Recent Developments in Small Scale Gas Turbines PDF

Recent Developments in Small
Industrial Gas turbines
Ian Amos
Product Strategy Manager
Siemens Industrial Turbomachinery Ltd
Lincoln, UK
Copyright © Siemens AG 2009. All rights reserved.
Content
Gas Turbine as Prime Movers

Applications
History
Technology
thermodynamic trends and drivers
core components
Future requirements
Market developments

Page 2 Nov 2010 Energy Sector
1
Gas Turbine as Prime Mover
Prime mover : A machine that

transforms energy from thermal,
electrical or pressure form to
mechanical form; typically an engine
or turbine.
Gas Turbines vary in power output

from just a few kW more than 400,000
kW.
The shaft output can be used to
generate electricity from an alternator
or provide mechanical drive for
pumps and compressors.
Siemens Industrial gas turbine range

Figures in net MW
Utility Turbines
SGT5-8000H 375
SGT5-4000F 287
SGT6-8000H 266
SGT6-5000F 198
SGT5-2000E 168
SGT6-2000E 113
SGT-800 47
Industrial Turbines
SGT-700 31
SGT-600 25
SGT-500 17
SGT-400 13
SGT-300 8
SGT-200 7
SGT-100 5

2
Industrial Gas Turbine Product Range
Portfolio
(MW) SGT-100-1S SGT-100-2S SGT-200-1S
SGT-800 47
SGT-700 30
SGT-600 25
SGT-500 17
SGT-400 13 SGT-200-2S SGT-300
SGT-300 8
SGT-200 7
SGT-100 5
SGT-400
SGT-500 SGT-600 SGT-700 SGT-800

Industrial Gas Turbine

Product applications
Power Pumping Compression CHP Comb. Cycle

Generation
An SGT-100 Thirty SGT-200 Two SGT-700 An SGT-800 CHP Two SGT-400

generating set is driven pump sets driven Siemens plant for InfraServ generating sets
installed on Norske on the OZ2 pipeline compressors for Bavernwerk’s operating in
Shell's Troll Field operated by natural gas chemical plant in cogeneration/
platform in the Sonatrach, Algeria liquefaction plant Gendork, combined cycle
North Sea owned by UGDC Germany. for BIEP at BP’s
at Port Said, Bulwer Island
Egypt. refinery, Australia

3
Gas Turbine Refresher
Comparison of Gas Turbine and Reciprocating Engine Cycle
AIR INTAKE FUEL COMBUSTION
EXHAUST
COMPRESSION
Continuous
Intermittent
AIR/FUEL INTAKE COMPRESSION COMBUSTION EXHAUST

Gas Turbine as Prime Mover
Gas Turbine Characteristics

Size and Weight Operation and Maintenance
High power to weight ratio No Lubricating oil changes
giving a very compact power High levels of availability
source
Vibration Fuel flexibility
Rotating parts mean vibration Dual fuel capability
free operation requiring simple Burn Lean gases (high N2 or
foundations CO2 mixtures)
Varying calorific values
Emissions
Very low emissions of NOx
4
Brayton Cycle
1-2 Air drawn from atmosphere and compressed

2-3 Fuel added and combustion takes place at constant pressure
3-4 Hot gases expanded through turbine and work extracted
(in single shaft approx 2/3 of turbine work is used to drive the compressor)

Ideal Engine Cycle:

Efficiency
( γ −1) / γ
 
 1  Cycle efficiency is therefore
Simple cycle efficiency = 1 −   only dependant on the
 P1  cycle pressure ratio.
 P2 
0.7 Assumption : Ideal cycle
Ideal thermal efficiency
0.6 with no component or

0.5 system losses.
0.4
0.3
0.2
0.1
0
0 10 20 30 40 50
Pressure Ratio

5
Engine Cycle:
The Real Engine
Deviations from Ideal Cycle ‘Real’ Efficiencies

•Aerodynamic losses in turbine and • Practical simple cycle gas
compressor blading turbines achieve 25 to 40 % shaft
• Working fluid property changes efficiency
with temperature • Complex gas turbine cycles can
• Pressure losses in intakes, achieve shaft efficiencies up to
combustors, ducts, exhausts, 50%
silencers etc. • However, heat rejected in the
• Air used for cooling hot exhaust can be used :-
components •Large combined cycle GT can
• Parasitic air & hot gas leakages achieve close to 60% shaft
efficiency
• Mechanical losses in bearings, •Cogeneration (Heat and Power)
gearboxes, seals, shafts can exceed 80% total thermal
• Electrical losses in alternators efficiency

