Design of A Gas Turbine Combustion System PDF

©Siemens Power Generation 2003.
All Rights Reserved

Design of a Gas turbine
combustion system
Torsten Strand torsten.strand@siemens.com
2/9/2006 Power Generation 1

Content
z The design requirements, criteria and targets
z The overall design process

z The gas turbine cycle: Excel calculations
z Burner and cooling mass flows: Design calculations
z Burner type: lean premixed, diffusion flame or something in between
z Combustor heat balance, choice of combustor design: Excel calculations
©Siemens Power Generation 2003. All Rights Reserved
z The component designs

z burners
z combustor : Excel calculations
z fuel system : Excel calculations
z Ignition and supervision systems
z Operation
z Start up
z Part load

Assumptions
z We are going to design a new gas turbine with the shaft power of 35MW for a
market consisting of
z 60% compressor drivers for pipe line compressors
z 40% industrial cogeneration
z The first customer segment want a very reliable and robust simple cycle unit
for pumping of gas from desolated gas fields in
z Siberia ( 0 to -50°C)
z Iranian mountains (-20 to +45°C, low ambient pressure)
z Saudi Arabian deserts (+10 to +50°C)
z Efficiency and emissions are not of prime interest
z Fuel is natural gas
z The second customer type want an efficient, but still very reliable gas turbine
with low emissions and suitable for steam production in waste heat recovery
boilers for industries, mainly in the western world. Fuel is natural gas or
industrial off gases.

Case 1
Gas Turbine in Simple Cycle
63.6 % losses
Gas Turbine
36.4 % electricity
100 % fuel
Pgt 44.30 MW
Pst 0 MW
Paux 0.10 MW
Pnet 44.20 MW
Heat duty 0 MJ/s
Qfired 121.4 MJ/s
Alfa ∞ ---
2/9/2006
Net electrical
Powerefficiency
Generation 36.4 % 4
Net total efficiency 36.4 %
Case 2
Gas Turbine in Cogeneration Cycle
12 % losses
52.2 % process heat

1-pressure HRSG
Gas Turbine
35.9 % electricity
Pgt 43.82 MW
Pst 0 MW
Paux 0.23 MW
Pnet 43.59 MW
100 % fuel Heat duty 63.4 MJ/s
Qfired 121.4 MJ/s
Alfa 0.69 ---

NetPower
electrical efficiency
Generation 35.9 % 5
2/9/2006
Case 3
Gas Turbine in Combined Cycle
Steam Turbine
(condensing)
12 % losses
16.8 %
520 deg C electricity
2-pressure
HRSG
31 deg C
31 deg C 15 deg C
Gas Turbine
27 deg C
100 % fuel 35.9 % electricity
35 % losses
Pgt 43.69 MW
Pst 20.78 MW
Paux 0.70 MW
Pnet 63.77 MW
Heat duty 0 MJ/s
Qfired 120.9 MJ/s
Alfa ∞ ---
2/9/2006 Net electrical efficiency 52.7 % Power Generation 6
Case 4
Gas Turbine in Combined Cycle
Steam Turbine
11 % (district heating)
losses
11.3 %
510 deg C electricity 42.1 %
2-pressure heat
HRSG
78 deg C 90 deg C
Gas Turbine
60 deg C
35.9 %
electricity 78 deg C Pgt 43.70 MW
Pst 14.18 MW
100 % fuel
Paux 0.62 MW
Pnet 57.26 MW
Heat duty 51.1 MJ/s
Qfired 121.4 MJ/s
Alfa 1.12 ---

2/9/2006 Powerefficiency
Net electrical Generation 47.2 % 7
Is it possible to use the same design
for both applications?
z Well, we will try!
z The compressor drive requires a variable speed power turbine, so we

have to assume a twin shaft unit
z The efficiency of the cogeneration unit ought to be in the range of

