Design of A Gas Turbine Combustion System

Siemens Power Generation 2003.
All Rights Reserved
Design of a Gas turbine

combustion system
Torsten Strand torsten.strand@siemens.com
2/9/2006
Power Generation
Content
Siemens Power Generation 2003. All Rights Reserved
z The design requirements, criteria and targets

z The overall design process
z The gas turbine cycle: Excel calculations
z Burner and cooling mass flows: Design calculations
z Burner type: lean premixed, diffusion flame or something in between
z Combustor heat balance, choice of combustor design: Excel calculations
z The component designs
z burners
z combustor : Excel calculations
z fuel system : Excel calculations
z Ignition and supervision systems
z Operation
z Start up
z Part load
2/9/2006
Power Generation
Assumptions
z We are going to design a new gas turbine with the shaft power of 35MW for a
market consisting of
z 60% compressor drivers for pipe line compressors
z 40% industrial cogeneration
z The first customer segment want a very reliable and robust simple cycle unit
for pumping of gas from desolated gas fields in
z Siberia ( 0 to -50C)
z Iranian mountains (-20 to +45C, low ambient pressure)
z Saudi Arabian deserts (+10 to +50C)
z Efficiency and emissions are not of prime interest
z Fuel is natural gas
z The second customer type want an efficient, but still very reliable gas turbine
with low emissions and suitable for steam production in waste heat recovery
boilers for industries, mainly in the western world. Fuel is natural gas or
industrial off gases.
2/9/2006
Power Generation
Case 1
Gas Turbine in Simple Cycle
63.6 % losses
Gas Turbine
36.4 % electricity
100 % fuel
Pgt
Pst
Paux
Pnet
Heat duty
Qfired
2/9/2006
44.30
0
0.10
44.20
0
121.4
MW
MW
MW
MW
MJ/s
MJ/s
Alfa
--Net electrical
Powerefficiency
Generation 36.4 %
Net total efficiency
36.4 %
Case 2
Gas Turbine in Cogeneration Cycle
12 % losses
1-pressure HRSG
52.2 % process heat
Gas Turbine
35.9 % electricity
100 % fuel
2/9/2006
Pgt
Pst
Paux
Pnet
Heat duty
Qfired
Alfa
NetPower
electrical
efficiency
Generation
43.82
0
0.23
43.59
63.4
121.4
MW
MW
MW
MW
MJ/s
MJ/s
0.69 --35.9 % 5
88.1 %
Case 3
Gas Turbine in Combined Cycle
Steam Turbine
(condensing)
12 % losses
520 deg C
2-pressure
HRSG
31 deg C
Gas Turbine
100 % fuel
2/9/2006
Alfa
Net electrical efficiency
31 deg C
15 deg C
27 deg C
35 % losses
35.9 % electricity
Pgt
Pst
Paux
Pnet
Heat duty
Qfired
16.8 %
electricity
43.69
20.78
0.70
63.77
0
120.9
MW
MW
MW
MW
MJ/s
MJ/s
--52.7 %
52.7 %
Power Generation
Case 4
Gas Turbine in Combined Cycle
Steam Turbine
(district heating)
11 %
losses
11.3 %
electricity
510 deg C
2-pressure
HRSG
78 deg C
42.1 %
heat
90 deg C
Gas Turbine
60 deg C
35.9 %
electricity
100 % fuel
2/9/2006
78 deg C
Pgt
Pst
Paux
Pnet
Heat duty
Qfired
43.70
14.18
0.62
57.26
51.1
121.4
MW
MW
MW
MW
MJ/s
MJ/s
Alfa
1.12 --Powerefficiency
Generation 47.2 %
Net electrical
89.3 %
Is it possible to use the same design

for both applications?
z Well, we will try!
z The compressor drive requires a variable speed power turbine, so we

have to assume a twin shaft unit
z The efficiency of the cogeneration unit ought to be in the range of
37% at full load, which means that the heat input is around 95MW
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Power Generation
The core engine 1
z We have now a basic design.

z A critical parameter is the Turbine Inlet Temperature. The higher TIT the
better gas turbine cycle, but generally also less robustness and higher
turbine cooling flow
z Let us assume a conservative TIT = 1300C
z From experience the turbine cooling flow will then be around 16%
95MWth
TIT
35MWe
Turbine cooling
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Power Generation
Turbine Inlet Temperature

and emissions
Turbine Inlet Temperature C and NOX
1500
200
Ceramics
Steam Cooling
Single Crystal Blades
GTX100
Jet Engines
1000
GT200
GT10B/C
GT35/GT120
100
Stationary Gas Turbines