Energy Cost Savings

GT cycle parameter study
43.0
25
42.0
22
41.0
Shaft Efficiency (%)
20
PRESSURE
40.0
18 RATIO
39.0
16
38.0
14
37.0 1400ºC 1450ºC
1350ºC
1300ºC
36.0 1250ºC
1200ºC FIRING TEMPERATURE
35.0
280 290 300 310 320 330 340 350 360 370 380 390 400 410 420 430 440 450 460 470 480
Shaft Specific Output (kJ/kg)
Increase Pressure ratio and firing temperatures for higher simple cycle efficiencies
6
Design Drivers :
Low Specific Fuel Consumption
Higher Pressure Ratios

• Increased Cycle Efficiency
• Increased number of compressor / turbine stages and
therefore cost
Complex Cycles
• Increased Cycle Efficiency and/or Specific Power
• Can impact operability, cost and reliability
Higher Firing Temperature

• Requires increased sophistication of cooling systems
• Can impact life and reliability and combustor emissions

Design Drivers :
Availabilty, Cost and Emissions
High reliability.
Moderates the trend to increase firing temperature and cycle
complexity.
Low Emissions (Driven by environmental legislation)

More difficult to achieve with high firing temperatures and
combustion pressures
Lowest possible cost.

Encourages smallest possible frame size, i.e. high specific
power high firing temperature.
Reduced Pressure ratios (< 20:1) to avoid auxiliary fuel
compression costs
Compromise is required in the concept design to get the best

balance of parameters
7
Core Engine Trends:
Key Parameter Trends
Machines
SGT-200
SGT-400
SGT-300
SGT-100
Future
Centrifugal Compr.
3CT
TG
TB
TA
TD
TF
TE
16
15 1300
ttiioo
Firing Temperature °C
14 RRaa
13 u
urree 1200
s
es
s
urree
Pr t
Pressure Ratio
12 aatu
eerr
11 mpp
eem
1100
T
T
10 inng
g
FFiir
9 1000
8
7 900
6
5 800
4
3 700
1950 1960 1970 1980 1990 2000
YEAR
Year
Engine Trends:
Thermal Efficiency
350 40
Specific Power (kJ/kg)
Thermal Efficiency (%)
SGT-400 38
300
36
34
250 SGT-100
32
SGT-200
200 30
Specific Power Output
Thermal Efficiency 28
150 TB5000
26
100 24
1975 1980 1985 1990 1995 2000 2005
Year
Dramatic impact of increased TET and pressure ratio over last 25 years:
• Specific Power increased by almost 100%
• Specific Fuel Consumption reduced by over 30%
• reduced airflow for a given power output and has resulted in smaller
engine footprints, reduced weight and reduced engine costs
8
Product Evolution
SGT-300
Introduced 1995
7,900 kWe 30.5% eff
TA
Introduced 1952
750kW 17.6% eff
Developed to 1,860kW

Gas Turbine Layout

- single shaft or twin shaft
Single Shaft
Expansion through a single series of
turbine stages.
Power transmitted through rotor
driving the compressor and torque at
the output shaft
Twin Shaft
Expansion over 2 series of
turbines.
Compressor Turbine (CT)
provides power for compressor
Useful output power provided by
free Power Turbine (PT)
9
SGT-400 Industrial gas turbine
Combustion
Compressor system Gas Generator Power
Turbine Turbine

Combustion
10
Environmental Aspects
Pollutants and Control
Pollutant Effect Method of Control
Carbon Dioxide Greenhouse gas Cycle Efficiency

Carbon Monoxide Poisonous DLE System
Sulphur Oxides Acid Rain Fuel Treatment
Nitrogen Oxides Ozone Depletion DLE System
Smog
Hydrocarbons Poisonous DLE System
Greenhouse gas
Smoke Visible pollution DLE System
DLE - Dry Low Emissions

Exhaust Emission Compliance
Emissions control:
Two types of combustion configuration need to be considered:
Diffusion flame
Dry Low Emissions (DLE or DLN) using Pre-mix combustion
Diffusion flame
Produces high combustor primary zone temperatures, and as NOx is a
function of temperature, results in high thermal NOx formation
Use of wet injection directly into the primary zone to lower combustion
temperature and hence lower NOx formation
Dry Low Emissions

Lean pre-mixed combustion resulting in low combustion temperature, hence
low NOx formation
With good design and control <25ppm NOx across a wide load and ambient
range possible
11
Combustion
NOx Formation
1000
100
NOx Formation Rate [ ppm/ms ]
10
0.1
0.01 Diffusion Flame
0.001
Lean Pre-mix
0.0001
0.00001
0.000001
1300 1500 1700 1900 2100 2300 2500
Flame Temperature [ K ]
Flame temperature affects thermal NOx formation

