IR Comparitive Materials Evaluation for Gas Turbine Kesseli Et Al
Transcript of IR Comparitive Materials Evaluation for Gas Turbine Kesseli Et Al
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COMPARATIVE MATERIALS EVALUTIONFOR A GAS TURBINE ROTOR
27th Annual Conference on Composites, Materials andStructures
January 27-30, 2003
Jim Kesseli, Shaun Sullivan, and Michael Swarden; Ingersoll-Rand Energy SystemsS.F. Duffy, Cleveland State University, E.H. Baker, Connecticut Research Technologies,
Matt Ferber, Oak Ridge National Laboratory,Jill Jounkouski, DoE OIT,Kyocera Research Center
Keywords: microturbine, silicon nitride, turbine, CARES, recuperator, ceramic, gas turbine, life analysis
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
Ingersoll-Rand’s Ceramic Microturbine (CMT) Plan
Following a low riskdevelopment path that willyield significant performanceincrease for PowerWorks™products in 2003
Introduce ceramic turbine rotorto operate within proven limits oftoday’s technology
Size and manufacturing limitsTemperatureStress
Use metallic alloy for turbinehousing and down-stream section,including recuperator. 70 kWe PowerWorks™
Microturbine Cogen System
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
Trade Study Final Conclusions:
Formula for Success:Define cycle to utilize IR’s highly durable, low-cost stainlesssteel recuperator
Gas inlet temperature below 700 CModerate turbine inlet temperature (TIT) (1000 to 1020 C) - toavoid unacceptable recession and coating cost/complexity Resulting rise in pressure ratio to 4.8 to 5.2
Low ceramic rotor tip speed - (Expansion ratio ~ 2 to 2.2) show large margin based on stress predictions, leading to lowstatistical failure predictions
Build from Kyocera’s proven manufacturing baseAdopt experience form high volume turbochargermanufacturingKeep rotor diameters below about 100-mm
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
PowerWorks™ - Frame 3
Air Inlet
GasifierCompressor
GasifierTurbine
PowerTurbine
Exhaust
Combustor
Generator
Gearbox
UtilityPower
ElectricPower To
User
Heat ToUser
400 ° F
WasteHeat
Recovery
CounterflowRecuperator
Unchangedbalance of plant
Ceramic rotor
Unchanged
All new and improved aero-components (compressor + 2 turbines)
Metallicpowerturbine(IN713LC)
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
Cycle selection - Defining recuperator stainless alloy, sets optionsfor PRc and TIT
0.32
0.34
0.36
0.38
0.40
0.42
0.44
0.46
2 3 4 5 6 7 8 9 10 11 12 13 14
Cycle Pressure Ratio
LHV
Elec
tric
al E
ffici
ency
TIT=1000oC Tamb=15oC, pamb=14.7psia ηc=83%, ηt=81.5% (polytropic) εHX=91%, ηgen=95% ∆p/p: 0.5% inlet, 1.0% exhaust 3.0% comb, 1.3% recup air 2.7% recup gas mech losses: 2% gasifier spool, 2% output shaft
LOCUS OF RECUPERATORINLET TEMP = 700oC(Max for Alloy-347)
LOCUS OF RECUPERATORINLET TEMP = 800oC
TIT=900oC
TIT=1200oC
TIT=1100oC
TIT=1300oC
TIT=1400oC Simple Recuperated CycleCMT design target
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
Performance optimization within proven andconservative limits of monolithic Silicon Nitride
Gasifier Turbine Aerodynamic and ThermodynamicSpecifications
TIT = 1000 CExpansion ratio = 2.1Physical Speed = 97,500 RPMRotor tip speed = 485 m/sRunning clearance, inducer tip = 0.46 mm (0.018 in.)Running clearance, exducer tip = 0.30 mm (0.012 in.)Minimum blade thickness at inducer tip = 2 mm (0.080 in)Minimum blade thickness at exducer trailing edge = 1.1 mm(0.044 in)Nozzle-less turbine housingBlade geometry must be “pullable” form mold100 mm rotor size limit
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7OK
OK
Blade Design - for pure radial moldrelease
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
State of the art Radial Inflow Turbine Efficiency vs Specific Speed
60%
65%
70%
75%
80%
85%
90%
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4
