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1 THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS 345 E. 47 St., Now York, N.Y GT-240 The Society shall not be responsible for statements or opinions advanced in papers or in discussion at meetings of the Society or of Its Divisions or Sections, or printed In its publications. Discussion is printed only if the paper is published in an ASME Journal. Papers are available Iron ASME for fifteen months alter the meeting. Printed in USA. Copyright 1992 by ASME New Advanced Cooling Technology and Material of the 1500 C Class Gas Turbine ABSTRACT H. MATSUZAKI, K. SHIMOMURA Tohoku Electric Co., Inc. Sendai, Japan Y. FUKUYAMA, T. ARAKI, J. ISHII, M. YAMAMOTO, S. SHIBUYA, I. OKUHARA Toshiba Corporation Yokohama, Japan BASIC DESIGN OF COMBINED CYCLE SYSTEM ,1 1 11) This paper describes the advanced cooling technology and materials (directionally solidified and single-crystal superalloys) which are considered key technological factors when developing the class high temperature gas turbine. Adopting a class gas turbine developed on the basis of the new technology, a combined cycle plant is likely to achieve a plant thermal efficiency of more than 55% (LEV). INTRODUCTION From the viewpoint of energy saving and reduction of environmentally damaging emissions (CO2 reduction in particular), it has recently become important to increase the efficiency of thermal power plants. One generally recognized solution to this problem is a combined cycle with a high temperature gas turbine and a steam turbine. Tohoku Electric Power Co. and Toshiba Corp. began a joint research project in May 1989 to carry out basic design of an overall combined-cycle plant, and to develop an advanced cooling technology including steam cooling, and directionally solidified and single crystal buckets, etc. as elemental technologies for the class high temperature gas turbines (Saito and Kano, 1990). The ultimate goal of this project is to apply such technologies to high temperature gas turbines to achieve a combined cycle plant thermal efficiency of 55% (LEV) or higher. This paper discusses basic design of combined cycle systems including high temperature gas turbines. Also discussed are advanced cooling technologies which are applied to steam cooled nozzles and air-cooled buckets as well as trial casting of directionally solidified and single crystal buckets coupled, with material evaluation. Selection of Cooling System Fig. 1 shows comparison of combined cycle plant thermal efficiency among several gas turbine cooling systems. As shown in Fig. 1, employing a high temperature air-cooled gas turbine which uses an advanced cooling technology and directionally solidified and single crystal buckets will achieve high efficiency of a combined-cycle plant. However, the joint research project proved that a combination of high pressure steam cooled (HP5C) nozzles and directionally solidi- a, 60 >, t) 4.) Li) 55 s 50 cu CL eC Class high pressure steam cooling 1100 C CT! an =I 'Ye 4>----- \ advanced air cooling Class CT Turbine Inlet Temperature C (at 1st stage Nozzle Inlet ) Pig. 1 Comparison of cooling technology. Presented at the International Gas Turbine and Aeroengine Congress and Exposition Cologne, Germany June 1-4, 1992
2 fied and single crystal buckets improved the efficiency by about 1% over an advanced air cooled system (see Fig. 1). By use of the HPSC system, it is possible to increase gas turbine inlet temperature and reduce cooling air effectively. Moreover, since the HPSC system is closed circuit, all the cooling steam extracted from the high pressure superheater section of the heat recovery steam generator can be fed back to high pressure steam turbine inlet. As a result, energy transferred to cooling steam can be effectively recovered. Based on the above mentioned factors, it is possible to realize a high efficiency combined cycle plant. High pressure steam cooling can also reduce gas temperature drop through the first-stage nozzle (14). Therefore, combustor outlet temperature can be decreased for the same 1st-stage bucket inlet temperature. This facilitates cooling design and NOx control for combustors. On the basis of these findings, a combination of steam cooled nozzles (IN) and single crystal air-cooled buckets (1B) using advanced cooling technology was chosen as the study model for the joint research project. Combined Cycle System and Cycle Parameters The objectives of selecting cycle parameters were to achieve higher efficiency than combined cycle plants with 1300"C class gas turbines. For the gas turbine using single crystal and