Combustion
NOx Formation
Flame Temperature as a function of Air/Fuel ratio
Lean burn Diffusion flame reaction

zone temperature
Diffusion flame
temperature
Flame
Lean Pre-mixed
(DLE/DLN)
Lean Stoichiometric Rich

FAR
12
Combustor Configuration
NOx product is a function of temperature
Diffusion
Combustion
- high primary zone
temperature
Cooling
Dry Low
Emissions
Combustion
-low peak temperature
achieved with lean
pre-mix combustion
DLE Lean Pre-mix Combustor

(SGT-100 to SGT-400 configuration)
Igniter Liquid
Core Main Burner
Pilot Robust design involving no moving
Burner parts
Radial
Swirler Fixed swirler vanes
Variable fuel metering via pilot and
main fuel valves
Main Gas
Injection
Pilot Gas Pre Chamber
Igniter Injection
Air
Gas/Air Gas
Mix Air
Double Skin
Impingement
Cooled Combustor

13
Lean Pre–Mix combustion
Simple fuel system

Variable fuel metering via pilot and main fuel valves
Low NOx across a wide operating range of load and ambient conditions
MAIN FLOW
CONTROL
BLOCK BLOCK M VALVE
VALVE VALVE
MAIN
MANIFOLD
BLEED
VALVE
PILOT
MANIFOLD
PILOT FLOW
CONTROL
VALVE

Combustion
DLE Lean Premix System
Key to success
good mixing of fuel and air
multiple injection ports around swirler
long pre-mix path

fuel injection as far from combustion zone as possible
good air flow distribution

can annular arrangement with top hats
use of pilot burner

CO control & flame stability
use of guide vane modulation/air bleed

air flow management

14
DLE System : Siemens experience
15million operating hours across the range (SGT-100 to SGT-800)

Approximately 1000 DLE units
About 90% of new orders DLE

Experience
Stable load accept/reject
Daily profile for unit running more than 8000hrs DLE operation on liquid fuel.
kW
Daily variations
Load Shed and Accept

15
Gas Fuel Flexibility
BIOMASS & Other gas
High Hydrogen
COAL GASIFICATION Refinery Gases Associated Gas
3.5 Landfill & Sewage 37 49 65

Gas LPG
Siemens Diffusion
Operating
Off-shore lean IPG Ceramics Off-shore rich gas Experience
Well head gas
Siemens DLE Units operating
DLE Capability Under
Development
Pipeline
Quality NG
Low Calorific SIT Ltd.
Medium Calorific Value (MCV) ‘’Normal’’ High Calorific Value
Value (LCV)
(HCV)
Definition
10 20 30 40 50 60 70
Wobbe Index (MJ/Nm³)
The change in WI by the addition of inert species to pipeline quaility gas

50
45 UK Natural Gas
CO2
40 N2
35
3
Wobbe MJ/m
30 Medium CV Fuel
MCV
Rangedevelopment
Definition
25
20
15
10
5 LCV Burner
0
0 10 20 30 40 50 60 70 80 90 100
CO2 or N2 content of UK Natural Gas
16
Examples of Siemens SGT Fuels Experience
NON DLE Combustion Sewage gas

standard burner
Natural Gas Gasified Biomass
Wellhead Gases Special Diffusion
burner
Landfill gas High Hydrogen gas
Special standard burner
Landfill Gas Diffusion Liquified Petroleum gas
burner UK Natural Gas modified MPI
Sewage Gas
High Hydrogen Gases 5 10 15 20 25 30 35 40 45 50 55 60 65 70
Diesel Wobbe Index MJ/m3
standard
Kerosene gases
LPG (liquid and gaseous)
Gaseous Fuel Range of Operation
Naphtha
‘Wood’ or Synthetic Gas
Gasified Lignite
DLE experience on Natural Gas, Kerosene and Diesel

DLE on fuels with high N2 and CO2 content.
DLE Associated or Wellhead Gases
Turbine
17
Aerodynamic optimised design !
Minimised loss
optimum pitch/width ratio
across whole span.
low loading
High speed
high stage number
low Mach numbers
thin trailing edges
low wedge angle
zero tip clearance

Aerodynamics
High Load Turbine
Computational Fluid Dynamics (CFD) used to complement experimental testing of

advanced components.
18
Analytical optimised design !
Reduce blade stresses

Minimal shroud
shroud may still be desirable
for damping purposes.
High hub/tip area ratio
Low rotational speed.
Maximise life
Low temperatures
Low unsteady forces

Mechanical Design -
Improved analysis software

(grid and solver) and improved
hardware allow traditional ‘post-
design’ to be carried out during
design iterations.
Meshing of complex cooled
blade could take many man
months in early 90’s - now
down to minutes.
More sophisticated analysis for
detailed lifing studies still
required after design.