Specific Speed [N*(m/rho)^.5] /[DH0s^.75]
Effic
ienc
y (to
tal-t
o-st
atic
)
from Rohlik (NASA SP-290)
Today's Frame 3 PowerWorks- Gasifier- Power TurbineCMT Targets
- Gasifier- Power Turbine
Nss ~ 0.9
Nss ~ 0.6
A conservative η target wasset due to perceivedcompromises on shroudclearances and bladethickness
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
State of the ArtCentrifugal-Compressor Polytropic Efficiency vs Specific Speed
70%
75%
80%
85%
90%
0.4 0.5 0.6 0.8 0.9 1.0 1.1Specific Speed
Poly
trop
ic E
ffici
ency
(tot
al-to
-tota
l)
from Rogers (91-GT-77)
Standard PowerWorks Frame 3CMT
CMT has more favorable specific speed - hence should get better efficiency
target
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
PowerWorks CMT : Ambient Temp Effect on Power and Efficiency
Revised to 72 kWe (including gas booster)
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
CMT Turbine Rotor Boundary Conditions for lifeanalysis
Transient date derived from Frame 3 startup conditionsHot and cold startup (transient) conditions derived formrepresentative PowerWorks measurements.Transient data scaled to CMT application:
Temperatures scaled from 870 C to 1000 C TITSpeeds scaled from 72,000 to 97,500 RPMRate of acceleration scaled by the ratio of the inertias of the Frame3 PowerWorks and the CMT rotor
Steady state data derived from BANIG™ computersimulation
* BANIG is a trademark of Concepts NREC
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
CMT Rotor Cold StartTIT vs. Time During Cold Start
0
400
800
1200
1600
2000
0:00:00 0:00:10 0:00:20 0:00:30 0:00:40 0:00:50 0:01:00
Time
TIT
(F
)
0
20000
40000
60000
80000
100000
RP
M
RPM
TIT
1000 C gas inlet temp
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
CMT Rotor Hot StartTIT vs. Time During Hot Start
0
400
800
1200
1600
2000
0:00:00 0:00:10 0:00:20 0:00:30 0:00:40 0:00:50 0:01:00
Time
TIT
(F
)
0
20000
40000
60000
80000
100000
RP
M
RPM
TIT 1000 C gas inlet temp
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
CMT Rotor Heat Transfer Coefficients
Steady state heat transfercoefficients derived fromcomputer simulation of rotorperformanceheat transfer coefficientcalculated using:
0
1
2
3
4
5
6
0 1 2
Z-dimension (in.)
Rad
ius
(in.)
color htcBTU/ft2F
MAROON 40YELLOW 75LTBLUE 125PURPLE 175
PINK 210DARKBLUE 305
3/12/1 PrRe332.0 ⋅⋅=Nu
)))1(Pr(7.12(1
PrRe2
3/22/1 −⋅⋅+
⋅⋅=
f
f
C
C
Nu
:000,90Re <
:000,90Re >
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
CMT Rotor Steady State TemperaturesTIT = 1000 CMaximum adiabatic Wall Temperature = 905 CMaximum rotor temperature difference = 60 C(excluding cooled attachment)*
2 kW~534 C
* low rotor temp gradients characteristic oflow expansion ratio and high thermalconductivity - both serving lower thermalstress
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
CMT Rotor Steady-State Stresses (Principle)
Kyocera stipulated design target of 200 MPa for SN237Steady state critical stress location is at back wall fillet
currently evaluating to 275 MPa (at bore)can be further alleviated with larger fillet, if necessary
275 MPAAll blade and root is below 200 MPa
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
Thermal-Only Stresses (steady-state)
Max wall stress at fillet = 86 MPa (12.5 KSI)
Typical blade stress = 8 MPa (< 1KSI)
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
CMT Rotor Worst Case StressesWorst Cases:
Vane234 MPa @ 38 sec. into Cold Start
Bore282 MPa @ 54 sec. into Cold Start
Back Wall278 MPa @ Steady State
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
CMT Rotor Transient Stresses
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
1st Principle Stress DistributionSpeed and Thermal Gradient Loading
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
45.00
0 50 100 150 200 250 300 350 400 450 500
Time - sec.
