Volume 7: Industrial and Cogeneration; Manufacturing Materials and Metallurgy; Microturbines, Turbochargers, and Small Turbomachines; Oil & Gas Applications最新文献

{"title":"Operation of Large Industrial Gas Turbines During Periods of Low Electricity Demands","authors":"S. Ingistov, V. Vassiliev, S. Savic, Sebastiaan Mulder","doi":"10.1115/gt2022-79392","DOIUrl":"https://doi.org/10.1115/gt2022-79392","url":null,"abstract":"\u0000 When grid power demand is low or the power price is negative, running a gas turbine at Full Speed No Load (FSNL) provides a way to avoid producing power, while maintaining the ability to both generate process steam for industrial purposes in a Heat Recovery Steam Generator (HRSG) and to respond quickly to sudden surges in grid power demand. In this paper, turbine thermodynamics of FSNL, closure of inlet guide vanes (IGV), and compressor bleed rates are analysed for General Electric’s 7EA gas turbine using the software Thermoflow.\u0000 This study shows that FSNL can be achieved only by bleeding of compressor mass flow through two available bleeds, one in the front section of the compressor, and one in the back section of the turbine. This paper shows that bleeding from bleed 1 will lower compressor work, saving fuel, but it will also drop the exhaust temperature too low, preventing steam production. With extraction from bleed 2, the exhaust temperature remains high. Either way, the exhaust energy is reduced due to reduction of mass flow, but steam generation in reduced amount is possible. The extracted mass flow is choked and limited by the critical section in the flow path of the compressor bleed. In this study, the required minimal size of the slot in bleed 2 is identified for a range of IGV positions.","PeriodicalId":301910,"journal":{"name":"Volume 7: Industrial and Cogeneration; Manufacturing Materials and Metallurgy; Microturbines, Turbochargers, and Small Turbomachines; Oil & Gas Applications","volume":"27 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115428692","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Advanced Tip Repair of Single Crystal HPT Blades With LW3 and LW4280 Welding Materials","authors":"A. Chan, Alexandre Gontcharov, P. Lowden, Thomas Mikolajewski, J. Sixsmith, R. Tollett, C. Greer","doi":"10.1115/gt2022-80473","DOIUrl":"https://doi.org/10.1115/gt2022-80473","url":null,"abstract":"\u0000 High pressure turbine (HPT) blades manufactured from single crystal (SX) materials exhibit tip degradation during service resulting in loss of coatings and parent metal, primarily from abrasion, thermal-mechanical fatigue cracking (TMF), creep, and oxidation. Currently, Gas Tungsten Arc Welding (GTAW) and Laser Beam Welding (LBW) with Merl 72 and Rene 142 (R142) welding materials are used for repairing the tips of SX HPT blades. Tips repaired with Merl 72, despite the superior oxidation resistance of the cobalt welding material, are prone to cracking due to the low mechanical properties of the Merl 72 welds at temperatures exceeding 1800°F (982°C). Additionally, despite the high strength of R142 in its cast condition, R142 welds are prone to weld stress-strain cracking and thus require preheating of the blades above 1700°F (926°C) to repair the part with a predetermined level of micro cracking present. Preheating can adversely affect the inert atmospheric conditions of the argon protection. This inadequate shielding of the welding area may result in contamination of welds with non-metallic inclusions which reduce creep and TMF properties.\u0000 The current study focuses on substantiating the replacement of Merl 72 with alternative LW3 and LW4280 nickel based welding materials for minor dimensional restoration and full tip replacement on SX HPT blades with a solid tip cap. LW3 and LW4280 contain 28 vol.% and 49 vol.% gamma prime phase respectively, after post weld aging heat treatment. A time-transient thermal mechanical Finite Element Analysis (FEA) of the SX HPT blade was completed for takeoff, cruise, and landing conditions. The resultant temperature and stresses from the FEA study were used as the basis for qualification of the tip repair. Tensile and stress rupture properties of dissimilar SX-LW3 and SX-LW4280 welds produced at ambient temperature using manual GTAW and Laser Direct Energy Deposition (L-DED) on a LAWS1000 welding system utilizing a 3D additive manufacturing (AM) concept were studied. It was demonstrated that LW4280 welds had superior stress rupture, and fatigue properties when compared to M 72. Cyclic oxidation resistance of LW4280 at 2048°F (1120°C) was found to be sufficient to ensure required durability