The Progress of Aero-Derivative Gas Turbines for Ground Usage in China

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1 E AMERICAN SOCIETY OF MECHANICAL ENGINEERS 345 E. 47 St., New York, N.Y 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 from ASME for fifteen months after the meeting. Printed in USA. Copyright 1985 by ASME The Progress of Aero-Derivative Gas Turbines for Ground Usage in China ZHANG YAO-XI Engineer, Aeronautical Documentation and Information Research Institute ABSTRACT The development and progress of aeroderivative gas turbines for ground usage in China is reviewed. Several models derived and models in development are mentioned. as a result of some feasibility studies the prospect for future gas turbine applications is also pointed out. BACKGROUND The first attempt in China to make use of an aircraft gas turbine engine for ground purpose was made in 1950s at Nanking Aeronautical Institute. Professor Xu Fuyao and others modified a retired jet engine as an airsupply power installation. A gas generator, modified from retired engine WP5, rotates two second stage axial compressors of jet engine PR-20, with power of 6000 shp at speed 9000 rpm, airflow 35 kg/sec, pressure 2.3 kg/cm. In 1960s. Xi-an Aero-Engine Factory (XAEF) modified one of the jet engine WP8 as the powerplant of a water surface ship. Some of the ground test items and a 100-hr endurance test of the power plant were completed, with maximum power of 24,000 shp and sfc of 320 g/hp hr. This was not put into use on ship because of its low performance. At the same time XAEF provided a stand-by power station of 12,000 kw with another model. For the same reason of low performance the stand-by power station has been closed. State sponsored development of aero-derivative gas turbines began in 1970s. In 1972 there was a British Industry Exhibition in Beijing with an industrial Avon exhibited. It showed that the development of aeroderivatives was successful in Rolls-Royce and in other companies. Since then the development work of aero-derivative gas turbines in China was restarted. THE DEVELOPMENT OF THE FIRST SERIES OF AERO-DERIVATIVE GAS TURBINES In 1974 the responsible department of the Ministry of Aircraft Industy sponsored Presented at the 1985 Beijing International Gas Turbine Symposium and Exposition Beijing, People's Republic of China September 1-7, 1985

2 the first civil market survey on the potential applications of gas turbines made in China. Much useful information and data were collected. At the same time the responsible departments of the Ministry of Oil Industry and of the Ministry of Ship-building Industry provided some details of requirements, including: Moring Power Station For new oil field the moving power station can be used to supply electrical power before the oil field network has been put into operation. The engineering schedule of the whole oil field may be performed in advance for 3-6 months. Pumping Station A large amount electrical power is consumed in water injection. Water injection takes more than 40% of the total electrical power consumption in the oil field, and for the oil fields in the late period of oil production this would take even more percentage. Use of gas turbines for early water injection will take advantage of increasing natural oil recovery. Fracturing Unit Trucks Aero-derivative gas turbines may be candidate power plants for fracturing unit trucks, because of their high power (1500 shp) and low weight. Compression and Transmission For natural gas compressors and for the intermediate compression pumping stations of pipelines. Off Shore Platform For driving slurry pumps and other equipment. At the request from ship-building industry the aero-derivative gas turbines in medium or low power level were considered of great urgency for high speed boats and air cushion vehicles. So it was recognized that the programs to develop aero-derivative gas turbines in kw level were of the most urgency Therefore, 3 models (i.e. WJ6, WJ5, and WZ5) were put into development immediately. WJ6G WJ6G is developed by Zhuzhou Aero-Engine Factory (ZAEF). It is derived from a turboprop engine WJ6. The WJ6G includes 3 models, i.e. WJ6G1, WJ6G2, WJ6G4. WJ6G1 is the first model, developed in It is a forward output version developing 2900 at 1000 rpm. WJ6G1A is similar to WJ6G1, but with an output speed of 3000 rpm. -G1 and -G1A are packaged by Beijing Heavy Generator Factory as power equipment of moving power station, designated YD G1 and -G1A may take diesel oil or natural gas fuel. A total 46 engines of these two versions have been produced, 40 of them being supplied to 5 oil fields. It is reported that WJ6G1 and -G1A are operating well with sufficient reliability. The total running time has accumulated up to 55,000 hrs, and for one single engine it has reached 5,500 hrs. WJ6G2 is a rear output version of 3100 shp, with the features of:. variable inlet guided vanes;. changed install angle of the 2nd stage turbine stators. For the purpose of improving the turbine efficiency, the profile of the 3rd stage turbine rotor blades is redesigned, then the engine has a name, WJ6G2A, of which the power is 3500 shp, and the sfc is lower by 5%. -G2A is developed at the request of Navy users. It has completed ground tests, and is ready for further tests on boat. WJ6G4 is a new project for the needs of railroad locomotives. The main modifications for WJ6G4 are: redesigning the combustion chamber; designing air-cooled 1st turbine blades; increasing the maximum output power to 4500 shp. WJ5D WJ5D is the industrial version of WJ5 which is produced by Harbin Aero-Engine Factory (HAEF) as the power plant for domestic civil transport Y-7. The development of the WJ5D initiated in The 1st WJ5D was assembled in 1979 with the power of 750 kw. Three generating sets equipped with WJ5D have been supplied to Xinjiang Oil Field for wax cleaning and others. A new version of 1250 kw is under development, the power plant package will be designated as YD