directionally solidified buckets and advanced cooling technology, 1450'C was chosen for the IN inlet gas temperature. For the above inlet temperature, an optimal pressure ratio of 18 was selected because it maximized both combined-cycle thermal efficiency and simple cycle specific output of the gas turbine alone (see Fig. 2). Fig. 3 shows a diagram of the combinedcycle system. Through the application of a 200 MW class gas turbine, the combined-cycle system, using a three-pressure reheating type heat recovery steam generator, is expected to achieve a thermal efficiency of over 55% (LHV). Basic Design of Scale Model Gas Turbine The selection of cycle parameters mentioned above was performed for a 200 MW class gas turbine. However, a 50 MW class machine was planned for development of key technologies of the 1500'C class high efficiency gas turbine. Combined Cycle 5 Pressure rata-- Ouiput Fuel Efficiency ST Efteusf Gus Fig. 3 A diagram of HPSC system. The basic design of a next generation 1500C class high efficiency scale model gas turbine was carried out as a part of a joint research project. This 1500*C class high efficiency scale model gas turbine was called the Advanced Gas Turbine (AGT) in the research project. Fig. 4 shows a cross-section of the AGT. It is a single-shaft type machine and the use of reduction gears enables it to drive a generator. The compressor is a 17-stage axial type with high pressure ratio and high flow rate. The combustion system consists of 10 combustors with effective cooling construction for high firing-temperature operation and valid means for NOx emission control. The turbine has three stages designed with advanced cooling and material technologies. The 17-stage axial compressor of AGT achieves a pressure ratio of 18 with high efficiency. Transonic blades are used for the first and second stage rotor blades. A portion of the compressor discharge air is used to cool the first and second stage turbine buckets. This air is extracted from the compressor discharge and cooled by the external air cooler, then led 36 S I mple Cycle F2L IN..145CMC _t >, o 35 5 _ 0 Pressure 0 2 ratio 0 -a 18.c 0 34 TIN., 1450t ) c Plant Specific Power ( kw/kg /s ) G/T Specific Power (kw/kg/s ) Fig. 2 Selection of the optimum pressure ratio.
3 Fig. 4 Cross-section of AGT. S. into the turbine to cool the buckets. Air is extracted from the 11th and 14th stages to cool the 2nd and 3rd stage nozzles. A variable inlet guide vane and 1st stage stationary blade provide start-up surge control, as well as improvement of partial load performance in combined cycle operation. The Dry Low NOx combustor (DLNC) is used for NOx emission control. The combustion system is composed of a pre-mix type combustor with pre-mix duct and a transition piece. To permit operation at a high firing temperature, effective cooling construction has been adopted for each part of the combustor. Compressor discharge air flows into the space between the flow sleeve and the combustion liner. For combustion liner cooling, slot cooling (a kind of film cooling) is used in combination with convection cooling by the external flow sleeve. The transition piece is a double surface structure and is cooled by impingement cooling, film cooling and convection cooling. The first stage turbine buckets and nozzles of the AGT, which operate in especially high gas temperature conditions, are provided with advanced cooling technologies. For the first stage nozzles, the HPSC concept is used. The first stage turbine bucket is cooled by the advanced film cooling concept. The cooling air for the turbine bucket is cooled by the external air cooler system. The cooling concepts for the 2nd and 3rd stage nozzles and 2nd stage buckets are similar to those of the 1300'C class gas turbine. For turbine buckets, directionally solidified and especially single crystal buckets are necessary from the view point of high temperature strength and cooling air reduction. Single crystal superalloy will be adopted for the 1st stage bucket and directional solidification superalloy for 2nd and 3rd stage buckets. The realization of the above mentioned concept is required for AGT development. The realization of turbine element technologies, which are HPSC, advanced air cooled bucket and manufacturing of single crystal and directionally solidified buckets etc., are very important. DEVELOPMENT OF ELEMENT TECHNOLOGIES Turbine Bucket and Nozzle Cooling Based on the preceding arguments on thermal cycle analysis, an HPSC nozzle / advanced air film cooled bucket combination was chosen as a primary cooling concept for the 1st stage. Table 1 summarizes the