1st P
rinci
ple
Stre
ss k
si
Back Wall FilletVaneBore
CMT Rotor Cold Start Stress Profiles
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
Fig 26. IRES, CMT Rotor Design #4, Dynamics Analysis Results.
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
Fig 27. IRES, CMT Rotor Design #4, Dynamics Analysis Results.
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. alIRES CMT Gasifier Rotor, Campbell Diagram
0
5000
10000
15000
20000
25000
30000
35000
40000
45000
50000
0 10000 20000 30000 40000 50000 60000 70000 80000 90000 100000
Rotor Speed - rpm
Freq
uenc
y - h
z
2nd Mode, Vane 2nd Bending, Primarily at Exducer
1st Mode, Exducer Bending
3/Rev Excitation
817% Frequency Margin
1/Rev Excitation
Fig 28. IRES, CMT Rotor Design #4, Dynamics Analysis Results.
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
CARES Analysis based on ORNL Materials Data Base
Material Data year Manufacturer
SN282 2001 Kyocera
SN237 2001 Kyocera
AS800 1995 Honeywell (FormerlyAllied Signal
NT154 1989 St. Gobain (formallyNorton)
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
CARES Model Results
Notes from Steve Duffy:• 38 second condition appears to be worst case
Steady State 38 Seconds 54 SecondsProbability of Failure 0.000000000747451 0.000001514190000 0.000001025080000Reliability 0.999999999252549 (9 nines) 0.999998485810000 (5 nines) 0.999998974920000 (5 nines)Failure Rate 1337880343 660419 975534
Steady State 38 Seconds 54 SecondsProbability of Failure 0.000000032730000 0.000075857000000 0.000034566800000Reliability 0.999999967270000 (7 nines) 0.999924143000000 (4 nines) 0.999965433200000 (4 nines)Failure Rate 30553009 13183 28929
Steady State 38 Seconds 54 SecondsProbability of Failure 0.000000021028900 0.000017031300000 0.000008595400000Reliability 0.999999978971100 (7 nines) 0.999982968700000 (4 nines) 0.999991404600000 (5 nines)Failure Rate 47553605 58715 116341
Steady State 38 Seconds 54 SecondsProbability of Failure 0.000237266000000 0.011407100000000 0.008427090000000Reliability 0.999762734000000 (3 nines) 0.988592900000000 (1 nine) 0.991572910000000 (2 nines)Failure Rate 4215 88 119
NT 154 - 1989 Vintage Material
AS 800 - 1995 Vintage Material
SN 282 - 2001 Vintage Material
SN 237 - 2001 Vintage Material
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
Survival Rate at 38sVolume Flaw Analysis
660419
1318358715
880
100000
200000
300000
400000
500000
600000
700000
800000
Silicon Nitride Materials
Num
ber
of In
itial
Spi
n U
ps
Bef
ore
Failu
re O
ccur
s
SN 237SN 282AS 800NT 154
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27
kgf/mm2
Transient (38sec. 89,292rpm)
237.2MPa
155.8MPaM G T-IR 38b x z j m (SN 237)
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
0.00 0.50 1.00 1.50 2.00 2.50
[ ^ [ ] (~ 89,292rpm )
Fractuer Probability,Pf
Total(AVE)
Total
Total
Total
Total
Total
Total
Fracture Probability of Rotor(SN237)
Rotational Speed / 89,292
-σσ
2σ
3σ
-2σ
-3σ
Stress Analysis· Reliability Analysis
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28
kgf/mm2
232.4MPa
154.0MPaTransient (54sec. 97,533rpm)
M G T-IR 54b x z j m (SN 237)
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
0.00 0.50 1.00 1.50 2.00 2.50
[ ^ [ ] (~ 97,533rpm )
Fractuer Probability,Pf
T otal(AVE)
Total
Total
Total
Total
Total