3 Industrial WZ5 WZ5 was developed originally for a domestic helicopter, because of its free turbine design, WZ5 may be used easily as an industrial version. The gas generator of WZ5 is as the same as that of WJ5. Wuxi Second Mechanical Research Institute (WSMRI) has packaged and supplied WZc engines and pumps as the water injection pumping equipment. 5 sets of them have been supplied to thexinjiang Water Injection Pumping Station. WZ5 has logged up to 33,650 hrs, and one single WZ5 has reached 8700 running hours in 1981, and hrs in 1984, the records of TBO for gas turbines produced in China. By the way, there is a project under consideration, i.e. to develop a fireextinguishing truck, using the WZ5 gas generator as a smoke producer at the request of coal miners. SOME AERO-DERIVATIVES DEVELOPED IN RECENT YEARS Since 1980 the development of aeroderivative gas turbines for ground usage in China has entered a new era. Professor Wu and others have made a lot of efforts to promote the application of the gas turbines in this country. A specialists group, named Gas Turbine Application Research Group, was established in An six-months investigation plan was performed to evaluate the production and development abilities and the potential applications in the future. Since then the management in this field has been strenthened, and a series of new organizations appeared, including:. China Gas Turbine Research and Development Corporation Professor Wu is the chairman of the board.. Gas Turbine Engineering Package corporation Cheng Huaming, the well-known aircraft engine specialist in China, is the chairman of the board.. Southern Power. Mechanical corporation It consists of Zhuzhou Aero-Engine WS9G Factory and Nan-hua Aero-Engine research Institute.. China Marine and Industrial Gas Turbine R & D Center It consists of Ship Propulsion Research Institute and Wu-xi Second Mechanical Reseach institute. With this background several new models have put into development. WS9G is derived from WS9 by Xi-an Aero- Engine Factory. There are two versions under consideration, i.e. WS9G1 and WS9G2. WS9G1: It is a derated version of 6000 hp class, required by the users as the power plant for small or auxiliary ships, and for energy conservation equipment for oil refineries. WS9G2: This is the version for marine use. The main changes of the WS9G2 are:. the fan blade tip-cut;. variable inlet guided vanes;. fuel nozzles redesign;. removal of magnesium parts, and titanium alloy stators applied, and coatings adopted where needed;. improved TBO. The first phase of WS9G2 development project has been getting on smoothly. The WS9G2 project was evaluated in 1980, and the fan tip-cut project was applied. The detail design began in As a performance demonstration engine, the first WS9G2 gas generator initiated its maiden run in August It started and ran successfully till the rotation speed about 80% being reached. The modifications and changes were made,when the stall, vibration and overtemperature occured. After these modifications the full speed was reached in 1983, The isentropic gas power reached about 18,000 hp. Industrial WP6 The industrial WP6 is developed at Shenyang Aero-Engine Factory. The origin WP6 is a turbojet engine for a Chinese fighter. It is the engine of large scale production in this country. More than ten 3