37% at full load, which means that the heat input is around 95MW

The core engine 1
z We have now a basic design.
z A critical parameter is the Turbine Inlet Temperature. The higher TIT the
better gas turbine cycle, but generally also less robustness and higher
turbine cooling flow
z Let us assume a conservative TIT = 1300°C
z From experience the turbine cooling flow will then be around 16%
95MWth
TIT
35MWe
Turbine cooling

Turbine Inlet Temperature
and emissions
Turbine Inlet Temperature C and NOX

Ceramics
1500 200 Single Crystal Blades Steam Cooling
GTX100
Jet Engines GT200

GT10B/C
1000 100
GT35/GT120
Stationary Gas Turbines
500
1940 1960 1980 2000
Year
The gas turbine cycle
T
Tflame
t5
p5, t5m
ηct = (t5m - t6)/(t5m - t6s)
p3, t3 p6, t6
ηpt = (t6m - t7)/(t6m - t7s)
ηc = (t3s - t2)/(t3 - t2)

p7, t7
p2, t2
s

The turbine pressure levels
z How are the pressure levels at the compressor and power turbine sat?
z The turbine can be seen as a tube with restrictors

z In order to pass a certain flow at a certain temperature there is an
associated flow area/pressure combination
z The flow area is determined by the turbine inlet guide vanes
zInner/outer diameter
zExit blade angle, which is on gas turbines is generally fairly large, which
means that the stage design is of reaction type (the enthalpy drop is
divided between vane and blade)
m = A *rot(2*Δp*ρ) = A *rot(2*Δp*p/RT) = Ψ*A*p/rot(RT)
For computational purposes the below formula is very useful

m*rot(T)/p = constant

Turbine flow
The flow capacity of the turbine is determined by the smallest

area in the turbine inlet guide vane and the root and tip section
diameters
the turbine “wideness”
the turbine flow number m*rotT/p
the ”turbine constant”
The flow capacity of the turbine determines the position of the

operating line in the compressor map.
An uncooled turbine has better efficiency than a cooled turbine, which
has less good profiles (lower aspect ratio, thick trailing edges) and
2/9/2006 mixing losses from the cooling flows Power Generation 13
The gas turbine cycle
T
Tflame
p5, t5m
t5
ηct = (t5m - t6)/(t5m - t6s)

The next step is to
make a simple
p3, t3 p6, t6 thermodynamic
ηpt = (t6m - t7)/(t6m - t7s)
model of the gas
ηc = (t3s - t2)/(t3 - t2)

p7, t7
turbine in order to get
p2, t2
the conditions for the
s combustor.
95Mth We will do it in Excel!
TIT
35MWe
Turbine cooling
Power Generation 6

SGT-600, Industrial gas turbine
Gas turbine principle & components


The core engine 2
z Now we need to choose the pressure level for the turbine inlet
z There is an optimal pressure level for efficiency associated with the
turbine inlet temperature, but it is generally quite high which means a low
TET. We have also to consider the steam production in the waste heat
recovery boiler, so we need a fairly high TET > 520°C ??
z We will try some pressures for TIT = 1300°C
z1800 kPa η=38.3% TET=509°C T3=438°C

z1700 kPa η=38.0% TET=517°C T3=426°C
z1600 kPa η=37.6% TET=526°C T3=413°C
z1500 kPa η=37.1% TET=536°C T3=400°C
z The higher the pressure the higher also the compressor exit air
temperature T3. That air is
zthe combustion air
zthe cooling air for the turbine and combustor walls
z For combustion high air temperature is generally better
z NOx and combustion pulsations have a tendency to increase

2/9/2006
with pressure
Power Generation 16
The combustor 1
z Now we have basic full load data for the combustor

z Air flow to the combustor: 82.8/426/1785 kg/s/°C/kPa
z Fuel flow: 2.02 kg/s
z Combustor exit flow: 84.8/1300/1700 kg/s/°C/kPa
z In order to design the combustor we have to know which

type of burner we are going to use
2.02 kg/s
84.8 kg/s
82.8 kg/s
1300°C
426°C
1700kPa
1785kPa

