer testing
Enabling Spar-Shell Cooling Tech.Enabling Spar-Shell Cooling Tech.
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012
• Downstream rows of large scale jet impingement arrays suffer from crossflow• This negative effect can be mitigated by increasing the crossflow area
Bunker. US Patent No. 6,000,908
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24
Impingement heat transfer testing performed at UCF*
Enabling Spar-Shell Cooling Tech.Enabling Spar-Shell Cooling Tech.
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012* University of Central Florida – UTSR Fellow Roberto Claretti under direction of Prof. Jay Kapat
Lead Wires
Thermocouple
TSP
Pressure tap lines
Channel exit diffuser
Heater Strips
Test technique: Constant heat flux, temperature sensitive paint
• Proven methodology• Accurate results
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25
Assembled, instrumented test article
Enabling Spar-Shell Cooling Tech.Enabling Spar-Shell Cooling Tech.
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012
Side walls provide the necessary height for Z/D=3
TSPJet plate
Bus Bar Slot
Yellow tape to protect surface from scratches (taped on the back of the part)
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Smooth channel checkout case
Enabling Spar-Shell Cooling Tech.Enabling Spar-Shell Cooling Tech.
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012
z
x
0
0.5
1
1.5
2
2.5
0 2 4 6 8 10 12 14 16 18 20
Nu/
Nu D
B
x/Dh
Re = 60,000 Re = 41,000 Re = 23,000
Laterally-averaged Nu/NuDB
4.08.0 PrRe023.0DBNu
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Impingement geometry
Enabling Spar-Shell Cooling Tech.Enabling Spar-Shell Cooling Tech.
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012
z/D
y/Dx/D
zy
x
Case z/D x/D xc/D Nx y/D yc/D NyValidation 3 3 63 20 8 32 4
Heated Area
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Impingement validation test results
Enabling Spar-Shell Cooling Tech.Enabling Spar-Shell Cooling Tech.
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012
Rej=16,000
Rej=13,000
Rej=10,000
Nu
y
xz
x
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29
Enabling Spar-Shell Cooling Tech.Enabling Spar-Shell Cooling Tech.
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012
Spar fabrication/bonding trials were successful
• Bond trial used a dead weight load• Essentially 100% complete bonding• External faying surfaces have concave faces• Lesson learned:
• Base material grain boundaries next to bond surface exhibited solid boride precipitation
• Process improvement measures identified
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Enabling Spar-Shell Cooling Tech.Enabling Spar-Shell Cooling Tech.
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012 30
Commercialization program schedule
2011 2012 20132011 2012 2013
Instrumentation, Assembly and Initial Engine Test/validation of Modified Production Engine Turbine Vane with Enhanced Spar‐Shell Enabling Cooling Technology
Design/Development of Spar‐Shell Cooling Technology into an Existing Production Engine
Engine Demo
Procurement of Partial Engine Set (10 Parts Total. 6 Parts Delivered to Engine) of Modified Production Engine Turbine Vanes with Enhanced Spar‐Shell Enabling Cooling Technology
DOE – Supported Program Designs, Develops, Manufactures, Instruments and Delivers Demonstration Hardware for Engine Test
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Enabling Spar-Shell Cooling Tech.Enabling Spar-Shell Cooling Tech.
Copyright 2012, Florida Turbine Technologies, Inc. All Rights Reserved.4 October 2012 31
Program on track to test Spar-Shell late next year
• Test vehicle and window of opportunity for Spar-Shell insertion identified
• Design is nearly complete• Long-lead hardware (castings) have been released to
production• Bench-level testing and dimensional inspections are
validating the hardware prior to full-scale engine test• Hardware will be instrumented with thermocouples and
pressure taps
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OutlineOutline
• Oxy-fuel turbomachinery development (with Clean Energy Systems & Siemens)
• Demonstration of enabling Spar-Shell cooling technology in gas turbines
• Sealing and leakage control technology
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Sealing & Leakage Control TechnologySealing & Leakage Control Technology
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R & D needs
Static seals• Joints between
mating surfaces Rotating seals• Gaps between
adjoining static and rotating hardware
Control leakage while permitting relative movement between parts
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Sealing & Leakage Control TechnologySealing & Leakage Control Technology
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R&D Needs:
• Leakage accounts for ~25% of parasitic losses in gas turbine engines
• Turbo machines are inherently leaky• Comprised of many parts having joints, gaps and clearances• Static-to-static interfaces• Static-to-rotating interfaces
• Pressure difference maintained across these orifices to control environment
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Sealing & Leakage Control TechnologySealing & Leakage Control Technology
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Anticipated seal misalignments considered in test plan
Shear
Twist
Offset + Shear
• Conventional (feather) seals can be expected to operate well under ideal conditions
• FTT has designed, and is developing a seal to work well under all conditions
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Sealing & Leakage Control TechnologySealing & Leakage Control Technology
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Static seal rig constructed to test leakage flows
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Initial results = Very encouraging
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Sealing & Leakage Control TechnologySealing & Leakage Control Technology
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Incr
easi
ng L
oad
Increasing Clearance
0
Desired Gap
Restorative Forces
Rot
atin
gR
otat
ing
High Pressure
Low Pressure
Low Pressure
PHPC
PHPC
PL
PLPL
PL
A1
A2
A3
A4
At Equilibrium: PH(A1) + PL(A2) = PC(A3) + PL(A4) Net Force = 0
Reduced Clearance: PH(A1) + PL(A2) < PC(A3) + PL(A4) Net Force =
Increased Clearance: PH(A1) + PL(A2) > PC(A3) + PL(A4) Net Force =
Seal Housing
Air-riding seal technology for advanced gas turbines
Air Riding TOBI Turbine Disk
Cooled Blade
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Existing test rig achieved surface speeds up to 620 ft/sec• Proof-of-concept demonstration• Measured leakage to date represents very small (~0.002”)
effective gap at various pressure ratios • Additional testing to extend and expand database
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• FTT is working closely with CES and Siemens to develop oxy-fuel turbomachinery.
• Spar-Shell turbine components incorporating sequential-impingement cooling are on target for first test late next year.
• FTT has taken a proactive role in the development of advanced sealing technologies.
Summary
Sealing & Leakage Control TechnologySealing & Leakage Control Technology
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Acknowledgements
Department of EnergyNational Energy Technology Laboratory
Siemens Energy
Clean Energy Systems, Inc.Power Without Pollution
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Thank You & Questions?
FTT Aerothermal ResearchFTT Aerothermal Research
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