Total
Fracture Probability of Rotor(SN237)
Rotational Speed/97,533
-σ
σ
2σ
3σ
-2σ
-3σ
Stress Analysis· Reliability Analysis
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29
kgf/mm2
Steady State (97,500rpm)
184.2MPa
206.8MPa
M G T-IR ^ ] ¶ j m(97500rpm ,SN 237)
1E-9
1E-8
1E-7
1E-6
1E-5
1E-4
1E-3
1E-2
1E-1
1E+0
1E-2 1E-1 1E+0 1E+1 1E+2 1E+3 1E+4 1E+5
Tim e(hour
Fractuer Probability,Pf
\ + (Ave)
\ + (95%Low)
\ + (95%Uppj
M G T 40,000Hr
Pf=0.925~ 10-6
Fracture Probability of Rotor(SN237)
Surface Internal Ave.
Surface Internal -2σ
Surface Internal +2σ
Stress Analysis· Reliability Analysis
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
First Kyocera SN237 rotors fabricated for IR CMTProgram (12/02)
- Excellent blade true positionand blade profile dimensionalcontrol- Excellent surface finish- Coordinate generation errorresulted in ultra-thin blades
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
Cold spin test equipment Cold spin system
Evaluation Development
Cold Spin Test
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
Cold Spin Test
Evaluation Development
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
Spin pit after rotor burst at 167,197 RPM
Rotor-less spindleSN237 rotor fragments
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Room temperature, Material :SN237Design Speed :97,500rpmBurst Speed = 167,197 (sample #1, only sample)Burst Speed ratio = 171% (Burst/Design)Burst Stress factor (N^2) = 2.9225.5MPa
172.9MPa
kgf/mm2
Cold Spin TestResults
M G T-IR R [ h j m (SN 237)
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
0.00 0.50 1.00 1.50 2.00 2.50 3.00
[ ^ [ ] (~ 97,500rpm )
Fractuer Probability,Pf
Total
As-firedmachinedInternal
Fracture Probability of Rotor(SN237)
Rotational Speed/97,500 RPM
Testspecimenburst!
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
Materials Evaluation- performed on first 2 rotors(February -October at ORNL)
Disk Test SpecimensCore drill 6 mm X 0.5 mm (~ 200 samples)Bi-axial bending test
Flexure bar test3 X 4 X 60mm barsBending test
Tests and evaluations to be performed for CARES data baseObtain bulk properties at various positions and orientations withinthe rotor at 900 to 1000 CFlexure test at 1000 C, after 1000-hr sustained load (nominally 200MPa)
Micro structural analysis, FractographyHigh-velocity, steam injection test at 1000 C (for recessionanalysis)
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
IR CMT Contributions to the Industry
Optimized elliptical blade fillet and back-face scallopmodel to minimize stress in ceramic rotorsImproved aero design models to optimize rotor forforeign object damage (FOD) toleranceEstablished reference rotor design and transientboundary conditions for which various materials maybe evaluatedProvide a viable engine for long-term evaluation ofcommercially viable ceramic turbine
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COMPARATIVE MATERIALS EVALUTION FOR A GAS TURBINE ROTOR Kesseli et. al
Next Steps:ORNL materials re-calibration with samplesform actual test rotors (Milestone: ConfirmCARES, 5/2003)Install and test in PowerWorks 70 kWeengine Milestone: η = 36% LHV, 6/2003)Engine endurance test (Milestone: ~ 3000 labtest hours, 10/2003)Engine Field Test (Milestone: retrofit approx.20 units, 2004)