Burner 1: types of burners
z The conventional combustors were designed for Stoichiometric combustion, using fuel
injectors with low air flows Φ ≅1. Water or steam injection were used for NOx reduction
z The lean premixed combustors are designed with a high air flow that cools the flame
z The low oxygen combustors relay on a combustion process in O2-depleted gas,

achieved by recirculation of combustion products
NOx ppmv Diffusion flames
200
Φ = 1/λ
Water Injection
100 Lean Premix Steam Injection
Combustion
0. 5 1.0 1.5
Fuel/Air Equivalence Ratio
Diffusion type dual fuel Injector
STD PART-
2100K
Water inlet POSITIONABLE ELBOW HCV GAS HOLES
PURGE HOLES
STEAM INLET
Gas inlet Air
Oil inlet
Dual fuel Injector for gas
and oil with water and
2/9/2006
steam injection Power Generation 19
NOx and CO vs Flame Temperature
NOx ppm CO ppm

EV Burner
DLE Gas
AEV Burner NOx
50 DLE Gas & Oil 40
40
30
CO
30
Low oxygen burner20
20
Catalytic burner
10 10
1700 1800 1900

Flame Temp K
2/9/2006 - Advanced DLE burners Power

- Generation 20
Our case
z The Oil&Gas customers have presently no high requirements on

emissions, but the industrial customers will have a requirement of NOx
< 10 ppm
z We will try to build a low NOx burner of lean premix type
z Our trial choice is a LP burner with a design flame temperature of 1750K

z How much air is needed for the combustion?
z We will do a heat balance calculation for the flame zone

The combustor 2
z Now we have the basic flow data for the combustor

z Air flow to the burner: 65/426/1785 kg/s/°C/kPa
z Fuel flow: 2.02 kg/s
z Wall cooling flow: 17/426/1785 kg/s/°C/kPa
2.02 kg/s
84 kg/s
65 kg/s 1300°C
1700kPa
17 kg/s
426°C
1785kPa
Wall cooling
z The burner air is around 65 kg/s out of the 82 kg/s combustion air
z We have around 21% of the combustion air for wall cooling, which
ought to be enough for a film cooled sheet metal combustor.
438
450 500 850
1477÷1300
If the film cooling air is on

the low side Thermal Barrier
Coating can be used.
If there is more air than
necessary for cooling, it can
be injected as dilution air in
the down stream part of the
combustor.
Wall cooling designs
The shown wall design is the traditional one for film cooled combustors.
Several similar designs with improved performance are in use
438
450 500 850
Impingement Convection
1477÷1300
The use of Thermal barrier coatings has been more common. Conventionally
only thin TBC (<0.5 mm) has been used. But lately also thick TBC (up to 1.5
mm) has become frequent.
In turbines with higher turbine inlet temperature, the cooling air has not been
enough for film cooling. Wall with only outside cooling and thick TBC is then
the solution.
Meal wall Bound coat TBC

Wall heat transfer: film cooling
z For initial design we can assume a heat flux to the combustor wall in the
range of 600kW/m2 but dependent on the gas temperature. The hot side heat
transfer is a combination of convective and radiation heat flux
z qhot = α*(Tgas – Twall) + const*S-B*[Tgas4 – Twall4]
α ≅ 590 when velocities are around 30 m/s and pressure 1700 kPa,
increasing at higher velocities and pressure. The radiation constant is
dependent on flame radiation and surface emissivity

In the combined impingement/convection cooled design we can assume
that the metal temperatures for one wall section starts at air temperature
and reaches 850°C, with an average wall temperature of 565°C.
It is then assumed that the injected cooling air will absorb the heat flow to
the surface
Q = qhot*A = m*cp*(565-tcool)
The length of a section depends of course on the design but 50 ÷ 70 mm is
common
The rings are laser drilled, rolled to form and seam welded in a fixture