19
Fatigue Life of Rotating Blades
Positions of Concern
Blade Vibration response
Predicted by FE and measured in
Lab.
Identifies critical blade frequencies
and modes (Campbell Diagram)
Aerofoil
High Cycle Fatigue
Fillet Radii between aerofoil &
platform
Fillets Top neck of firtree root
Low Cycle Fatigue

In areas of highest stress
Eg - blade root serrations
Root Serration (including skew effects)

Mechanical Design - Vibration analysis
Campbell Diagram for LPT Blade (Blade only)
EO20 EO19 EO18

6000
EO17
mode 6
mode 5
5000
105%
4000
95%
100%
Frequency (Hz)
EO11
EO10
mode 4
3000 EO9
mode 3
EO6
2000 mode 2
mode 1 EO3
1000
0
15000 15500 16000 16500 17000 17500 18000 18500 19000 19500 20000
Iteration 3 version 10 Engine Speed (rpm) D G Palmer 3-8-01

20
Cooling optimised design !!
Large LE radius
minimise stagnation htc
thick trailing edge thickness
and large wedge angle for
cooling
thickness distribution to suit
cooling passages.
Minimise gas washed
surface.

Cooled Blading Designs

SGT100 > SGT300 > V2500 Aeroengine

21
SGT400 First Vane Cooling Features
Impingement
Cooling
Film
Cooling
Turbulators
Cast 2 Vane
Segment Trailing Edge
Ejection

SGT-400 13MW Industrial Gas Turbine

First Stage Cooled Vane
Hot Blades are life

limited.
-Oxidation
- Thermal fatigue
- Creep
Life typically 24,000

hrs.
Life can be increased
or decreased
depending on duty
and environment.

22
SGT-300 First Stage Cooled Rotor Blade
Ceramic Core forming SGT300 8MW Industrial Gas Turbine

Cooling Passages Multi-Pass Cooled First Stage Rotor Blade

HP Turbine Blade Coatings
Hot Gas Surface Coatings for Corrosion & Oxidation protection

Aluminide,
Silicon Aluminide (Sermalloy J)
Chromising
Chrome Aluminide, Platinum Aluminide
MCrAlY
Internal Coatings on Cooled Blades operating in poor environments
Ceramic Thermal Barrier Coatings

Yttria stabilised Zirconia
Plasma Spray Coatings used on Vanes
EBPVD Coatings used on rotating blades
More uniform structure for improved integrity

23
Turbine Validation Process
Design Analysis
Assess
evaluation
and
calibration
of methods
Prototype Test

New technology incorporated into existing

engine platforms
SGT-100 Product Development
New ratings have been released
Aerodynamic modifications to
Compressor Blade compressor and turbine.
• Stator stages S1& S2 HP Rotor blade
• Rotor stages R1 & R2 • SX4 material
• Triple fin shroud
• Step Tip seal Power generation, 5.4MWe
(launch rating 3.9MW
previously 5.25MWe)
Mechanical Drive, 5.7MW

(previously 4.9MW)
T P

24
Industrial Gas Turbines
Advanced Materials & Manufacturing
SGT400 PT 2 Nozzle Ring

Bladed Turbine Disc

25
The Gas Turbine Package
In addition to the main package, the following is also

required:
Combustion air intake system

Gas turbine exhaust system
Enclosure ventilation system (if enclosure fitted)
Control system
UPS or battery and charger system

SGT-300 Industrial gas turbine

Package design – The latest Module Design
Available as a factory assembled

packaged power plant for utility and
industrial power generation applications
Easily transported, installed and
maintained at site
Package incorporates gas turbine,
gearbox, generator and all systems
mounted on a single underbase
Preferred option to mount controls on
package, option for off package.
Common modular package design
concept
Acoustic treatment to reduce noise
levels to 85 dB(A) as standard (lower
levels available as options)
26
Typical Compressor Set