design conditions of the 1st stage nozzle and bucket. The cooling configuration development studies are briefly summarized in this section. Table 1 Summary of design conditions of first stage nozzle and bucket Gas total temperature 1450'C C4 Coolant Steam Air Coolant inlet temperature 389C 410 C Coolant outlet temperature Coolant inlet pressure MPa 1.18 MPa Coolant outlet pressure 9.72 MPa - Coolant/gas mass flow rate 8.8 % 4.0 % IN 1B Relative Total Temperature. Steam Cooled Nozzle. In the HPSC concept, steam is introduced into the turbine nozzle from the high pressure superheater section of the heat recovery steam generator. Nozzles are used as a high pressure superheater and all the cooling steam is fed back to high pressure steam turbine inlet for effective energy conversion. In the design of the HPSC nozzle, a small straight hole configuration (similar to that of water cooled nozzle (Blazek et al, 1980, Shilke et al, 1981, Fukuyama et al, 1989)) was selected. The steam film cooling was not applied because of a large loss of thermal efficiency, which is caused by the steam injection into the moderate pressure hot gas path, and the large amount of water consumption in the plant. Fig. 5 shows the designed cooling hole arrangement in the midspan cross section. Thirty-two cooling holes are distributed radially. The selected diameter of the cooling hole was 2.0 mm and was allocated 2.5 mm underneath the vane surface. In the trailing region of the
4 The basic cooling design has been completed and the practical application of the HPSC nozzle will be evaluated on the basis of the thermal stress, precision cast manufacturing, machining and fabrication. Leading Section. Pressure Side Cooling Hulce (Grcup-2) Trailing Section Cooling Holes (Group-3) Outer Endwall 7 Holes Suction Side Cooling Holes (Group-i) Fig. 5 Cooling hole arrangement in the mid-span cross section of HPSC nozzle. OUT Po = 9.72 NPa IN Pi = t4pa To = 540C Ti C Channel-8 Channel-4 Channel Advanced Air Cooled Bucket. The 1st stage bucket is cooled by an advanced film cooling concept (Araki et al, 1987). Fig. 7 shows the design cooling configuration. The configuration adopted for the 1st stage bucket is a combination of a serpentine internal cooling circuit with transverse ribs, multi-row film cooling on both suction and pressure surfaces, the shower head cooling on the leading edge and small blowing holes for the trailing section. The cooling air passages are formed with three independent channels. The leading side passage serves the impingement cooling to the inner surface and film cooling to the outer surface of the leading edge region of the bucket. The mid chord passage utilizes a 5-pass serpentine configuration to enhance inner side heat transfer and supply air to both suction and pressure surface film cooling rows. The trailing side passage is consisted of a 3-pass serpentine configuration which delivers air to the small parallel air blowing holes to cool the thin trailing section of the bucket. Fig. 8 indicates the influence of cooling air flow rate on the mid-span surface averaged cooling effectiveness for the 1st stage bucket. Precision cast design and manufacturing of test buckets has also been completed. Fig. 9 shows the twodimensional experimental bucket with instrumentation and the 4-bucket cascade to be tested in the high temperature test rig. Group 3 11 Holes Group 2 6 Holes Group 1 15 Holes Film Cooling Channel -5 Channel-3 Inner Endwall Holes Channel-2 Shower Head Cooling 4 Fig. 6 Schematic diagram of HPSC nozzle cooling flow circuit. vane, holes of diameter 1.5, 1.6 and 1.8 mm were used and ware placed near the center of the vane thickness. Fig. 6 indicates the schematic diagram of a nozzle cooling flow circuit. The vane and endwalls of the nozzle are cooled by two parallel pass flow networks. Steam is supplied to and also collected from the outer-endwall. The cooling circuit is composed of 6 distribution channels, connection ducts and parallel cooling holes of the vane suction side, the vane pressure side, the vane trailing region, the inner endwall and the outer endwall. The design point cooling steam over gas mass flow rate [Gc/Gg x 100] is 6.6%, where Gc is cooling steam flow and Gg is inlet gas flow, and the nozzle surface mean cooling effectiveness v c of mid-span cross section is expected to be 0.7, where, c is defined as below. Impingement Cooling Turbulence Promoter Trail ing Edge Blowing Trailing Edge -- Blowing Holes n e r (Tg-Tm)/(Tg-Tc) Tg:1N inlet gas temperature Tm:metal temperature Tc:coolant inlet temperature Fig. 7 Cooling configuration of 1st stage air-cooled bucket.
