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In This Issue SEPTEMBER 2020 VOL 60 NO. 3 In this Issue... 52 AMRGT 2021 54 As the Turbine Turns... ASME 56 The Effect of Heat Transfer Gas Turbine Segment on Turbine Performance 11757 Katy Frwy, Suite 380 Houston, Texas 77079 58 Awards Information go.asme.org/igti ASME (AMRGT) ADVANCED MANUFACTURING AND REPAIR FOR GAS TURBINES Symposium By Douglas Nagy, Liburdi Turbine Services EVENT.ASME.ORG/AMRGT FALL 2021 Presented by ASME’s Gas Turbine and exciting processing techniques, of- without publication format expressly Segment (GTS) and International Gas ten combining computer-aided design/ to allow the rapid and timely transfer of Turbine Institute (IGTI) Division, the manufacturing principles, results in new information that is accessible to authors popular Advanced Manufacturing and and more efficient ways to address com- from all types of businesses. Keynote Repair for Gas Turbine (AMRGT) two- ponent design and manufacture. and educational seminars are includ- day symposium will return for 2021. Coming out of the COVID-19 ed for all participants. Special Panel This specialist event brings to- Pandemic, many companies have risen sessions encourage lively discussion of gether engineers, designers, researchers, to the challenge to re-tool for pandemic ground-breaking topics. Submit an ab- production engineers and business lead- support. Organizers expect an unprec- stract at event.asme.org/AMRGT. ers from companies that design, man- edented pent-up demand for jet engine ufacture, repair, and own gas turbines. and gas turbine maintenance as the Furthermore, AMRGT also appeals to economy spools-up again. Upon return Significance to the Community individuals and companies that design to the new-normal factory floors will AMRGT Supports and execute advanced manufacturing place even stronger emphasis on de- Gas turbine and jet-engine industry has processes and equipment. bottlenecking, flexibility, efficiency, and been wracked by a ‘perfect storm’ of both AMRGT explores the critical in- worker-safety. The AMRGT is the key economic downturn and environmental terdependence of production demand event for the professionals to network awareness. Surveys have shown that for lower costs, lighter environmental between developers and users and learn although passenger flights may soon footprint, and faster more flexible fab- how to best take advantage of these new resume, the public is still hesitant to par- rication and challenges those in our processes to support these arising needs ticipate [1]. Furthermore, long periods of manufacturing process research and de- in the turbomachinery industry. inactivity have taken a toll not only on velopment community. Similarly, novel, AMRGT uses a presentation the pocketbooks of operators, but also Pictured: AMRGT 2020 For more information, contact [email protected]. on the condition of the equipment. Deferred maintenance often between the ‘push’ of technological advances out of academia leads to increased maintenance costs when executed. and the technology ‘pull’ resulting from industry’s needs. This Therefore, going forward, there will be strong demand for is the universe where job-creation occurs, smart ideas meet flexible repair options. Reopening a shuttered factory with an technical capability to meet a commercial need. Evolving public out-of-practice workforce will not be enough. policies emphasizing ‘on-shore production’ open new commer- The AMRGT symposium encourages the interaction cial opportunities every day. Key Takeaways for Attendees Who Should Attend? • Gain knowledge of the latest design strategies for additive- • Gas turbine manufacturing and design engineers built parts and repair techniques from renowned experts. • Equipment and process designers for • Contextualize how advanced manufacturing is changing advanced manufacturing business models and enhancing business transformation. • Gas turbines service and repair professionals • Drive technology adoption through knowledge • Gas turbine asset owners involved with dissemination, workforce development, standards maintenance repair and overhaul (MRO) development, and conformity assessment solutions. • Secondary service providers for the gas turbine industry • Network with experts in advanced • Engineers supporting MRO of gas turbine machinery manufacturing for gas turbines. • Advanced coatings and welding processes engineering professionals 1. Webinar: From crisis to complacency: mapping public opinion • Academics and students involved with during the COVID-19 pandemic. Cliff van der Linden, McMaster design for advanced manufacturing University, June 29, 2020 ASME TURBO UPCOMING AWARD EXPO 2020 OPPORTUNITIES VIRTUAL 2021 ASME IGTI Aircraft Engine Technology and Industrial Gas CONFERENCE Turbine Technology Awards Nominations due to [email protected] by October 15, 2020. Virtual Event Dates September 21-25, 2020 2021 Student Scholarships Register online at Application process is open event.asme.org/Turbo-Expo December 1, 2020 – March 1, 2021. For more information, visit asme.org/asme-programs/ students-and-faculty/scholarships Award Winners on