4 thousand WP6 have been produced. Thus the WP6 has the advantage of low production cost. It was reported by a refinery design and project establishment that in a sufficient envelope the WP6 has its proper merits when used as a preinstalled unit in oil refinery. A WP6 is modified by Shenyang Aero-Engine Factory as the power plant of the power station for the factory itself since The power plant made its first run in 1983 and then the maximum power of 4000 kw was reached. Afterwards there was a contract, singned by Shenyang Aero-Engine Factory with Daqing Oil Field to supply two sets of WP6 generating stations. FEASIBILITY INVESTIGATION The investigation of feasibility for an aero-derivative engine to be used in nonaero programs is a matter of common concern of both manufacturers and users. Several items of feasibility study which have been done by them in recent years are: Gas-Steam Cogeneration Scheme of WS9G1 It is an energy conservation scheme for an oil refinery. The productivity of the oil refinery is about 7 million tons/year. Using the process gas as fuel, two sets of WS9G1, used as the preinstalled units, may gain electricity of 9600 kw, and produce an amount of 26 ton steam at medium pressure from the exhaust gas boilers. Then the fuel utilization factor of the system of the oil refinery may increase from about 80% to 90%. It is estimated that the gain of the electricity will be about 77 million kw-hr/year. Net benifit will be 4.5 million yuan/year. Gas Turbine for Locomotives Some points about the locomotive gas turbines are identified by engineers at Rolling Stock Research Institute of Railroad Ministry, and at Southern Power Mechanical Corporation as: (1) Operational requirements. taking heavy oil as fuel increasing the power up to 4,000 4,500 shp; having ability to operate in a variety of conditions; low noise; thermo efficiency no less than 30% with a regenerator; TBO no less than 10,000 hrs, but 4,000 hrs being the aim at first phase; having the potential in increasing power level; the ten-thousand ton-km cost must be close to that of steam locomotives. (2) Applicable model It is reasonable to take WJ6G as the origin, aimming at a new uprated version WJ6G4, specified for locomotives. Necessary improvements of WJ6G4 include:. 4 stage compressors stators regulation;. combustion chambers redesign to meet with the requirements of firing heavy oil;. increasing turbine inlet temperature upto 1125 K;. noise reduction;. compressor stage addition with compressor pressure ratio increasing from 7.77 to 9.3;. putting coatings where needed;. increasing the TBO, and improving reliability and maintainability. PROSPECT OF FUTURE APPLICATIONS Various people from aircraft-building, ship-building, oil, fighting vehicle-building industries and from Railroad Ministry have done a lot of studies on the potential applications of gas turbines made in China. The most promising fields in which gas turbines may find their application opportunities are expected as follows:. Oil fields pipelines, natural gas collection, water injection, fracturing, emergency or stand-by generating equipments, moving power stations for peak load or base load duty, gas-steam 4

5 U cogeneration equipments with the process gas as fuel for oil refineries. War ships various water surface ships with gas turbines as main power or boosts for acceleration, or with gas turbines forming cogenerators together with steam turbine engines. Fighting vehicles fighting tanks, and high speed carreers with gas turbines as their new power plants promise well in this country. Railway locmotives the gas turbines used must take heary oil as fuel. Generation an appropriate quantity of gas turbines may be needed for emergency or stand -by equipments of utilities and those of State key units and enterprises. table Power sfc Airflow Compressor Combustion Turbine Power Model Turbine shp g/hp.hr kg/sec CPR Stage No. Type No. Stage No. TIT, c Stage No. WJ6G MIX WJ5D MIX Length Width Height m Engine Dry Weight kg WP6(RF-1) CAN WZ5(Indus.) MIX WJ6G2A cross section 5