5 I 0 r, II ra g , (a) Two - dimensional experimental bucket with instrumentation a Cooling Flow Rate GOR6 Ix] LO Fig. 8 Influence of cooling air flow rate on cooling effectiveness for 1st stage bucket. (b) Four-blade cascade in the high temperature test rig. Fig. 9 Photographs of experimental bucket. Material Study To realize high temperature gas turbines of the class, materials having higher temperature capability are required for hot parts such as buckets and nozzles, in addition to the application of the advanced cooling technologies mentioned above. Single crystal and directional solidification superalloys can meet such demand for bucket materials in this advanced gas turbine, which have much higher creep and stress rupture strength and thermal fatigue life, comparing to conventional casting superalloys used in current gas turbines. Especially, single crystal superalloys are most promising for first stage buckets in advanced gas turbines from the viewpoint of high temperature strength. However, it is necessary to establish the production technologies for large size hollow buckets and verify mechanical properties of large size products, since land base gas turbine buckets are much larger than those of aero jet engine parts which have much more production experience. Several steps of the bucket casting trial have been performed under cooperation with the casting supplier, in order to establish the production parameters for large size single crystal and directionally solidified buckets having complex serpentine internal cooling circuits of the 50 MW class and larger gas turbines. For bucket materials used in this study, CMS/C-2 single crystal (Harris et al, 1983) and CM247LC directional solidification superalloys (Erickson, 1985) were chosen because they have the highest level of creep and stress rupture strength among the same kind of superalloys. In these casting trials, various casting parameters have been adjusted, that is, o process parameters such as pouring temperature, mold temperature and withdrawal rate o core and mold materials selection o configurational modification for bucket producibility The first steps of the bucket casting trials were made by a high rapid solidification process for existing first stage hollow buckets of the C-15 MW class gas turbine developed by Toshiba (Yamamoto et al, 1987, Hijikata et al, 1990). Fig. 10 and Fig. 11 show single crystal and directionally solidified buckets, indicating that both buckets can be made by good crystal or columnar grain growth without any abnormal equiaxed grain growth and other casting defects such as freckling, etc. Moreover, there was no recrystallization after solution treatment in both buckets. From microscopic observation in cross section and nondestructive examination of buckets, the distribution of porosity and shrinkage was clarified. In the next step, solid first stage buckets of the 50 MW class were made before the complex hollow bucket production in order to check the process parameters in larger buckets about twice the size of the first casting trial. Fig. 12 shows that single crystal and directionally solidified solid buckets were successfully made. Based on solid buckets production experiences, hollow buckets for 50 KW class first stage have been manufactured, of which configuration is as described in Fig. 7. Directionally solidified hollow bucket production has been established as shown in Fig. 13, which has good columnar-grain structure and cooling passage configuration. Casting trial 5