Wall cooling: convection cooling
z In the case when there is not enough air for

film cooling, outside convection cooling with
the combustion air has to be used.
z The cooled side heat transfer has then to

match the hot side heat flux
z Q = qhot*A = α*A*(twall – tair)
z When using TBC the heat flow through the wall

is reduced by the low heat conductivity of the
ceramics, λ = 1.1÷ 1.6 and the lower absorption
of radiation
Annular combustor with convection
cooled walls
z The cold side heat transfer coefficient α is a
function of the air velocity, pressure and the
shape of the surface. Usually the wall surface
has ribs, fins etc to enhance the heat transfer
up to 1.7 times

Combustor size
z The bulk flow velocity in the combustor can tentatively be set to

around 30 m/s, which means that there is a need for a flow area in the
combustion chamber inlet exit section of around 0.63 m2
z The turbine inlet velocity can be in the range of 100-130 m/s, which means
that there is a need for an exit area in the range of ~0.2 m2
z The length of the combustor depends on what residence time we want. This
could be investigated by combustion kinetics calculations, but a value based
on experience for natural gas and diesel oil is 15÷20 ms 15 ms
which gives a axial length of around 600 mm
z Now it is time to make a choice of combustor type

z Annular
z Can-annular
z Tilted or in line with the flow

Annular versus can-annular
z The annular combustor has compared to the can-annular type

z less wall surface area to cool
z fewer auxiliaries
z Spark plugs
z Flame detectors
z Annular combustors are used in almost all jet engines and many high
temperature industrial turbines
z The can-annular design has most often

z fewer but larger burners
z transition ducts between the circular combustion chambers and sectors of
the turbine inlet, which is difficult to design and cool
z Can combustors are used in many industrial turbines by tradition and for
easier maintenance
z The can type of combustor is easier to develop since the testing can be done on
one of the combustors, while it is quite difficult to use the test results from a
sector test of an annular combustor

A GE can combustor
Premixed Pilot
Transition duct
Main swirl premixers

2/9/2006
GE Frame 5
Power Generation
30
Siemens G30 Combustor
Concept
Pilot Burner
Main Burner
Double Skin Impingement

Cooled Combustor
Power Generation 31
Annular combustor for
.
Siemens SGT-600
18 DLE burners
Sheet metal (HastX),
annular combustor
with film cooled
walls and
impingement cooled
front panel
Number of cooling
holes 5800
Outer diam ~ 1 m
Power ~ 75 MWth
Manufactured by
Trestad Svets in
Trollhättan (now a
Siemens Company)
DLE combustor for 25 ppmv with EV burners since 1991

Flows in conventional annular
combustor
Primary injection Secondary injection
Primary zone
2/9/2006
Turbulence and mixing by primary and secondary Power
jets Generation 33
Annular combustor types
Tilted annular combustor

with removable burners
for easier maintenance
In line annular combustor

with burners fixed to the
combustion chamber

Annular combustor dimensions
z Assume tentatively
outer radius inner radius height
z at the combustor front panel: 600 400 200
z at combustor exit: 450 390 60
The philosophy for the wall Combustor wall design

contour differs. There are e.g.

parallel walls and pear like forms. 700
600
CFD calculations on 500
• the velocity and temperature Radius mm 400 Outer wall
distribution at the combustor exit 300 Inner wall
200
• the recirculation pattern 100
are important aspects as well as 0

-200 0 200 400 600
manufacturing aspects.
Axial position mm

Combustor re-circulating flow
The recirculation of hot gases Combustor wall design
in the combustor is necessary 700

for
600
• ignition of the flame
500
• lowering of NOx by reducing
Radius mm
400
the O2 content in the flame
300
The recirculation can be
200
achieved in different ways, but
the most common is to use 100
swirling flows. 0
-200 0 200 400 600
Swirling jet aerodynamics is Axial position m m
important and a lot of research
is done in that field
Exit temperature profile
The radial temperature

profile is very important
for the rotating blade
life. Due to the wall
cooling flows a peaky
profile can be expected,
which is good for the

blades (cold root and tip
sections), if it is not too
hot in the centre.
Dilution air can be used
to shape the exit profile.
The tangential profile is
important for the
stationary vanes.
DLE evolution, GT 15-50 MW
- history
Lean premix combustion in two-slotted cone, multiple
burners:
Residence time reduced by using many small burners, • introduced 1991, NOx ≈ 25 ppmv on gas
with short flames:
• introduced 1986, NOx ≈ 75 ppmv on gas Lean premix combustion in four-slotted cone + mixing
tube, multiple burners:
• introduced 1999, NOx < 15 ppmv on gas
Single burner 1st gen. DLE 2nd gen. DLE 3rd gen. DLE
GT10B Used in:

