Test Results of the World s First 1,600 o C J-series Gas Turbine

Transcription

1 Mitsubishi Heavy Industries Technical Review Vl. 49 N. 1 (March 2012) 18 Test Results f the Wrld s First 1,600 C J-series Gas Turbine SATOSHI HADA *1 KEIZO TSUKAGOSHI *2 JUNICHIRO MASADA *3 EISAKU ITO *4 Gas-turbine cmbined-cycle (GTCC) pwer generatin is expected t be a market success because it is the cleanest and the mst efficient thermal pwer generating system that cmplements renewable energy surces. Mitsubishi Heavy Industries, Ltd. (MHI) has develped the wrld s first 1,600 C J-series gas turbine by utilizing cmpnents and technlgy frm the natinal prject aimed at develping 1,700 C -class gas turbine. Lng-term reliability testing f the M501J gas turbine cntinues, fllwing testing at the demnstratin cmbined-cycle pwer plant (T-pint) at ur Takasag Machinery Wrks frm February t June The cmmercial versin f the M501J gas turbine has already been shipped t Kansai Electric Pwer Cmpany s Himeji N. 2 pwer statin and will enter peratinal use in Octber This reprt describes the features f the M501J gas turbine and the test results f M501J gas turbine at T-pint. 1. Intrductin Gas-turbine cmbined-cycle (GTCC) pwer generatin is the cleanest and mst efficient pwer generating system f all the fssil-fuel-burning appraches. It has the fllwing scial and ecnmic impacts: (1) The lng-term wrld market fr GTCC pwer generatin is expected t grw. (2) A great demand exists fr GTCC pwer generatin in develping cuntries because GTCC systems can be cnstructed quickly and prvide a stable surce f electricity. (3) The need exists in develped cuntries fr highly efficient pwer generatin fr further enhancement f ecnmic efficiency and envirnmental adaptability. (4) The superir lad-absrbing capability f GTCC pwer generatin is in increasing demand because f the grwth f renewable energy surces. Mitsubishi Heavy Industries, Ltd. (MHI) develped the M701D 1,150 C-class large-capacity gas turbine in the 1980s and demnstrated high plant thermal efficiency and reliability with a liquid-natural-gas-burning cmbined-cycle generatin plant at Thku Electric Pwer Cmpany s East Niigata Thermal Pwer Statin 3. This led t the develpment f the M501F gas turbine with a turbine inlet temperature f 1,350 C in 1989 and the M501G gas turbine with a turbine inlet temperature f 1,500 C and steam-cled cmbustr in 1997, each with imprved efficiency and reliability. Starting in 2004, MHI participated in the natinal 1,700 C -class gas turbine cmpnent technlgy develpment prject, cncentrating n develping new technlgies required fr higher turbine inlet temperatures and efficiency. We have develped the M501J gas turbine, the first turbine in the wrld with a turbine inlet temperature f 1,600 C capable f a cmbined-cycle pwer-generating grss thermal efficiency f 61.5% under ISO nrmal lw heat value (LHV) cnditins (Figure 1). We are als develping the M701J fr 50 Hz. This reprt describes the features f the M501J gas turbine and the results f its first verificatin test cnducted at the T-pint facility in ur Takasag Machinery Wrks starting in February *1 Gas Turbine Engineering Department, Pwer Systems *2 Chief Engineer, Pwer Systems *3 General Manager, Gas Turbine Engineering Department, Pwer Systems *4 Deputy General Manager, Takasag Research & Develpment Center, Technlgy & Innvatin Headquarters

2 Mitsubishi Heavy Industries Technical Review Vl. 49 N. 1 (March 2012) 19 Figure 1 MHI gas turbine (60-Hz machine) efficiency and utput 2. M501J gas turbine features The M501J gas turbine was designed with a turbine inlet temperature f 1,600 C by integrating the prven cmpnent technlgies used in the 1,400 C F-series and the 1,500 C Gand H-series turbines. The M501J als benefited frm the develpment f key technlgies fr the natinal 1,700 C -class gas turbine prject (Figure 2). Adptin f the higher inlet temperature and latest cmpnent technlgy means that the cmbined-cycle grss thermal efficiency, which is significantly better than that f cnventinal machines, will be 61.5% n a LHV basis (Figure3, Table 1). Therefre, a pwer plant with a natural-gas-burning J-series cmbined-cycle plant can reduce carbn dixide emissins by apprximately 60% cmpared t a cnventinal cal-burning thermal pwer plant. Figure 2 M501J gas turbine cncept Figure 3 M501J gas turbine features Table 1 J-series gas turbine perfrmance Series Turbine inlet temperature Rtating speed Gas turbine utput (grss) Cmbined-cycle utput (grss) Cmbined-cycle efficiency (grss LHV ISO base) Cmpressr/pressure rati Cmbustr Turbine 2.1 M501G 1,500 C 3,600 rpm 267 MW 399 MW M501J 1,600 C 3,600 rpm 327 MW 470 MW 58% r higher 61.5% r higher 17 stages/20 16 cans 15 stages/23 16 cans Rw 1 t rw 4 blades, air cled; Rw 1 t rw 3 vanes and blades, air cling; Rw 1 t rw 3 vanes, air cled; Rw 4 vane and blade, uncled Rw 4 vane, uncled Overall design The design f the M501J gas turbine is based n these prven F- and G-series features: The cmpressr shaft end drive cnnected t the generatr reduces the thermal expansin and eliminates the need fr a flexible cupling. The rtr has a tw-bearing structure t supprt the cmpressr and turbine ends. An axial flw exhaust structure is used t ptimize the cmbined-cycle plant layut. The rtr structure has blt-cnnected disks with the trque pin in the cmpressr rtr and a disc with curvic cupling in the turbine rtr t ensure reliable trque transmissin.

