ceramic stationary gas turbine development … stationary gas turbine development program ... -...
TRANSCRIPT
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Ceramic Stationary Gas TurbineDevelopment Program
Ceramic Stationary Gas TurbineCeramic Stationary Gas TurbineDevelopment ProgramDevelopment Program
VP19990487-001
Jeffrey R. Price
Program Manager
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OverviewOverview
• Project Description
• Ceramic Component Development
• Field Testing
• Summary
VP19990487-002
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Project DescriptionProject DescriptionProject DescriptionProject Description
VP19990487-003
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Ceramic Stationary Gas Turbine(CSGT) Program
Ceramic Stationary Gas Turbine(CSGT) Program
• Program Sponsor- U.S. Department of Energy (DOE)- Office of Industrial Technology, Washington, DC- Program Manager - Patricia Hoffman
• DOE Project Management- DOE Chicago Operations Office, Argonne, IL- Project Manager, Stephen Waslo
VP19990487-004
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Program Objectives and ApproachProgram Objectives and Approach
• Improve Stationary Gas Turbine Performance inCogeneration through Selective Replacement ofCooled Metallic Hot Section Components withUncooled Ceramic Parts
• Retrofit Industrial Gas Turbine Engine - Centaur 50S- 1st-Stage Ceramic Blades- 1st-Stage Ceramic Nozzles- Ceramic Combustor Liners
VP19990487-005
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• Increase TRIT: 1010°C 1121°C (1850°F 2050°F)- Improve Thermal Efficiency: 29.6% 31.3%- Increase Output Power: 4 5 MW
• Reduce Gas Turbine Emissions- Demonstrate < 25 ppmv NOx- Potential < 10 ppmv NOx- Potential < 25 ppmv CO
Program Objectives and ApproachProgram Objectives and Approach
VP19990487-006
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CSGT Ceramic RetrofitCSGT Ceramic Retrofit
Centaur 50S Engine at Texaco Site
Combustor withCeramic Liners
CeramicNozzle
Disk withCeramic Blades
VP19990487-007
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CSGT Program TeamCSGT Program Team
VP19990487-008
Prime Contractor
Monolithic Ceramic Materials
AS-800 Silicon Nitride
SN-281/SN-282 Silicon Nitride
CFCC Combustor Liner Materials
SiC/SiC Composites
SiC/SiC Composites
Environmental Barrier Coatings
Nondestructive Evaluation
Materials Testing Support
Cogeneration End User
Solar Turbines Incorporated
AlliedSignal Ceramic Components
Kyocera Industrial Ceramics Corp.
AlliedSignal Composites, Inc.
BFGoodrich Aerospace
Pratt & Whitney
Argonne National Laboratory
Caterpillar Technical Center
Oak Ridge National Laboratory
University of Dayton Research Institute
Texaco (Formerly ARCO Western Energy)
Malden Mills Industries
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Ceramic Component DevelopmentCeramic Component DevelopmentCeramic Component DevelopmentCeramic Component Development
VP19990487-009
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Metallic and AS-800 Ceramic BladesMetallic and AS-800 Ceramic Blades
VP19990487-010
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Ceramic Blade TestingCeramic Blade Testing
VP19990487-011
• May 1997, AS-800 Blades- Terminated after 948 Hours- Foreign Object Damage
• May 1998, AS-800 Blades- Terminated after 352 Hours- Foreign Object Damage
Two Field Installations at TexacoTwo Field Installations at Texaco
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Ceramic Blade Development IssuesCeramic Blade Development Issues
• Improve Impact Resistance ofCeramic Blade Materials - Conduct Impact Study - Improve Material Properties - Energy Absorbing Coatings - More Robust Airfoil Designs
• Evaluate Alternate Attachments
- More Robust Attachments - Non-Compliant Layer Designs
VP19990487-012
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Cooled Metallic and UncooledCeramic Nozzles
Cooled Metallic and UncooledCeramic Nozzles
VP19990487-013
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SN-88 Silicon NitrideNozzle Assembly
SN-88 Silicon NitrideNozzle Assembly
VP19990487-014
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Ceramic Nozzle TestingCeramic Nozzle Testing
• Short-Term Engine Test - 1 Hrat Full Load
• No-Load Idle, 50% Load,100% Load
• Nozzle Airfoil Performed Well
• Chipping in Nozzle Attachmentand Outer Shroud Area
Initial Design ValidationInitial Design Validation
VP19990487-015
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Ceramic Nozzle TestingCeramic Nozzle Testing
• 2nd Short-Term Engine Test- 1 Hr at Full Load
