perspective on r&d needs for gas turbine power … on r&d needs for gas turbine power...
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1
Perspective on R&D Needs for Gas
Turbine Power Generation
Eli Razinsky
Solar Turbine Incorporated
2010 UTSR Workshop
October 26, 2011
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2
• Overview
• Specific Requirements
Research Requirements
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Overview – Current / Future Challenges
• Technical Improvements Will Be Harder to Achieve –“Learning Curve”
• Society Requirements
Adequate Power
Availability of Fuel
o Affordable
o Minimal Degradation of the Environment
“Green”
• Competition for Resources Increased
Engineers
o Training
o Expertise
o Commitment
o Enthusiasm
Computer Power – Speed & Cost
Funding Limitations
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Overview – Required Approach
• Pragmatic Research
Address Critical Problems & Requirements
PerformancePerformance
OptimizedOptimized
ProductProduct
EmissionsEmissions
RAMRAM--DD LifeLife--
Cycle Cycle
CostsCosts
PerformancePerformance
OptimizedOptimized
ProductProduct
EmissionsEmissions
RAMRAM--DD LifeLife--
Cycle Cycle
CostsCosts
Must be Applicable in Industrial Design/Analysis Environment
o Iterative Multi-Disciplinary Process
o Demanding Design & Development Schedules/Costs
o Manufacturability
o Robust
Validation/Calibration Mandatory
Transferable
• Collaboration
Universities
OEM
OEM Value Stream
• Train the Next Generation of Turbomachinery Engineers
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• Status
Still Has Limitations, e.g. Heat Transfer
Can’t Completely Replace Testing
Unsteady, DES, LES Not Practical Yet
Turbomachinery CFD History
• CFD Capabilities Progressed Significantly
Model Fidelity
Flow Physics
MODEL FIDELITY SIGNIFICANTLY INCREASED
Meanline
1-D Models
1950’s
Airfoil
3-D Navier-Stokes
1980’s
Multistage
3-D Steady &
Single Stage
Unsteady
1990’s
Airfoil
2-D Inviscid
Blade-to-Blade
& Streamline
1960’s
Airfoil
3-D Inviscid
Euler
1970’s
Multistage 3-D
Unsteady
2000’s
More Testing
More Empiricism
More Exact
Less Testin
g
Continuous Valid
ation and C
alibratio
n
More Detailed M
odel
Increased Computational
Requirements
Simplifi
ed Model
Low Computational
Requirements
Meanline
1-D Models
1950’s
Airfoil
3-D Navier-Stokes
1980’s
Multistage
3-D Steady &
Single Stage
Unsteady
1990’s
Airfoil
2-D Inviscid
Blade-to-Blade
& Streamline
1960’s
Airfoil
3-D Inviscid
Euler
1970’s
Multistage 3-D
Unsteady
2000’s
More Testing
More Empiricism
More Exact
Less Testin
g
Continuous Valid
ation and C
alibratio
n
Continuous Valid
ation and C
alibratio
n
More Detailed M
odel
Increased Computational
Requirements
Simplifi
ed Model
Low Computational
Requirements
• Application Transitioned
From Post Design Analysis
To Fully Integrated Critical Tool For Design of Turbomachinery
• Product Payoff
Reduced Development Time/Cost
Improved Performance
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Reliable, Available
Commercial,
University & Gov.
CFD Software
Comprehensive
Technical
Skills,Training
and Experience
Extensive
Data-Base
Continuous
Upgrades,
Validations
and Calibrations
High Performance
Computer System
Advanced
High Fidelity
CFD
CFD Future Success Can be Greatly Enhanced by Committed Integrated Approach
Turbomachinery CFD – Future
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Perspective on R&D Needs for
Gas Turbine Power Generation –
Combustion
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Fuel Injector - Jets In Crossflow
• Requirements
Analysis Varying Fuel Hole
Location and Diameter to Produce
Optimal Fuel/Air Profile at the Exit
of the Injector
CFD Analysis with LES Since
Process is Transient
Test Validation/Calibration
• Challenge to Simulate Fuel Injector
Passage with Jets of Methane Fuel
Injected into Air Passage
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Combustor Liner Durability
Section 1” From Injector Exit
Section 4” From Injector Exit
Section 1” From Injector Exit
Section 4” From Injector Exit
• Challenge to Predict Liner Temperature
Complex Flowfields
Chemical Reaction (CR)
Cooling
Conduct Blind Test CFD Conjugate Heat Transfer
o CFD by Partner Universities?
o CFD Options
RANS, LES etc.