3 Mitsubishi Heavy Industries Technical Review Vl. 49 N. 1 (March 2012) 2.2 Cmpressr The M501J cmpressr was designed as an axial flw type with a pressure rati f 23; it was based n the technlgy used in the H-series cmpressr, which had a pressure rati f 25. Three-dimensinal (3D) advanced design techniques were used t imprve the perfrmance and reduce the shckwave lss in the initial stages and frictinal lss in the intermediate and final stages. This cncept was evaluated by 3D cmputatinal fluid dynamics (CFD) sftware and verified using the full-scale high-speed research cmpressr (Figure 4). Figure 5 shws an example f 3D CFD analysis results. In additin, bleeding was used in the lw-, middle-, and high-pressure stages during cmpressr start-up. Rtating stall n start-up was suppressed, and the partial-lad perfrmance f the cmbined cycle was imprved, by cntrlling the inlet guide vane (IGV) and three-stage variable statr vanes. 2.3 Cmbustr The M501J cmbustr was based n the prven steam cling system used in G-series gas turbines. Althugh the turbine inlet temperature was increased by 100 C frm 1,500 C in the G-series t 1,600 C, the emissin density f nitrgen xide (NOx) was suppressed t the same level as that f the G-series thrugh the use f lw-nox technlgies, such as reducing the lcal flame temperature in the cmbustin area by imprving the cmbustin nzzle (Figure 6) fr mre hmgeneus mixing f fuel and air. Air flw tests, atmspheric-pressure cmbustin tests, and high-pressure cmbustin tests were cnducted t verify the perfrmance and reliability, and the results were applied t the detailed design f the cmbustr. 20 Figure 4 High-speed research cmpressr Figure 5 Air flw near the cmpressr endwall (advanced 3D design result) Figure 6 Imprved cmbustin nzzle regin 2.4 Turbine The M501J turbine is an axial-flw, fur-stage, high-lad, high-perfrmance turbine. T imprve its perfrmance, a 3D endwall cnturing was used t cntrl the secndary flw generated at the endwall, the design f which cnsidered the flw field interference and hrseshe vrtex frm the blade leading edge. This was in additin t the cmplete 3D design used in the G-series turbine. The metal temperature was maintained at the level f a cnventinal machine using the technlgy develped in the natinal 1,700 C -class gas turbine prject. The 100 C temperature increase was half ffset by high-perfrmance cling technlgy and half by an advanced thermal barrier cating (TBC, Figure 7). Figure 7 Cmpnent technlgies fr a turbine inlet temperature f 1,600 C

4 Mitsubishi Heavy Industries Technical Review Vl. 49 N. 1 (March 2012) Rw 1 t rw 4 rtating blades and rw 1 t rw 3 statinary vanes are air-cled. The rw 4 blades in the G-series turbine were nt cled, but thse in the J-series turbine were cled t cpe with the higher inlet temperature. MGA1400 (Mitsubishi Gas Turbine Ally) used fr the rtating blades, while the vanes were made f MGA2400. The rw 1 t 3 blades were made f DS (directinal slidified) superally. MGA1400 and MGA2400 were als used in the F-series and G-series gas turbines. The cling structure was imprved fr the F-series and again fr the G-series turbine, and the J-series uses high-perfrmance film cling and advanced TBC develped in the natinal prject, as shwn in Figure 8. The film cling effectiveness f high-perfrmance film cling was tested after selecting the ptimum film shape in a flat plate cmpnent test, in a large-scale lw-speed rtatinal test, and in a medium-pressure cascade test (Figure 9 and 10). High-perfrmance film cling and advanced TBC were applied t the M501G turbine blades at T-pint, its effectiveness was tested by a special measurement, and then lng-term testing f the actual machine tk place. The design f the J-series turbine blade was based n these test results, and the final verificatin was dne using the first M501J gas turbine after cnducting the high-pressure high-temperature cascade test. 21 Figure 8 Turbine cling structure imprvement Figure 10 Result f film efficiency measurements with lw speed rtating test facility Figure 9 Lw speed Rtating test facility verview 3. Verificatin test results at the T-pint demnstratin pwer plant In develping the M501J turbine, each cmpnent was tested in the basic design stage, and the results were reflected in the detailed design. Cmmercial mdels were prduced nly after the entire turbine had been tested in T-pint. Figure 11 shws a phtgraph f the T-pint at the MHI Takasag Machinery Wrks. T-pint was equipped with a M501G gas turbine, a steam turbine, and a heat recvery steam generatr biler. T-pint plant has lgged mre than 2,300 start and stp cycles and 39,253 ttal perating hurs and made a huge cntributin t imprving the perfrmance and reliability f the M501G gas turbine. Wrk t cnvert the M501G turbine t M501J started in Octber 2010, and perating tests f the first M501J gas turbine started in February The tests prceeded as scheduled with the first spin-up n February 2nd and the first ignitin n February 7th; the inlet temperature reached 1,600 C n the seventh start-up. Varius tests were then cnducted until the end f April when the