• Design Modifications toAttachment Structure
• Chipping Was Eliminatedduring Second Test
• 100-Hr Cyclic Engine Test
Further Design ValidationFurther Design Validation
VP19990487-016
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Some Nozzles Cracked in 68-HrEngine Test
Some Nozzles Cracked in 68-HrEngine Test
• Materials Degradation - NeedEnvironmental Barrier Coating
• Re-evaluate Ceramic Nozzle andAttachment Structure Design
• Nine of 11 Nozzles in 120º arc
• White Deposit on All Airfoils
• Cracks Originated From Trailingedge: 3(OD), 6 (ID), 2 (OD+ID)
• OD and ID Attachment in GoodCondition
VP19990487-017
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Ceramic Nozzle TestingCeramic Nozzle Testing
• 4 Hours
• 172 Pieces of Instrumentation- 74 Metal Thermocouples- 38 Air Thermocouples- 60 Pressure Taps
• 11 Nozzles with Laser-Drilled Holeson Inner and Outer Shrouds
• Thermal Paint- Secondary Clamp Ring- Outer Shrouds- Tip Shoe Support Ring
• Data Currently Being Analyzed
Redesign Efforts in ProgressRedesign Efforts in Progress
Instrumented Engine Test - August 1999Instrumented Engine Test - August 1999
VP19990487-018
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CFCC Combustor LinersCFCC Combustor Liners
• Simple Design: SoLoNOxRetrofit
• ACI and BFG SiC/SiC CFCCCylindrical Liners
• Hi-Nicalon / SiC CFCC- CVI- Melt Infiltration
BFG 3-D Nicalon/SiC (CVI)
ACI 2-D Enhanced Nicalon/SiC (CVI)
VP19990487-019
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CFCC Combustor Liner AssemblyCFCC Combustor Liner Assembly
VP19990487-020
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CFCC Combustor Liner TestingCFCC Combustor Liner Testing
• > 400 Hr of In-House Engine Test Time- 100 Hr - Max. Time on Single Build
• Excellent Durability- NDE Inspection Before and After Tests
• Emissions- 50 - 100% Load Range- NOx < 15 ppmv- CO < 10 ppmv
VP19990487-021
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DLC Enhanced SiC/SiC CFCC CombustorLiners after 100-Hr Engine Test
DLC Enhanced SiC/SiC CFCC CombustorLiners after 100-Hr Engine Test
VP19990487-022
Acceptable for Field Testing Acceptable for Field Testing
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Field TestingField TestingField TestingField Testing
VP19990487-023
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Texaco Field Test SiteTexaco Field Test Site
VP19990487-024
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CSGT Field TestingCSGT Field Testing
VP19990487-025
• Texaco (Formerly ARCO WesternEnergy), Bakersfield, California
• Steam and ElectricityCogeneration
• Reduced Emissions- < 15 ppmv NOx- < 10 ppmv CO
• More than 10,000 Total Hours ofFull-Load Field Operation
5 Field Installations5 Field Installations
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CSGT Field TestingCSGT Field Testing
• World’s First Commercial Installation- May 21, 1997- 1st-Stage AS-800 Silicon Nitride Blades- Ceramic-Grade Nicalon Enhanced SiC/SiC Liners
• Test Terminated after 948 Hrs of Field Operation- Failure of 1st-Stage AS-800 Blades Attributed to Foreign Object Damage
VP19990487-026
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CFCC Liners after 1st Field TestCFCC Liners after 1st Field Test
• Inner Liner Heavily Oxidized
• Localized Oxidation on Outer Liner
• No Degradation of Secondary Components
• Need for Environmental Barrier Coating andBetter Heat Transfer Identified
VP19990487-027
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2nd CSGT Centaur 50S Field Test2nd CSGT Centaur 50S Field Test
• ARCO Western Energy - February 27, 1998
• Hi-Nicalon Enhanced SiC/SiC Combustor Liners- More Stable Fibers- Higher Density- Thick SiC Protective Seal Coat
• Combustor Modifications to Reduce CFCC Liner Wall Temperature- Maximum Temperature Measured: 2103°F
• Reduced Emissions- < 15 ppmv NOx, < 10 ppmv CO
VP19990487-028
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CFCC Liners after 2258-Hr Field TestCFCC Liners after 2258-Hr Field Test
• Inner Liner Sectioned for Analysis- Oxidized vs Unoxidized Areas- Microstructure- Recession- Residual Strength
• Liner Degradation Closely MatchesExposure Testing at ORNL
• Significantly Less Oxidation than1st Field Test
• Part Could Have Continuedin Service
• Outer Liner Accepted forAdditional Field Testing
VP19990487-029
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CSGT Centaur 50S Field TestCSGT Centaur 50S Field Test
• December 1998, Start of 4th Quarter Field Installation
• Hi-Nicalon/Enhanced SiC CVI Outer Liner (ACI)
- Reused from Field Test 3
• Hi-Nicalon/SiC MI Inner Liner (BFG)
- New
• 4-Hrs Acceptance Test at Solar