of repaired blades for 6,000 cycles in cases of damage to protective coatings. Some examples of repairs of HPT blades developed using these materials and technologies are provided.","PeriodicalId":301910,"journal":{"name":"Volume 7: Industrial and Cogeneration; Manufacturing Materials and Metallurgy; Microturbines, Turbochargers, and Small Turbomachines; Oil & Gas Applications","volume":"24 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129895373","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Establishing a Generic Stress-Life Framework for Single-Crystal Nickel-Base Superalloys","authors":"Firat Irmak, Sahil Karim, Nathan O’Nora, A. Gordon","doi":"10.1115/gt2022-83276","DOIUrl":"https://doi.org/10.1115/gt2022-83276","url":null,"abstract":"\u0000 Selection of materials to be used for components experiencing extreme conditions is a critical process in the design phase. Nickel-base superalloys have been frequently used for hot gas path components in the turbomachinery industry. These components are required to withstand both fatigue and creep at extreme temperatures during their service time. In general, the extreme temperature materials mostly embody polycrystalline, directionally solidified, and single crystal superalloys. Single crystallization has been utilized with nickel-base superalloys since 1980s. This method forms one grain by eliminating all of the grain boundaries, which has resulted with thermal, fatigue and creep properties superior to conventional alloys. It is essential for design engineers to predict accurate damage behavior and lifespan for these components to prevent catastrophic failures. This study presents generic elastic and stress-life models for single crystal nickel-base superalloys based on observed trends. Despite the development of over 50 variations of single crystal Nickel-base superalloys, the behavior of these alloys nominally follows similar mechanical behavior trends with respect to temperature and orientation. Temperature-, rate-, and orientation-dependence of these materials are studied. In this study, [001], [011] and [111] orientations are mainly considered. The goal is to eliminate extensive time and cost of experiments by creating parameters to be used in life calculations for generic single crystal alloys. While the stress-based approach to fatigue analysis of materials was the first to be developed, it continues to endure with broad usage in a wide variety of engineering applications. These models tend to be used for the cases with high number of cycles to failure behavior or called high-cycle fatigue (HCF) conditions. In this work, the total damage is divided into two different modules; fatigue and creep damages. Miner’s Rule is utilized to combine these modules. Models which can predict the cycles to failure data with the most usage-like conditions and require least amount of data are preferred. Parameters for the models are built on regression fits in comparison with a comprehensive material database. This database includes elastic, plastic, creep, and fatigue properties.","PeriodicalId":301910,"journal":{"name":"Volume 7: Industrial and Cogeneration; Manufacturing Materials and Metallurgy; Microturbines, Turbochargers, and Small Turbomachines; Oil & Gas Applications","volume":"47 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131126195","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Carbon Capture: CO2 Compression Challenges and Design Options","authors":"Matt Taher","doi":"10.1115/gt2022-82209","DOIUrl":"https://doi.org/10.1115/gt2022-82209","url":null,"abstract":"\u0000 Carbon Capture and Storage are essential technologies to help achieve the ambition of net zero anthropogenic greenhouse gas emissions by 2050 [1]. Independent of the method used to capture the CO2, it remains central to compress carbon dioxide for liquefaction, transportation, and storage. The CO2 stream exiting almost any capture technology is in the gas phase, while it will be transported as a sub-cooled liquid for ship-based transportation or a dense-phase in pipeline-based transportation. The CO2 compression process that involves compressing low-pressure CO2 in gas phase to high-pressure supercritical phase is ‘transcritical’, i.e., with subcritical low-side and supercritical high-side pressure.