Development of the GT36 Sequential Combustor · 2017. 11. 6. · High Pressure Combustor Test Rig GT36 in Birr Test Power Plant • Transferability to engine operation confirmed for

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Development of the GT36 Sequential Combustor

Gerhard Früchtel, Douglas Pennell

Verbrennungsforschung in der Schweiz 2017; ETH Zürich

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Agenda

• GT36 introduction

• GT36 CPSC combustor

• GT36 validation

• Conclusions & questions

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More than 160 Years Background

TODAY

Global leading OEMof GT and ST

2014

Incorporation of JointVentures with

Shanghai ElectricCompany

2012100 years of

Steam Turbinemanufacturing

2010150th Gas

Turbinemanufactured

2007OSP™

concept launch

2005Total TechnologicalIndependence

1995 First Combined Cycle Power Plantbased on Ansaldo Energia GT

1991Ansaldo Energiaestablished

1962First supercritical600 MW PowerPlant

1923 First Power Plant

1853 Giovanni Ansaldo& Co. established

2016

Acquisition of Alstomadvanced HDGT

technology and Assets

Acquisition of PowerSystem Manufacturing

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Heavy Duty Gas Turbine PerformanceNew Equipment Portfolio

AE94.2A

AE94.3A

GT26

AE64.3A

500 MW / 41.5%

Model Output / Efficiency Frequency

340 MW / 41%

345 MW / 41%

310 MW / 39.8%

185 MW / 36.2%

50 Hz

60 Hz

50 Hz

50 Hz

50 Hz

50 / 60 HzGT gross performance including once-through-cooler contribution where applicable

100% Methane, ISO conditions, duct and auxiliary losses excluded

GT36-S6GT36-S6

GT36-S5

78 MW / 36.3%

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Ansaldo’s H-Class Gas Turbine: GT36

15 stage compressor(4 vanes variable)

4 stage turbine

CPSC can combustor12 cans (60Hz)16 cans (50Hz)

GT36 S5 (50Hz) GT36 S6 (60Hz)

SC*

CC 1+1**

SC*

CC 1+1**

Power, MW 500 720 340 500

Efficiency, % 41.5 61.5 41.0 61.3

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GT36 Gas Turbine Evolution

GT26

GT36

GT36 CPSC features

• Sub 25vppm NOx & CO

• Turn Down < 30% GT load

• Gaseous Fuel Flexibility:Wobbe Index: 31-50MJ/mn

3

Up to 18%molar C2+ hydro-carbonswith H2 fuel doping capability

• Dual fuel capability with distillateOil#2 and online fuel changeover

• Hot gas path inspection 13 days

SequentialCombustor

AxialCompressor Turbine

PremixCombustor

GT26 Sequential Combustion

• 23 years of reliable reheattechnology proven in F-class fleet

Technology evolution of existing product portfolio using in-house knowhow

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Agenda

• GT36 introduction

• GT36 CPSC combustor

• GT36 validation

• Conclusions & questions

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Stre

amTe

mpe

ratu

re

Length /residence time

B1(M1)

A1F1

A1F1

C2

Short residence timecombustion and CPSCflame hotspots avoided

C1

Premixed1st stage

combustion

CPSC

AxialStaged

B1(M1)

CPSC mixes allfuel and all airtogether before

sequentialauto-ignition

B2(M2)F2

F2B2

(M2)

CPSC A2

Mixer ExitTemperature, MET à

B: BurnerM: MixerC: CombustorA: AirF: Fuel

…and comparison to a generic axially staged combustion systemCPSC Operating Principle

Axial Staged A2

Axial Staged A2

Combustorexit remainingtemperature

spread

Peaktemperature foraxially staged

combustor

CPSC NOxadvantage

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Key ComponentsGT36 CPSC Combustor