(Annular GTX100
combustor) GT10B&C
GT35C
GT35 (Can-annular
combustor)
Silo Combustors Annular Combustors

Dual fuel Injector
STD PART-
Water inlet POSITIONABLE ELBOW HCV GAS HOLES
PURGE HOLES
STEAM INLET
Gas inlet
Oil inlet
Dual fuel Injector with
water and steam
2/9/2006
injection Power Generation 39
The burner 2
z There is one basic philosophy for the lean premix burner: the fuel and air has
to be mixed as evenly as possible. The better mixing, the lower NOx.
z Choice of swirl strength for good ignition and recirculation

z Low swirl and weak recirculation is providing an unattached flame with
low pressure drop. The mixing in of oxygen depleted recirculation
products is quite low. Ignition has to secured by zones with higher fuel
concentrations. The flow out from the combustor is quite even.
z High swirl burners has often flames attached to a flame holder. The
recirculation is strong, but in many cases the mixing in of the recirculation
flow is not as good as it could be. The exit profile is often distorted by the
swirling flows reaching all the way to the turbine.

Swirl Burner Operation
1. 2.
Gas fuel 1) Gas fuel is injected along the air
inlet slots and is immediately mixed
with the air.
2) At the burner exit a lean mixture

Air enters the flame zone, which is
stabilised by the vortex breakdown

in the inner core of the exit flow
3) The high air flow velocity inside of

3. 4. the burner protects the burner wall
against flame flashback
4) Operation with oil No2

An oil-water emulsion is injected in
the center of the EV cone. The oil-
water jet is atomised and partly
evaporated; ignition of the vapour
occurs in the vortex breakdown
zone. NOx formation is reduced and
remains below 42 ppm

A 2nd generation premix burner
z Most lean premixed burners have

z A swirl generator which can be axial, radial or tangential
z A device to mix in the fuel as evenly as possible often integrated in the
swirl generator
Most lean premixed burners has a pilot flame that is supporting the
main flame at part load, when the flame temperature tends to be too
low
A 3rd generation dual fuel burner
Pilot oil
Main gas
Pilot gas
Main oil
Concentric tubes for fuel supply
2/9/2006 - A burner for 10 -15 ppm NOx

Power Generation 43
The DLE dual fuel burner function
Mixing tube Cone Main liquid fuel injection Gas fuel and
Liquid fuel
Combustor wall
Combustor hood
Flame
Compr. discharge air
Pilot gas fuel injection Main gas fuel injection

Pilot liquid fuel injection
Dry Low Emissions on gas and oil
Power Generation 44
A high swirl burner
Pilot fuel Radial Swirler
injection with Quarl
with Main fuel
Igniter injection
Flame Holder

Emissions and pulsations
z In a burner with very good mixing it is theoretically possible to come done in

NOx to around 5 ppm at 1750K, but
z It is hard to do the mixing that well
z A very well mixed flame has a tendency to be weak and sensitive to
disturbances
z Instable flames can induce pulsations and acoustic phenomena in the
combustion chamber
z In order to have stable combustion a fuel richer zone is arrange somewhere

to anker the flame, often designed as a pilot diffusion flame that can be
controlled by its own fuel supply. That flame is often producing quite a lot of
NOx, maybe 1÷2 ppm/% pilot fuel, so even a small pilot can supply an
additional 5 ppm NOx
z The pilot flame is often arranged in the centre of the burner, but also at the
exit ring