\u0000 This paper is intended to provide a summary of the current CO2 compression technologies and design challenges. Different possible pathways to compress CO2 from subcritical to supercritical conditions are explained. Also, the anomalous behavior of supercritical CO2 and its effect on design and performance of the compression system is highlighted. Inline centrifugal compressors and integrally geared compressors are compared for transcritical CO2 compression applications. Also, the use of centrifugal pumps and reciprocating compressors are briefly addressed.","PeriodicalId":301910,"journal":{"name":"Volume 7: Industrial and Cogeneration; Manufacturing Materials and Metallurgy; Microturbines, Turbochargers, and Small Turbomachines; Oil & Gas Applications","volume":"26 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134088321","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Investigation on Exhaust Energy Recovery System Using Radial Turbine in High-Power Proton Exchange Membrane Fuel Cells","authors":"Wei Jiuxuan, Qi Mingxu, Zhang Hong, Lichao Xue","doi":"10.1115/gt2022-82822","DOIUrl":"https://doi.org/10.1115/gt2022-82822","url":null,"abstract":"\u0000 With the increased power density and capacity of the proton exchange membrane fuel cell (PEMFC) stack, the intake air pressure level is getting higher and can reach up to 3.5bar in some cases, leading to a higher exergy level of the exhaust gas at the fuel cell cathode. To improve the system efficiency of the PEMFC, the energy of the fuel cell exhaust gas at the cathode side can be recovered with a turbine and partially drive the compressor to save part of the power needed by the electric motor. To evaluate the potential capability of the PEMFC exhaust gas recovery, detailed insights regarding the energy recovering capability of the turbine from exhaust gas energy as a result of gas supply pressure, air stoichiometric ratio, current density and operating temperature are presented in the current study. A systematic model of the fuel cell system is established and validated. The model includes the air supply system, electric motor driven turbocharger, fuel cell stack components and necessary pressure drop as well as the gas dynamic model inside the stack. The model can be used to simulate the recovery process of the exhaust gas energy at arbitrary fuel cell operation loadings. It can be used to predict the system energy recovery efficiency once the loading condition of the fuel cell is known. Results indicate that the energy recovery system performance is determined by the fuel cell operating conditions. Results also show that the gas inlet state, current density, electrochemical reaction process and pressure loss play a key role in the recovery efficiency of the turbine and the ratio of recovery power to fuel cell output power. The recovery efficiency is higher at a larger pressure ratio and current. To verify the accuracy of the system model, a high-power fuel cell is used for validation, the rated power of the proton exchange membrane fuel cell stack is calibrated through the electrochemical model from the energy recovery system and good agreement is achieved between the simulation and experiment.","PeriodicalId":301910,"journal":{"name":"Volume 7: Industrial and Cogeneration; Manufacturing Materials and Metallurgy; Microturbines, Turbochargers, and Small Turbomachines; Oil & Gas Applications","volume":"67 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"132801429","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"FELTMETAL™ Abradable Turbine Seal Materials: Structure and Property Responses to Blade Rub and Oxidation","authors":"E. Motyka, R. Schricker, Kelly Ceiler","doi":"10.1115/gt2022-82300","DOIUrl":"https://doi.org/10.1115/gt2022-82300","url":null,"abstract":"\u0000 Abradable seals are a common technology employed to improve turbine engine performance by reducing the gap between blades and the casing in compressor and turbine stages. Because operating conditions and material requirements vary significantly as a function of turbine stage and turbine design, many abradable compositions have been developed. Generally, all abradable seal materials employ voids or pores in the microstructure as a designed-defect to mitigate thermal and kinetic energy from blade rub. Some also have added non-metallic phases to provide other means of maintaining a seal that is sacrificial to the blade tip.\u0000 This paper describes the microstructures of specific fiber metal abradable materials known as FELTMETAL™, as well as the distinctly different abradable microstructures of honeycomb material and thermal spray coating. The effect of the porosity and metallic surface area in each type of microstructure on seal abradability and seal oxidation is discussed. In addition, the effect of oxidation by aging at elevated temperatures on strength, ductility, and abradability for several FELTMETAL™ materials is also discussed.