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Development of a Design Tool for Modern Gas Turbine Combustors and Commissioning of a Gas Turbine Combustion Research Laboratory by Michele Capurro B. Eng, Carleton, 2004 A thesis submitted to the Faculty of Graduate Studies and Research In partial fulfillment of the requirements for the degree of Master of Applied Science Ottawa-Carleton Institute for Mechanical and Aerospace Engineering Department of Mechanical and Aerospace Engineering Carleton University Ottawa, Ontario Canada April 2008 © Copyright by Michele Capurro, 2008 Library and Bibliotheque et 1*1 Archives Canada Archives Canada Published Heritage Direction du Branch Patrimoine de I'edition 395 Wellington Street 395, rue Wellington Ottawa ON K1A0N4 Ottawa ON K1A0N4 Canada Canada Your file Votre reference ISBN: 978-0-494-40634-2 Our file Notre reference ISBN: 978-0-494-40634-2 NOTICE: AVIS: The author has granted a non L'auteur a accorde une licence non exclusive exclusive license allowing Library permettant a la Bibliotheque et Archives and Archives Canada to reproduce, Canada de reproduire, publier, archiver, publish, archive, preserve, conserve, sauvegarder, conserver, transmettre au public communicate to the public by par telecommunication ou par Plntemet, prefer, telecommunication or on the Internet, distribuer et vendre des theses partout dans loan, distribute and sell theses le monde, a des fins commerciales ou autres, worldwide, for commercial or non sur support microforme, papier, electronique commercial purposes, in microform, et/ou autres formats. paper, electronic and/or any other formats. The author retains copyright L'auteur conserve la propriete du droit d'auteur ownership and moral rights in et des droits moraux qui protege cette these. this thesis. Neither the thesis Ni la these ni des extraits substantiels de nor substantial extracts from it celle-ci ne doivent etre imprimes ou autrement may be printed or otherwise reproduits sans son autorisation. reproduced without the author's permission. In compliance with the Canadian Conformement a la loi canadienne Privacy Act some supporting sur la protection de la vie privee, forms may have been removed quelques formulaires secondaires from this thesis. ont ete enleves de cette these. While these forms may be included Bien que ces formulaires in the document page count, aient inclus dans la pagination, their removal does not represent il n'y aura aucun contenu manquant. any loss of content from the thesis. Canada ABSTRACT In response to rising environmental concerns, Natural Resources Canada contracted the Mechanical and Aerospace Engineering Department of Carleton University to develop a preliminary design for a 50 kW zero-emission power plant. The work presented in this thesis focuses on the microturbine combustor for this particular type of power plant. The first major task was the development of a design tool for the design of gas turbine combustors. The design methodology is largely based on established empirical and semi- empirical correlations for conventional gas turbine combustors. The methodology was updated and supplemented by recent correlations to address the particular issues of modern lean premixed combustor. The preliminary design of a lean premixed gas turbine combustor was generated using the new design tool. The new combustor was manufactured and instrumented, and is ready for testing. The second major task was the commissioning of a gas turbine combustion research laboratory. The laboratory was designed and constructed so that the performance of the new gas turbine combustor and the accuracy of the design tool could be evaluated at a later time. iii ACKNOWLEDGEMENTS I am especially grateful to Dr. Donald Gauthier for giving me the opportunity to work on such an interesting and challenging research project. Thank you whole-heartedly for all the supervision, guidance and professional advice you have given me throughout this thesis. My gratitude goes out as well to the staff at Environment Canada. A special thank you is expressed to Jim Fearn, Guy Bracewell, Peter Barton and Fred Hendren for their support during this effort. I would also like to acknowledge the Mechanical and Aerospace Department at Carleton University. Many thanks goes to Ms. Christie Egbert and Ms. Nancy Powell for all the administrative support and Mr. Alex Proctor and Kevin Sangster for letting me use the mechanical workshop and, more importantly, for the valuable assistance and expertise. A special thank you goes out to Mr. Get Nunez for supporting my enrolment in the Master's program and for providing parts needed for the research laboratory. I would like to acknowledge and express my deep gratitude to Dr. Ali Mahallati for all his generous assistance. A much felt thank you