Pulsations
z The combustion pulsations are generally of two types

z High frequency acoustics (1000-3000 Hz) generated by the instationary
heat release in the turbulent shear layers of the swirling jet
z Low frequency combustion dynamics (50-500Hz) generated by the
movements of the flame front
z It is possible to design combustion systems without pulsations, often after a

period of testing and tuning of the aerodynamics and fuel distribution
z But if not successful

z the high frequency can be damped by “Soft walls”
z the low cycle frequencies can be damped by Helmhold´s dampers
Helmhold´s
damper
Soft wall

The fuel system
z The piping system for distribution of fuel to the burners has basically three
pressure drops caused by
z The control valve
z The fuel injector flow area and calibration nozzle
z The piping system losses in bends or due to wall friction
The minimum pressure drop over the control valve must be around 200 kPa to
achieve a stable control
z The total pressure drop over the burner depends somewhat on the injector
design, but a calibration nozzle is most often used to provide
z Even flow to all burners
z A safety against too high gas flow in case of an injector failure

A typical gas fuel system for a 18
burner combustor with main and pilot
Gas fuel unit 2, located inside the GT enclosure

Quick shut-off valves

Gas control valves
Enclosure wall
From gas fuel unit 1
To atmosphere
Ventilation valves

Fuel system pressure losses
z The main pressure drops occurs over the

z burner
z control valves
z The losses in pipes, bends, shut off valves etc are calculated by
Δp = λ*ρ*c2/2
z The burner pressure drops are calculated by

Δp = {m/Aeff}2*1/(2ρ)
Aeff,main = 30 ÷ 60 mm2
Aeff,pilot = 10÷15 mm2
z The required pressure drop over the valves is then calculated from the
available pressure or
z the required gas pressure is calculated for a minimum valve pressure drop of
2/9/2006 200 kPa on the coldest day (max power output) Power Generation 50
Fuel system and valves
The fuel valve calculations uses the basic equation

m = Ψ*Av*p1/rot(RgTg)
Critical flow
Sub critical flow
The critical pressure ratio

κ
⎛ 2 ⎞ κ −1
π = ⎜ ⎟
κ +
crit
⎝ 1 ⎠

Fuel valves
The fuel valves can of different designs but they generally has an
effective flow area as a function of shaft position
but with a small influence of the pressure ratio
Main valve matrix

p2/p1=
1400 0.2
1200 0.3
Effective area mm2
1000 0.4
800 0.5
600
0.6
400
0.7
200
0.8
0
0 10 20 30 40 50 60 70 80 90 10 11 0.9
0 0
Actual
Position %

The Ψ factor
Psi overall
Psi register
0.750
p2/p1 psi 1.35 Kkap
0.700 0.00 0.6761 0.1751
0.50 0.6761 0.1751
0.650 0.55 0.6759 0.1576

0.60 0.6700 0.1401
0.600
1.25 0.65 0.6562 0.1226
0.550 1.3 0.70 0.6338 0.1051
1.35 0.75 0.6017 0.0876
psi
0.500 1.4 0.80 0.5582 0.0700

1.4 approx 0.85 0.5002 0.0525
0.450
1.35 0.90 0.4217 0.0350
0.400 Psi register 1.00 0.2500 0.0000
0.350
Psi = psi1.35+Kkap*(kappa-1.35)
0.300
0.250
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1
Pressure ratio

The operation
z The gas turbine is very flexible

z The gas turbine plant is very compact and contains everything needed
for the operation, which means that there are a number of systems in the
plant (lubrication, fuel distribution and control, ventilation, fire detection
and control…..)
z Quick to start and take up load by a number of preset sequences:
zpush the button for start and stop of fuel change over
z Controlled from a PC
z Can be controlled by power turbine load or speed or generator frequency
z Has built in safety systems for protection of
zPersonnel (explosions from fuel leaks or flame out)
zThe unit (overheating of critical parts, over speed etc)