SGT-400
New Package Design
Minimised customer interfaces reducing contract execution/installation costs
1 7 6
1 Combustion Air Intake
2 Enclosure Air Inlet
3 On-Skid Controls
2
4 Fire & Gas System
3
5 Interfaces
6 Lub Oil Cooler
7 Enclosure Air Exit 4
5
Highly flexible modular construction
Customer configurable solutions based upon pre-engineered options
Standard module interfaces to allow flexibility and inter-changeability
Additional functionality provided dependent upon client needs
Base design provides common platform for on-shore and off-shore PG and MD
27
Future direction
Future Trends
- guided by market requirements
Universal demand for further increases in efficiency and reliability, and

reduction in cost.
Oil & Gas (Mech drive and Power Gen)

Fuel flexibility - associated gases, off-gases, sour gas
Remote operation
Emissions -inc CO2
Independent Power Generation

Fuel flexibility - syngas, biofuels(?), LPG
Flexible operation - part load operation
Distributed cogeneration (rather than centralised generation)
Emissions - inc CO2

28
Oil and Gas
remote operations / fuel flexibility
•First application of its kind in Russia
(Western Siberia) burning wellhead gas
which was previously flared
•Solution:
Three SGT-200 gas turbine
•Output 6.75 MWe each
•DLE Combustion system
•Guaranteed NOx and CO
emission levels of 25ppm
•Min. air temp. (-57oC)
•Max. air temp. (+34oC)
•Gas composition with Wobbe Index
>45MJ/m3
•Total DLE hours approximately 22,300
hours for each unit
•Significant reduction of emissions : 80-90%
reduction of NOx level
•Siemens has supplied 135 gas turbines for
Power Generation , Gas compression and
pumping duty throughout the Russian oil &
gas industry
Power Generation
re-emergence of cogeneration
WATER
GRID FUEL
BOILER
OR
DRIER
PRODUCT / STEAM
~
29
Thank You

30

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Recent Developments in Small

Industrial Gas turbines

Copyright © Siemens AG 2009. All rights reserved.

Gas Turbine as Prime Movers

Copyright © Siemens AG 2009. All rights reserved.

Prime mover : A machine that

Gas Turbines vary in power output

Siemens Industrial gas turbine range

Copyright © Siemens AG 2009. All rights reserved.

SGT-500 SGT-600 SGT-700 SGT-800

Copyright © Siemens AG 2009. All rights reserved.

Industrial Gas Turbine

Power Pumping Compression CHP Comb. Cycle

An SGT-100 Thirty SGT-200 Two SGT-700 An SGT-800 CHP Two SGT-400

Copyright © Siemens AG 2009. All rights reserved.

AIR/FUEL INTAKE COMPRESSION COMBUSTION EXHAUST

Gas Turbine as Prime Mover

Gas Turbine Characteristics

1-2 Air drawn from atmosphere and compressed

Copyright © Siemens AG 2009. All rights reserved.

Ideal Engine Cycle:

0.6 with no component or

Copyright © Siemens AG 2009. All rights reserved.

Deviations from Ideal Cycle ‘Real’ Efficiencies

Copyright © Siemens AG 2009. All rights reserved.

Energy Cost Savings

Higher Pressure Ratios

Higher Firing Temperature

Copyright © Siemens AG 2009. All rights reserved.

Low Emissions (Driven by environmental legislation)

Lowest possible cost.

Compromise is required in the concept design to get the best

Thermal Efficiency (%)

Copyright © Siemens AG 2009. All rights reserved.

Gas Turbine Layout

Copyright © Siemens AG 2009. All rights reserved.

Copyright © Siemens AG 2009. All rights reserved.

Pollutant Effect Method of Control

Carbon Dioxide Greenhouse gas Cycle Efficiency

DLE - Dry Low Emissions

Copyright © Siemens AG 2009. All rights reserved.

Exhaust Emission Compliance

Dry Low Emissions

0.01 Diffusion Flame

Flame temperature affects thermal NOx formation

Flame Temperature as a function of Air/Fuel ratio

Lean burn Diffusion flame reaction

Lean Stoichiometric Rich

DLE Lean Pre-mix Combustor

Copyright © Siemens AG 2009. All rights reserved.

Simple fuel system

Copyright © Siemens AG 2009. All rights reserved.

long pre-mix path

good air flow distribution

use of pilot burner

use of guide vane modulation/air bleed

Copyright © Siemens AG 2009. All rights reserved.

15million operating hours across the range (SGT-100 to SGT-800)

Copyright © Siemens AG 2009. All rights reserved.

Copyright © Siemens AG 2009. All rights reserved.

3.5 Landfill & Sewage 37 49 65

The change in WI by the addition of inert species to pipeline quaility gas

NON DLE Combustion Sewage gas