6 50 arr ": Fig. 10 Single crystal (right), directionally solidified (middle) and conventional casting (left) buckets of 15 MW class gas turbine. Fig. 11 Internal cooling passages are exposed by grinding away half the single crystal (right) and directionally solidified (left) buckets of 15 MW class gas turbine. Fig. 12 Single crystal (right) and directionally solidified (left) first stage solid buckets of 50 MW class advanced gas turbine. Fig. 13 Directionally solidified hollow bucket for 50 MW class first stage. of single crystal hollow bucket is also progressed. High temperature material testing has been carried out to verify the strength levels of large size parts, using single crystal and directionally solidified slabs up to 150 mm and 300 mm in length, respectively, as shown in Fig. 14. Typical stress rupture test results are summarized in Fig. 15, where test specimens were sampled in longitudinal direction from various locations of slabs. Compared to typical conventional casting superalloy IN738LC and Mar-M247, both directionally solidified and single crystal slabs have much higher rupture strength which are almost the same levels as reported (Harris, K., 1983, Erickson, G.L. 1985). Stress rupture elongation of both slabs are extremely high. In Fig. 15, stress rupture test result of a specimen machined from airfoil of the 50 MW class first stage solid bucket is also plotted. It is confirmed that bucket casting possesses as high a strength as those of a slab. In addition, various kinds of mechanical testing have been performed, including low and high cycle fatigue tests, tensile test and physical property measurements such as elastic modulus and thermal expansion, etc at elevated temperatures. It was found that low cycle fatigue life in longitudinal direction of directionally solidified slab is several times longer than that of conventional casting alloy, but single crystal slabs have still longer life. As for nozzles, casting productivity of the steam cooled nozzles mentioned above will be studied in future programs
7 CONCLUSION Basic design of combined cycle systems has been completed. The HPSC system is one of the attractive cooling concepts for 1500C class gas turbines. The HPSC system adopted for gas turbines results in achieving about 1% improvement of combined-cycle efficiency over advanced air cooling system. Also the basic design of advanced cooling technology and the study of material for the AGT has been almost finished. As a result of the above mentioned study, a large amount of data was obtained, which is leading to attainment of the ultimate goal, realization of a high efficiency combined-cycle plant. ACKNOWLEDGMENT Authors express thanks to Mr. Sudo, Mr. Morikuni, Mr. Makita of Tohoku Electric Power Co. for giving us the opportunity to carry out the development of the AGT. Fig. 14 Single crystal (right) and directionally solidified (left) large size slabs rit L' ao 20 0 C1747LC Longitudinal X Machined fro, airfoil of class tol d bucket lithin 10 of [0011 orientsticm. A Mai Ccoventionsl cut rig Mar-M247 -\..\401247LC /, - CMSX-2 \ 1N738LC ai NN REFERENCES Araki, T. et al, 1987, "High Temperature Wind Tunnel Testing of Film Cooled Blade", The 1987 Tokyo International Gas Turbine Congress, 87-TOKYO-IGTC-63. Blazek, W.S., Schiling, W.F., and Schilke, P.W. 1980, "Water-Cooled Gas Turbine Monometallic Nozzle Development", ASME Paper 80-GT-97. Erickson, G.L., 1985, "Directionally Solidified DS CM247LC-Optimized Mechanical Properties Resulting from Extensive Solutioning,", ASME Paper 85-GT-107. Fukuyama, Y., and Araki, T., 1989, "Testing of Water-Cooled Nozzle for High Temperature Gas Turbine", Experimental Heat Transfer, Fluid Mechanics, and Thermodynamics, pp Harris, K., Erickson, G.L., and Schwer, RE., 1983, "Development of The Single Crystal Alloys CMSX-2 and CMSX-3 for Advanced Technology Turbine Engines,", ASME Paper 83-GT-244. HiJikata, T. et al, 1990, "Cooling Characteristic of Air Cooled Nozzle and Bucket in Test Rig for High Temperature Turbine", GTSJ Conference, SENDAI, JAPAN. Saito, T., and Kano, K., 1990, "Development of Next Generation High Efficiency Gas Turbine Technology", Journal of the GTSJ, Vol. 18, No. 69. Schilke, P.W., and DeGeorge, C.L., 1981, "Water- Cooled Gas Turbine Monometallic Nozzle Fabrication and Testing", ASME Paper 81-GT-162. Yamamoto, H., Okamura, T., and Kobayashi, T., 1987, "Gas Turbine Development", Toshiba Review, Vol. 42, No P=1. (20+log tr) x10' Fig. 16 Stress rupture test results of single crystal and directionally solidified slabs and solid buckets.
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