goes to Mr. Carlo Rea and Scanivalve Corporation who donated an expensive piece of equipment to the research laboratory. My utmost respect and gratitude is expressed to a true gentleman, my father-in-law David Emery. I whole-heartedly thank you for all the unconditional support and love given to me over the years. Words can not express the gratitude and appreciation I feel towards my wife, Audrey, who sacrificed so much through the years so that I could fulfil my ambitions. I also thank you for your time and patience in editing my thesis. I would like to thank my family in Italy for the wisdom, guidance and help provided to me throughout the years. Finally, I would like to thank everybody who contributed to the successful realization of this thesis, while expressing at the same time my apologies for not being able to mention you personally one by one. iv TABLE OF CONTENTS Abstract iii Acknowledgements iv Table of Contents v List of Tables x List of Figures xi Nomenclature xxi 1 Introduction 1 1.1 Research Project Overview 1 1.2 Research Project Details 5 1.3 Thesis Overview 6 1.4 Thesis Objectives 7 1.5 Thesis Outline 9 2 Literature Review 11 2.1 Combustion Modelling 11 2.1.1 CFD Modelling 13 2.1.2 Reactor Theory Modelling 18 2.1.3 Empirical and Semi-empirical Design Methodology 22 2.2 Manufacturing of Combustor and Gas Turbine Combustion Research Laboratory 23 3 Techonology and Terminology 26 3.1 Gas Turbine Layout and Cycle Analysis 26 3.2 Combustion Flame Types 30 3.3 Flame Temperature 30 3.4 Stoichiometry 30 3.5 Equivalence Ratio 31 v 3.6 Flammability Limits 32 3.7 Stability Limits 32 3.8 Autoignition 33 3.9 Flashback 33 3.10 Combustor Nomenclature 33 3.11 Combustor Types 38 4 Design Methodology for the Preliminary Design of a Gas Turbine Combustor40 4.1 Combustor Preliminary Design Approach 42 4.2 Equivalence Ratio Estimation 44 4.3 Adiabatic Flame Temperature and Mixture Mole Fractions 45 4.4 Liner Air Mass Flow Rate Distribution 52 4.5 Casing and Liner Sizing 56 4.5.1 Casing and Liner Area 56 4.5.2 Annulus Area 60 4.5.3 Liner Primary, Secondary and Dilution Zone Lengths 60 4.6 Swirler Design 64 4.7 Dome Sizing 71 4.8 Combustor Resizing for Lean Premixed Combustion 74 4.8.1 Resizing Motivations 74 4.8.2 Resizing Approach for Lean Premixed Combustors 76 4.9 Diffuser and Snout Sizing 78 4.10 Liner Cooling Mechanism 84 4.10.1 Heat Transfer Terminology 84 4.10.2 Uncooled Wall Temperature 85 4.10.2.1 Internal Radiation, Ri 87 4.10.2.2 External Radiation, R2 89 4.10.2.3 Internal Convection, Ci 90 4.10.2.4 External Convection, C2 91 4.10.2.5 Calculation of Uncooled Liner Wall Temperature 92 4.10.3 Calculation of Cooled Liner Wall Temperature and Cooling Mass Flow.... 93 4.10.3.1 Cooling Slot Effectiveness, ric 94 4.10.3.2 Equivalent Hot Gas Temperature, Tg" 95 vi 4.10.3.3 Film Coolant Temperature, Tc 96 4.10.3.4 Cooling Air Mass Flow Rate, rhc 96 4.10.3.5 Hot Gas Mass Flow Rate, m 97 4.10.3.6 Annulus Mass Flow Rate, m AK1 98 ' AN 4.10.3.7 Area Calculations Ac, Ag, AAN 98 4.10.3.8 Calculation of Cooled Wall Temperature 98 4.11 Injection Hole Sizing 99 4.12 Fuel Injection Theory 106 4.12.1 Fuel Atomization Process 107 4.12.2 Droplet Evaporation Process and Evaporation Model Ill 4.12.3 Droplet Motion 118 4.12.4 Ignition Process and Ignition Model 120 4.12.4.1 Autoignition 123 4.12.4.2 Flashback 125 4.13 Pollutant Emissions Prediction 125 4.14 Combustor Structural Considerations 127 5 Combustor Preliminary Design Geometry 131 5.1 Preliminary Geometry of Lean Premixed Combustor 131 5.1.1 Design Considerations 133 5.1.2 Overview of Combustor Dimensions 134 5.1.3 Selection of Fuel Nozzle 139 5.1.4 Selection of Ignition System 140 6 Premixed Combustor Manufacturing Process 142 6.1 Material Overview for Engine Hot Section Components 142 6.2 Selection of Combustor Liner Material 145 6.3 Overview of Superalloys Manufacturing Processes 146 6.4 Overview of Superalloys Joining Processes 147 6.5 Selection of the Combustor Liner Manufacturing Method 150 6.6 Combustor Casing Material Selection 157 6.7 Selection of Combustor Casing Manufacturing Method 159 6.8 Liner Casing Assembly 161 vii 6.9 Premixer Manufacturing Process 164 6.10 Fuel Nozzle Modifications 166 7 Gas Turbine Combustion Research Laboratory 170 7.1 Gas Turbine Combustion Research Laboratory Layout and Location... 170 7.2 Gas Turbine Room 173 7.2.1 Allison 250-C20B Overview 173 7.2.2 Allison 250-C20B Air Flow Path 175 7.2.3 Allison 250-C20B Engine Modifications 176 7.2.4 Allison 250-C20B Instrumentation 188 7.3 Combustion Room 198 7.3.1 High Pressure Air Delivery System 199 7.3.2 Air Delivery System Design and Flow 199 7.3.3 Air Delivery System Components 211 7.3.4 Air Delivery System Instrumentation 219 7.3.4.1 Microturbine Combustor Instrumentation 219 7.3.4.2 Orifice Instrumentation 232