Page 56 53 As the Turbine Turns... ASPECTS OF GAS TURBINE THERMAL EFFICIENCY #43 - September 2020 By Lee S. Langston, Professor Emeritus, electric power generation and is now displayed in a special University of Connecticut museum in Birr, Switzerland. According to our IGTI founder, R. Tom Sawyer, official testing of the world’s first operational gas turbine began on July 7, 1939. In his 1945 textbook, The Modern Gas Turbine In the family of heat engines, the gas turbine is unique in [1], Sawyer reviewed the test program carried out at the that it is used to produce two different kinds of useful power. BB works in Baden. This very first shaft power gas turbine By converting combusted fuel heat into work, a gas turbine power plant had a thermal efficiency of 17.38%, based on the engine can produce external shaft power (e.g., to drive a heating value of the fuel oil rate and the heat equivalent of connected electric generator) or jet power (e.g., as a jet en- the electrical output of the generator. Since the component gine, to produce thrust forces to propel an aircraft). This efficiency of electrical generators is very high, the generally means that the gas turbine’s thermodynamic figure of merit, quoted thermal efficiency, for this very first shaft power gas thermal efficiency, is multifaceted, and calls for a nuanced turbine is η == 18%. 18% examination. Since then, in the intervening 80 years, engineers have The shaft power category here, covers the market for greatly increased gas turbine thermal efficiencies, with out- nonaviation gas turbines. The jet power category covers the put as high as 500 MW. Gas Turbine World [2] cites specifi- market for aviation gas turbines, be they turbojets, turbofans. cations of simple cycle gas turbines manufactured by some turboprop and helicopter engines, or auxiliary power units two score OEMs. The highest measured thermal efficiency (APUs) (all of which, of course, have internal shaft power). is 44.7% for General Electric’s LMS100 model, an almost Thermal efficiency, , is defined in simple words as η = 18% factor of three improvement from the Neuchâtel gas turbine. useful output divided by costly input. The input is the rate Electric power plant operators have an “upside down” at which energy is supplied to the gas turbine engine, calcu- or reciprocal way of representing thermal efficiency values, lated from a measured fuel flow rate and the fuel’s heating going back to the early days of coal use for steam power (coal value. The output power for a shaft power gas turbine can has a wide range of heating values). It is called “Heat Rate” be measured under test [1] by a dynamometer or even a cal- (HR) and is defined as the amount of heat supplied (U.S. ibrated electrical generator. However, the power output of a convention, in BTUs) to generate 1.0 kWh of electricity. For jet engine in flight is difficult to measure directly. This would example, η == 44.7% 18% quoted in the last paragraph, divided into entail measuring the rate of production of kinetic energy of energy conversion factor 3412 Btu/kWh, yields HR = 7628 the gases passing through the engine, as well as engine thrust Btu/kWh [2]. and flight velocity. Instead, jet engine OEMs measure engine By the 1990s, gas turbine combustion and hot turbine thrust directly on a static test stand and appraise individual technology had advanced to yield shaft power gas turbine component efficiencies (compressor, turbine etc.) to infer exhaust gas temperatures high enough to be used to gener- performance. ate steam to power steam turbines. The resulting combined Since is such an important parameter in energy con- η = 18% cycle power plant (Brayton and Rankine and abbreviated as siderations, let us look at how it is treated from the stand- CCGT) thus generates electric power from two prime mov- points of shaft power and jet power gas turbines. The ideal ers using one unit of fuel (usually natural gas). pattern cycle for all gas turbines, the Brayton cycle, will be From conservation of energy and the definition of called upon to provide help with some explanations. thermodynamic thermal efficiency, η, =the 18 combined% cycle η η η η η Shaft Power thermal efficiency, CC, =can Bbe+ derivedR − B fairlyR simply as, The world’s first shaft power gas turbine was built and tested ηCC = ηB + ηR − ηBηR (1) by Swiss firm Brown Boveri (BB) in 1939. It was a 4 MW out- put machine, originally installed in the city of Neuchâtel for 54 ηCCηwhereCC== ηBηB and++η RηR− are−ηBη thermalBηRηR efficiencies of the Brayton and Equ. (2) yields a value of η == 69%. 18% For the no-flight case of M0 = 0.8 Rankine cycles, respectively.η TakingCC = ηB =+ 40%ηR − (a ηgoodBηR value = 0, Equ. (2) yields η == 65%, 18% amounting to a 6% decrease from for modern gas turbines)ηCC = η Band+ ηR =− 30%ηBη R(a reasonable value M0 = 0.8. 0.8 This then gives an illustration of the important at typical CCGT conditions), the sum minus the product in Equ. (1) yields ηCC == 58%,ηB + a ηvalueR − η ofBη combinedR cycle efficiency Figur emperatur trop am greater than either of the individual efficiencies.
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