First Stage, (FS)– Gas and oil startup & premix

burner & combustor– Ansaldo F-class

low NOx low turndowntechnology

– Capacity adapted to GT36combustor

– High degree of identical or similarcomponents to F-class design

Dilution Air Mixer– Multi row mixer with nozzles

configured for uniform inlet profileto sequential burner

– Regulates MET* range foroptimum SB performance

– Utilized experience from silocombustor designs of legacyBBC/ABB/Alstom gas turbines

Sequential Burner (SB)– Reheat burner for emission and

turndown performance (low residencetime)

– Direct evolution of GT26 SEV burnerdesign and fuel injector technologies

– Multi point (dual) fuel injection with highconcentration of vortex generators forimproved mixing

– Integrated thermo-acoustic dampingfeatures

– Optimized for low combustor exittemperature spread

Sequential Liner (SL)– Sequential combustor and interface to turbine– Leveraged PSM Ansaldo can transition duct

expertise and design portfolio– Thermally free movement to reduce stresses– High-temperature alloy with improved creep

strength and durable dense vertically cracked TBC

SB Fuel

FS Fuels

* MET: Mixer Exit Temperature

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Agenda

• GT36 introduction

• GT36 CPSC combustor

• GT36 validation

• Conclusions & questions

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Validation Vehicles

Validation Drivers /Technical Risks

CFD

and

Anal

ytic

alTo

ols

Wat

erch

anne

l(L

DA,

PIV,

LIF)

Flow

benc

h

Atm

osph

eric

Test

s

Hig

hPr

essu

reTe

sts

Com

bust

orR

emov

alTe

st

GT3

6-S6

Engi

neTe

stC

ente

r

Component lifetime ü ü ü

Combustor operation andperformance ü ü ü ü ü ü

Transferability of results ü ü ü ü ü ü

Emissions ü ü ü ü ü

Maintenance ü ü ü

Fuel distribution system ü ü

Fuel manifold (internal fueldistribution) ü ü

Can to can scatter ü ü

Combustor Design ProcedureValidation vehicle applicability versus technical risks

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GT36 in Birr Test Power PlantHigh Pressure Combustor Test Rig

• Transferability to engine operationconfirmed for the first (Premix) and thesecond stage (Sequential).

• Correlation of operation window,pulsation and emission as expected

• Operating range emissions confirmed• Metal temperature readings transferable

• Test rig based validation was a key elementof the GT36 burner development

• Full scale rig testing performed since 2013

Combustor – Confirmation of correlation and transferability Rig-to-EngineGT36

ü

ü

üü

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Combustor and flame Images (viewed facing upstream)High Pressure CPSC Gas Operation

Firs

tSta

geCo

mbu

stor

Flam

e

Sequ

entia

lCom

bust

orFl

ame

Low load:Sequentialburner off

Part load:Sequential

burnerignited

Full load:Sequentialburner atmax firing

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GT36 Gas TurbineTest Power Plant in Birr, Switzerland

• GT36 Test Engine located in Birr,Switzerland and operational since2016.

• Engine instrumented with > 3000instruments, with > 500 rotatingparts instrumentation.

• Extended performance testingcompleted for design and off-designconditions.

• Engine test results confirm designperformance targets.

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Agenda

• GT36 introduction

• GT36 CPSC combustor

• GT36 validation

• Conclusions & questions

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Validation completed on April 12, 2017

• Start-up and shut-down testing performed

• Grid synchronization and electricity exportfunctional

• Hot- and cold-start performance verified

• Loading gradients confirmed

• Full load operation and mapping confirmsdesign

GT36 Test Engine Validation

Performance:P [MW] üη [%] üTIT [ºC] üTAT [ºC] üṁ [kg/s] üp [bar] ü

Emission:NOx [vppm] üCO [vppm] ü

Operability:OPC [-] üTurndown [%] ü

Engine in Operation, picture taken fromoutside enclosure

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Press ReleaseQuestions?

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A new generation is bornNew products.

New technologies.New service capabilities.

Ansaldo Energia: a global player in the power generation market.