The start procedure
z The start procedure goes like this

z The gas turbine is rotated by an electric motor in order to get an air flow
through the combustor
z The igniter is activated (spark plug or torch burner)
z The fuel valve is put in a preset start value and the shut off valve is
opened. Ignition has to occur within seconds, otherwise shut down.
z Speed is increased and fuel flow is ramped up

z At some point the turbine is making enough power to accelerate the
compressor; the unit is self sustained and the electric motor is phased
out
z Acceleration continues up to idle, where the generator is phased into the
grid
z Loading up to full load in 5 ÷ 10 minutes depending on requirement
zFast loading means lower lifetime on critical parts
zThe combustor often contains parts that are sensitive to thermal fatigue,
but the life of a combustor is mostly limited by oxidation or buckling

Mechanical drive start
Exhaust temp Self-sustaining

GG speed
Fuel flow
Cross ignition
Torch ignition

Part load operation
z When the power (fuel flow) is reduced from full load the air flow is also going
down and so is the pressure and air temperature
z On a single shaft unit the rotor speed is constant and the air flow can be
controlled by the inlet guide vanes of the compressor so that the flame
temperature is kept high in a wide load range
z On a twin shaft unit the rotor speed is going down, but not as much as
one could wish. The flame temperature drops and flame stability has to
be kept up by increasing the pilot flame
z There are a number of ways to keep the flame temperature high at part
load e.g.
zBleed off of compressor air
zBypass of air
zStaging of burners (reducing the number of burners that are fueled)

Combustion supervision
z The combustor is supervised by flame

detectors, usually two separate systems to
prevent explosions
z fuel must not be injected when there is no
flame
z The burners are usually checked with the

turbine exhaust temperature measurements
z Deviation in temperatures can indicate
burner problems
z Some combustors have differential pressure

and pulsation measurement (fast pressure
transducers)
z Some burner have temperature measurements

Calculation tasks
z The task is to design a gas turbine combustion system with certain data
z It is advisable to use the Excel program GTZ-Combustor`s manual
version, which can be improved by introduction of a number of iterations
and modifications if you like to
z You will be assigned a small set of data and from that you have to make
some choices, as discussed in this presentation
z You will be assigned
za power out put: 18, 26 or 35 MW

zan application for which you have to discuss and decide on NOx level,
burner type and combustor type
– gas pipe line compressor driver
– industrial heat &power generation
– peak&reserve power
zThen you have to go through the design procedure and come up with a
combustor wall design, burner type and number/size of burners, cooling
and dilution flows
zThe result will be your Excel sheet!

The Excel program
z The Excel program consists of a number of sheets

z Termo 1: Gas turbine thermodynamic lay out calculations
z Termo 2: Gas turbine thermodynamic part load calculation: (fixed
geometry)
z Combustor 1: Film cooled combustor geometry and wall cooling
Combustor 2: Convection cooled combustor geometry and wall cooling
z Burners 1: Nominal design of burners coupled to Termo1

z Diffusion, DLE, low oxygen and catalytic burner flows
z Burner 2: Part load operation coupled to Termo 2
z Fuel system: Fuel system calculations
z Fuel: Fuel analysis

The program
z It is basically a manual program for educational purpose, but in order to

simplify things for you there are
z some iterations and couplings between sheets, which can go wrong.
Restart by using the Run/test 1/0 button.
z The calculated m*rotT/p values in Termo 1 must be copied to Termo 2
manually as fixed values when the nominal design is done

The design steps
z On Termo1:
z put in your nominal data for ambient conditions, TIT and fuel flow
z make your choice of burner type 1-4
z Iterate air flow, fuel flow, pressure level until you have got what you want
in output efficiency and TET (also number of burners and burner size)
z You have now determined the main flow areas in the unit Aeff ~ m*rotT/p
z Copy those values to Termo 2 (the fixed geometry program)

z In the shaded area you have the relevant data for the combustor, which
are copied to the two combustor sheets from Termo 2
z You have to choose one of them (film cooled or convection cooled)
z If there is not air enough for film cooling you have to use convection cooling
z Set Termo 2 to combustor design conditions
zNominal or worst case?
z Make a combustor wall geometry
z Make a wall cooling configuration
z If you have done the design at nominal conditions check at worst conditions
Fuel system
z Set Termo 2 to worst conditions = max fuel flow
z Assume a design pressure drop across the control valve, typically 200 kPa
and pressure drops in the piping system
z Find the required fuel pressure (often we want a margin of 5%)
z Choose the size of the fuel valve so that is around 85 ÷ 90% open at this
condition
z If the fuel valve pressure drop is set = 0 the pressure drop is calculated and
the valve position can be used to to match the required flow area with the
valve area.