\u0000 It is proposed that the pore structure aids in mitigating blade contact energy primarily by internal deformation of the metal matrix surfaces and that abradability is improved by formation of protective metal oxide films that reduce ductility without significant loss of strength.","PeriodicalId":301910,"journal":{"name":"Volume 7: Industrial and Cogeneration; Manufacturing Materials and Metallurgy; Microturbines, Turbochargers, and Small Turbomachines; Oil & Gas Applications","volume":"17 6","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"120871009","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Study on Titanium Aluminide Turbine Wheel Blade Machining for Turbochargers by Electrochemical Machining (ECM)","authors":"Masahiro Aono, Tatsuya Shimizu, Nobuaki Obi, A. Goto","doi":"10.1115/gt2022-80752","DOIUrl":"https://doi.org/10.1115/gt2022-80752","url":null,"abstract":"\u0000 A turbocharger is the device of a car that is used to add extra air into the combustion chambers of an engine. Recently, researches have been conducted on the use of TiAl materials in turbine wheels to replace traditional Ni-based alloys. Since TiAl material has good heat resistance and is lightweight, it is effective in reducing the moment of inertia of the turbine wheel.\u0000 However, the TiAl material has a problem that it has high viscosity when it is melted and that it is not suitable for precision casting. Even when the thickness of the turbine wheel blades is increased to about 1 mm, the molten TiAl does not always flow to the tip of the mold, and the problem of chipped tip often occurs.\u0000 In this study, authors investigated the method of manufacturing blades with thickness of more than 1 mm by precision casting in a yield of almost 100%, and then machining them into thin shape of about half thickness by electrochemical machining (ECM).\u0000 In ECM, it is well known that the flow of the electrolyte affects the machined shape. It was difficult to finish the blade in the desired shape at first and unmachined area remained. Then authors examined the flow of electrolyte using computational fluid dynamics (CFD) analysis and tried to make it appropriate. As a result, a technology was established to machine turbine wheel blades that meet the requirements for shape accuracy and surface roughness in a short time of about 100 seconds.","PeriodicalId":301910,"journal":{"name":"Volume 7: Industrial and Cogeneration; Manufacturing Materials and Metallurgy; Microturbines, Turbochargers, and Small Turbomachines; Oil & Gas Applications","volume":"29 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124115486","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"100-Hour Test of an Inside-Out Ceramic Turbine Rotor at Operating Conditions","authors":"P. K. Dubois, B. Picard, A. Gauvin-Verville, P. Méthot, A. Landry-Blais, L.-P. Jean, S. Richard, J. Plante, M. Picard","doi":"10.1115/gt2022-79194","DOIUrl":"https://doi.org/10.1115/gt2022-79194","url":null,"abstract":"\u0000 Converting sub-MW turbine rotor blades to ceramics is not a trivial endeavour, but the promise of a substantial increase in turbine inlet temperature (TIT), and therefore cycle efficiency and power density, could mean wide use in upcoming, distributed power, turboelectric aircraft. The inside-out ceramic turbine (ICT) rotor configuration attempts to address this by loading ceramic blades in compression, as centrifugal force pushes them against a rotating structural composite shroud. This paper reports significant experimental progress in the development of ICT rotor technology, aimed at the development of a high-efficiency, turboelectric powerpack.\u0000 A 20-kW scale, single spool, recuperated ICT was operated with monolithic silicon nitride blades, for a total of 113 h above 1100 °C, including 13 h at the design tip speed of 400 m/s and a cumulative 100 h at 360 m/s, with no critical failure. ICT rotors sustained short excursions with TIT up to 1200 °C and tip speeds up to 430 m/s in hot conditions, and 500 m/s in ambient conditions. An ICT rotor was successfully integrated within a complete recuperated turbogenerator with a nested high speed electric motor. Results suggest that further work on an ICT turbogenerator should enable it to reach a TIT of 1275 °C, a target to achieve 45 % cycle efficiency in the sub-MW range.","PeriodicalId":301910,"journal":{"name":"Volume 7: Industrial and Cogeneration; Manufacturing Materials and Metallurgy; Microturbines, Turbochargers, and Small Turbomachines; Oil & Gas Applications","volume":"18 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115014327","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}