• 2758 Hrs of Full-Load Operation
• 2758 Hrs on Inner Liner
• 5016 Cumulative Hrs on Outer Liner
• Test Stopped to Evaluate Liners on April 11, 1999VP19990487-030
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Hi-Nicalon/Enhanced SiC CVI Outer LinerHi-Nicalon/Enhanced SiC CVI Outer Liner
After Field Test 4 (5016 Hours on Liner)After Field Test 4 (5016 Hours on Liner)
TDC: Top Dead Center
BDC: Bottom Dead Center
Gas Flow
Fore
AftThermocouple
Injector Location
Split1 2 3 4 65 7
ShearCracks
8Split
TDCBDC
VP19990487-031
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Hi-Nicalon/SiC MI Inner LinerHi-Nicalon/SiC MI Inner Liner
After Field Test 4 (2758 Hours on Liner)After Field Test 4 (2758 Hours on Liner)
Gas Flow
Fore
Aft
Thermocouple
TDC: Top Dead Center
BDC: Bottom Dead Center
Injector Location
TDC BDC
1 2 3 4 65
VP19990487-032
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Field Test of EnvironmentalBarrier Coatings
Field Test of EnvironmentalBarrier Coatings
• Start Date - April, 1999
• Inner Liner: Ni-Nicalon/SiC MI(ACI)
• Outer Liner: Hi-Nicalon/E-SiCCVI (ACI)
• EBC: Plasma-Sprayed Oxide (P & W)- Optimized EBC from NASA EPM Program
• Over 4900 Hrs Field Exposure- 22 Starts
• Periodic Borescope Inspections
VP19990487-033
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Malden Mills IndustriesLow Emissions Demonstration
Malden Mills IndustriesLow Emissions Demonstration
VP19990487-034
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• CFCC Hot-Wall Combustor Liners withEnvironmental Barrier Coating
− Inner Liner: BFGoodrich Melt-Infiltrated SiC/SiC
− Outer Liner: AlliedSignal CompositesCVI SiC/SiC
− Environmental Barrier Coating:Plasma-Sprayed Oxide Deposited byPratt & Whitney
• Similar Combustion System in Operationat Texaco in Bakersfield
− Over 4900 Hours of Full-LoadOperation
− Low Emissions Demonstrated
• NOx < 15 ppmv
• CO < 10 ppmv
Low Emissions CombustorDemonstration
Low Emissions CombustorDemonstration
VP19990487-035
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• Acceptance Test of 1st CFCCLow Emission Centaur 50SCompleted July 28 at Solar’sDeSoto Facility
• Acceptance Test Emissions
− 50 to 100% Load
• NOx < 15 ppmv
• CO < 10 ppmv
• Engine Shipped to Malden Millson July 29
Low Emissions CombustorDemonstration
Low Emissions CombustorDemonstration
VP19990487-036
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• Two Centaur 50S Engines
• Installation of Low EmissionCFCC Combustion System in1st Engine Initiated August 9
• Full Production August 23
− 8000-Hr Demonstration
• Emissions Requirements
− NOx < 15 ppmv
− CO < 10 ppmv
• Installation in 2nd Engine -July / August 2000
• Over 1200 hrs of Operation- 34 starts
Malden Mills Low EmissionsDemonstration
Malden Mills Low EmissionsDemonstration
VP19990487-037
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• 2758 hour Field Test Operation of BFG MI Inner Liner - April 1999
• 5016 hour Field Test Operation of ACI CVI Outer Liner - April 1999
• EBC’s Developed/Optimized for CFCC Liners - Field Test Started in April 1999
• Malden Mills Installation Completed on Schedule- August 1999
• Over 1200 Hours of CFCC/EBC Operation at Malden Mills
• Over 4900 Hours of CFCC/EBC Operation at Texaco
• Instrumented Engine Test of Ceramic Nozzle Assembly - August 1999
CSGT Milestones/AccomplishmentsCSGT Milestones/Accomplishments
VP19990487-038
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Summary of CSGT ProgramSummary of CSGT Program
• Functional Designs Have Been Completed for Monolithic Blades,
Nozzles, and Combustor Liners
• Designs Have Been Demonstrated in Rig and Engine Testing
• Gas Turbine Emissions Have Been Reduced Using CFCC
Combustor Liners
• Over 11,000 Hrs of Engine Testing at the Commercial Cogeneration
Field Test Sites
− Over 1300 Hrs on Ceramic Turbine Blades
− Over 11,000 Hrs on SiC/SiC CFCC Combustor Liners
− Over 6000 Hrs on CFCC Liners with EBCs
VP19990487-039
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Summary of CSGT ProgramSummary of CSGT Program
• Critical Materials and Design Issues Need to Be Resolved
− Better Fracture Toughness of Monolithics
− Combustor Liners: Environmental Resistance: EBC Coatings
− Blades: FOD Resistance, Long Term Durability of Attachment
− Nozzles: Attachment Durability, Material Durability, EBC Coatings
• Engine Testing Will Continue
− Ceramic Nozzle Engine Test In-House: 100+ Hrs
− Continued Field Testing
• Texaco Site: EBC Coated SiC/SiC CFCC Liners
• Two 8,000-Hr Engine Tests at Malden Mills, MA
VP19990487-040
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