Design sequence for turbine, burner
and combustor
Make a turbine lay out in Termo 1

considering TIT, p5, TET and efficiency
Choose a burner type considering the target NOx level.

Adjust the no of burners and/or burner diam. to get the
right flow conditions for the required burner λ in Burner 1
Choose a combustor type considering the cooling flow available
Transfer the m*rotT/p values to Termo 2 and

set Termo 2 to combustor design conditions
Go to Combustor 1 or 2 and adjust the dilution flow.

Design the combustor wall geometry trying to fulfill the design criteria
Design the wall cooling by adjusting number and diameter of the cooling holes in Combustor 1
Or the height of the cooling ducts in Combustor 2

Design the fuel system
Set Termo 2 to worst conditions ambient conditions

considering the max power output
Assume that the fuel valve should be 85 -90% open with a

pressure drop of 200kPa at this condition
Adjust the necessary fuel inlet pressure
Adjust the valve size so that the valve flow area = required flow area

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2/9/2006 Power Generation 1

z The design requirements, criteria and targets

z The overall design process

z The component designs

2/9/2006 Power Generation 2

2/9/2006 Power Generation 3

52.2 % process heat

Alfa 0.69 ---

Alfa 1.12 ---

z Well, we will try!

z The compressor drive requires a variable speed power turbine, so we

z The efficiency of the cogeneration unit ought to be in the range of

2/9/2006 Power Generation 8

z We have now a basic design.

2/9/2006 Power Generation 9

Turbine Inlet Temperature C and NOX

Jet Engines GT200

Stationary Gas Turbines

ηpt = (t6m - t7)/(t6m - t7s)

ηc = (t3s - t2)/(t3 - t2)

2/9/2006 Power Generation 11

z The turbine can be seen as a tube with restrictors

m = A *rot(2*Δp*ρ) = A *rot(2*Δp*p/RT) = Ψ*A*p/rot(RT)

For computational purposes the below formula is very useful

2/9/2006 Power Generation 12

The flow capacity of the turbine is determined by the smallest

The flow capacity of the turbine determines the position of the

ηct = (t5m - t6)/(t5m - t6s)

ηc = (t3s - t2)/(t3 - t2)

2/9/2006 Power Generation 14

Gas turbine principle & components

2/9/2006 Power Generation 15

z1800 kPa η=38.3% TET=509°C T3=438°C

z For combustion high air temperature is generally better

z NOx and combustion pulsations have a tendency to increase

z Now we have basic full load data for the combustor

z In order to design the combustor we have to know which

2/9/2006 Power Generation 17

z The low oxygen combustors relay on a combustion process in O2-depleted gas,

NOx ppmv Diffusion flames

Gas inlet Air

NOx ppm CO ppm

1700 1800 1900

2/9/2006 - Advanced DLE burners Power

z The Oil&Gas customers have presently no high requirements on

z Our trial choice is a LP burner with a design flame temperature of 1750K

z How much air is needed for the combustion?

z We will do a heat balance calculation for the flame zone

2/9/2006 Power Generation 21

z Now we have the basic flow data for the combustor

If the film cooling air is on

Meal wall Bound coat TBC

2/9/2006 Power Generation 24

dependent on flame radiation and surface emissivity

2/9/2006 Power Generation 25

z In the case when there is not enough air for

z The cooled side heat transfer has then to

z When using TBC the heat flow through the wall

2/9/2006 Power Generation 26

z The bulk flow velocity in the combustor can tentatively be set to

z Now it is time to make a choice of combustor type

m = A rot(2Δpρ) = A rot(2Δpp/RT) = ΨAp/rot(RT)