5 Mitsubishi Heavy Industries Technical Review Vl. 49 N. 1 (March 2012) turbine was disassembled and each part inspected. Lng-term reliability peratinal testing started in July 2011, resulting in 58 start-up tests and 3,540 hurs f peratin by the end f December 2011 (Figure 12). The special measurement and the test results f each cmpnent are described in the sectins that fllw. 22 Figure 11 MHI Takasag Machinery Wrks T-Pint demnstratin cmbined-cycle pwer-plant Figure 12 M501J test peratinal recrd at T-pint 3.1 Special measurement utline The M501J turbine at T-pint was equipped with at least 2,300 special measuring sensrs, including apprximately 100 rtating parts mnitrs in additin t the mre usual mnitring devices. 3.2 Cmpressr The natural frequency, vibratin stress f blades and vanes, and pressure fluctuatin were measured t determine the starting characteristics and the blade/vane reliability in the cmpressr. Desirable characteristics, such as the extinctin f rtating stall at apprximately 60% f the rtating speed, were cnfirmed (Figure 13). Cmpressr efficiency and inlet air flw were measured at each IGV angle t shw that the design perfrmance was achievable. Figure 13 Cmpressr starting characteristics 3.3 Cmbustr The metal temperature, vibratin stress, and stress fluctuatin were measured in the cmbustr. During peratin with a turbine inlet temperature f 1,600 C, the metal temperature f the cmbustin liner was less than the maximum allwable temperature (Figure 14). The cmbustin pressure fluctuatin and vibratin stress were cnfirmed t be within the allwable range. 3.4 Turbine The metal temperature was measured by installing thermcuples n turbine blades and vanes. The metal temperature f rtating blades was measured using a telemetry system. The temperature was verified t be lwer than the allwable metal temperature at the 1,600 C inlet temperature. Figure 15 shws the distributin f the metal temperature n the turbine rw 1 vane. The temperature distributins f the rw 1 blade surface and platfrm were measured with a pyrmeter. Figure 16 shws a typical temperature measurement f the mving blade platfrm. Detuning t the natural frequency was verified acrss the peratinal range, and the vibratin stress was verified t be lwer than the maximum allwable stress.

6 Mitsubishi Heavy Industries Technical Review Vl. 49 N. 1 (March 2012) 3.5 Disassembly inspectin result The gas turbine was disassembled in June 2011, and the sundness f each part was cnfirmed as shwn in figure 17. Lng-term peratinal reliability testing then began, and the turbine and cmbustr were inspected in Octber Figure 14 Metal temperature f cmbustin liner at a turbine inlet temperature f 1,600 C Figure 15 Metal temperature measurement f the rw 1 vane Figure 16 Temperature distributin n platfrm in the turbine rw 1 blade btained using a pyrmeter 4. Cnclusin Figure 17 Disassembly inspectin result GTCC pwer generatin is the cleanest and mst efficient apprach t pwer generatin using cmbustin f fssil fuels and has many favrable scial and ecnmic aspects. MHI has develped the wrld s first 1,600 C J-series gas turbine using technlgies develped during the Japanese natinal 1,700 C -class Ultra-high Temperature Cmpnent Technlgy Develpment prject. The first M501J gas turbine has nw cmpleted the trial peratin. MHI will cntribute t the reductin f carbn dixide emissins and help stabilize electric pwer generatin with the J-series GTCC pwer generatin system, which has a grss thermal efficiency f 61.5% (LHV basis). References 1. Umemura, S. et al., Develpment and Operating Status f "1500 C Class" Gas Turbine, Mitsubishi Heavy Industries Technical Review Vl. 35 N. 3 (1998) pp It. E. et al., Develpment f Key Technlgy fr Ultra-high-temperature Gas Turbines, Mitsubishi Heavy Industries Technical Review Vl. 47 N. 1 (2010) pp It. E. et al., Develpment f Key Technlgies fr an Ultra-high-temperature Gas Turbine, Mitsubishi Heavy Industries Technical Review Vl. 48 N. 3 (2011) pp Hada, S. et al., Evlutin and Future Trend f Large Frame Gas Turbine fr Pwer Generatin A new 1600degree C J class gas turbine, IGTC, IGTC