Different Reaction Mechanisms
• Requirements
Conduct Combustor Testing
o Obtain Liner and Heat Flux
o Effect of CR on Heat load
o Effect of Primary Zone Conditions
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Combustor Exit Profile
0
20
40
60
80
100
1000 1500 2000 2500
Combustor Exit Temperature
Co
mb
us
tor
Ex
it S
pa
n
0
20
40
60
80
100
1000 1500 2000 2500
Combustor Exit Temperature
Co
mb
us
tor
Ex
it S
pa
n
0
20
40
60
80
100
1000 1500 2000 2500
Combustor Exit Temperature
Co
mb
us
tor
Ex
it S
pa
n
0
20
40
60
80
100
1000 1500 2000 2500
Combustor Exit Temperature
Co
mb
us
tor
Ex
it S
pa
n
Durable Turbine Dependant on
Combustor Exit Temperature
• Effusion Cooling Plays Dual Role
– Impacts Exit Cone Metal Temperature
– Impacts Combustor Exit Temperature Profile
Effusion
Cooling
• Need to Characterize Effect of Effusion Cooling Blowing Ratio &
Number of Rows on Combustor Exit Temperature Profile
• CFD Validation/Calibration
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Perspective on R&D Needs for
Gas Turbine Power Generation –
Aero/Thermal
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Blade/Platform Heat Load Assessment
• Challenge To Predict Adiabatic Wall Temperature and Heat
Transfer Coefficient Accounting for
GT2010-22702
GT2010-22702
Platform Air Leakage
Disk Cavity Buffer Air
GT2010-22702
Platform Air Leakage
Disk Cavity Buffer Air
Platform Air
Leakage
Disk Cavity
Buffer Air
GT2010-22702
Platform Air Leakage
Disk Cavity Buffer Air
GT2010-22702
Platform Air Leakage
Disk Cavity Buffer Air
Platform Air
Leakage
Disk Cavity
Buffer Air
Often Critical
Location
Near Tip (Difficult to
Cool Internally)
Near Platform
& Platform
Often Critical
Location
Near Tip (Difficult to
Cool Internally)
Near Platform
& Platform
Often Critical
Location
Near Tip (Difficult to
Cool Internally)
Near Platform
& Platform
Inlet Temperature Profile
Buffer/Leakage Air Effects
Hot Streaks etc.
• Require
Models to Account for Effects Early in Design Cycle
CFD Based Modeling for Detailed Design
Experimental Validation/Calibration
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Blade/Platform Cooling Configuration Design
• High Heat Load Due to the Flat Combustor Outlet Temperature
Profile (Premixed Lean)
• Large Heat Load Variation
• Heat Load Prediction is Difficult
• Few Papers Related to the Platform Heat Transfer
(External/Internal)
• Casting Challenges
• Need Innovative Cooling Design Concepts & Validation/Calibration
GT2005-68415
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Multistage CFD For Design Environment
•Current CFD Options
Unsteady RANS (Sliding Mesh)
o High Fidelity Modeling of Flow Through Blade Rows
o Requires Full Model
o Unacceptable Computational Time for Iterative Design Environment
Steady RANS (Mixing Plane)
o Flow Assumed Mixed Out Circumferentially
Step Increase in Entropy
Mixing Plane Losses Are Not Same As Loss Generated In Real Unsteady Flow Downstream
o Computational Time Acceptable
Comparison of Entropy with
Mixing Plane & Unsteady
Calculations (Denton
GT2010-22540)
Mixing Plane
Interface
•Need Improved, Verified Steady State “Mixing Plane” Model - Open Documentation for Application
Flux Conservation
Indifference to Local Flow Direction
Robust
•Blind Test Validation/Calibration
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CFD Aero/Thermal Challenges
• Challenge – Temperature Prediction Error of 10 to 20 oF is Significant
• Require
Efficient Modeling
Experimental Validation
• Conjugate HT Analysis of Airfoils
Pure Convective Analysis No Longer Good Enough
HT Affected by Local Phenomena & Lateral Conduction
• Disk Cavity
Ingress/Egress
Seal Effectiveness for Various Configurations
High Swirl (Windage Effect)
Disk Pumping
GT2010-22432
3D CFD
GT2006-90033
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Perspective on R&D Needs for
Gas Turbine Power Generation –
Materials
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• Challenge
– Accumulation of Creep Damage in a
Component can Lead to Deformation
and Rupture with Catastrophic Results
– Often Creep Damage Difficult to
Monitor During Operation and Difficult
to Predict Accurately
– Creep-Fatigue Interaction
Materials Needs for the Future
Cross Section
of Creep Strain
Through a
Cooled Airfoil
Probabilistic
Distributions
Used to
Drive Lifing
Predictions
• Requirements
– More Accurate Creep Damage Models
o Damage Initiation
o Progression in Single Crystal Materials
– Faster More Cost Effective Methods for Developing Creep Material Data
o Virtual Test Rigs
– Improved Data Driven Probabilistic Lifing Models
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• Requirements
– High Cr Alloys (with Necessary Mechanical
Properties)
– Coatings
o Environmental
o Thermal
– Improved Testing Systems
o Rig Tests that Demonstrate Engine
Environment
Materials Needs for the Future
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Offshore
Application
COG
Application
• Material Durability when Exposed to
Various Operating Environments
H2S/H2/Offshore
Coke Oven Gas
Na2SO4, K2SO4, CaSO4 & MgSO4
• Degradation Mechanisms Including
High Temperature Oxidation, Hot
Corrosion, and Sulfidation
• Require New Metals, Coatings &
Cooling
Turbine Blade Tip
Hot Corrosion
Materials Needs for the Future
Injector Tip
Degradation
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