500
1940
1960
1980
2000
Year
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10
The gas turbine cycle

T
Tflame
p5, t5m
p3, t3
t5
ct = (t5m - t6)/(t5m - t6s)
p6, t6
pt = (t6m - t7)/(t6m - t7s)

c = (t3s - t2)/(t3 - t2)
p7, t7
p2, t2
s
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11
The turbine pressure levels
z How are the pressure levels at the compressor and power turbine sat?
z The turbine can be seen as a tube with restrictors
z In order to pass a certain flow at a certain temperature there is an
associated flow area/pressure combination
z The flow area is determined by the turbine inlet guide vanes
zInner/outer diameter
zExit blade angle, which is on gas turbines is generally fairly large, which
means that the stage design is of reaction type (the enthalpy drop is
divided between vane and blade)
m = A *rot(2*p*) = A *rot(2*p*p/RT) = *A*p/rot(RT)

For computational purposes the below formula is very useful
m*rot(T)/p = constant
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12
Turbine flow
The flow capacity of the turbine is determined by the smallest
area in the turbine inlet guide vane and the root and tip section
diameters
the turbine wideness
the turbine flow number m*rotT/p
the turbine constant
The flow capacity of the turbine determines the position of the

operating line in the compressor map.
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An uncooled turbine has better efficiency than a cooled turbine, which

has less good profiles (lower aspect ratio, thick trailing edges) and
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13
mixing losses from the cooling flows
The gas turbine cycle

T
Tflame
p5, t5m
t5
ct = (t5m - t6)/(t5m - t6s)
p6, t6
p3, t3
pt = (t6m - t7)/(t6m - t7s)

c = (t3s - t2)/(t3 - t2)
p7, t7
p2, t2
The next step is to

make a simple
thermodynamic
model of the gas
turbine in order to get
the conditions for the
combustor.
We will do it in Excel!
95Mth
TIT
35MWe
Turbine cooling
Power Generation
2/9/2006
Power Generation
14
SGT-600, Industrial gas turbine
Gas turbine principle & components
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Power Generation
15
The core engine 2

z Now we need to choose the pressure level for the turbine inlet
z There is an optimal pressure level for efficiency associated with the
turbine inlet temperature, but it is generally quite high which means a low
TET. We have also to consider the steam production in the waste heat
recovery boiler, so we need a fairly high TET > 520C ??
z We will try some pressures for TIT = 1300C
z1800 kPa
z1700 kPa
z1600 kPa
z1500 kPa
=38.3%
=38.0%
=37.6%
=37.1%
TET=509C
TET=517C
TET=526C
TET=536C
T3=438C
T3=426C
T3=413C
T3=400C
z The higher the pressure the higher also the compressor exit air
temperature T3. That air is
zthe combustion air
zthe cooling air for the turbine and combustor walls
z For combustion high air temperature is generally better

z NOx and combustion pulsations have a tendency to increase
with pressure
Power Generation
2/9/2006
16
The combustor 1
z Now we have basic full load data for the combustor

z Air flow to the combustor: 82.8/426/1785 kg/s/C/kPa
z Fuel flow: 2.02 kg/s
z Combustor exit flow: 84.8/1300/1700 kg/s/C/kPa
z In order to design the combustor we have to know which
type of burner we are going to use
2.02 kg/s
82.8 kg/s
426C
1785kPa
2/9/2006
84.8 kg/s
1300C
1700kPa
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Burner 1: types of burners

z The conventional combustors were designed for Stoichiometric combustion, using fuel
injectors with low air flows 1. Water or steam injection were used for NOx reduction
z The lean premixed combustors are designed with a high air flow that cools the flame
z The low oxygen combustors relay on a combustion process in O2-depleted gas,

achieved by recirculation of combustion products
NOx ppmv
Diffusion flames
200
= 1/
Water Injection
100
Lean Premix
Combustion
0. 5
Steam Injection
1.0
1.5
Fuel/Air Equivalence Ratio

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18
Diffusion type dual fuel Injector
Water inlet
2100K
STD PARTPOSITIONABLE ELBOW
HCV GAS HOLES
PURGE HOLES
STEAM INLET
Air
Gas inlet
Oil inlet
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Dual fuel Injector for gas

and oil with water and
steam injection
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NOx and CO vs Flame Temperature

NOx ppm
CO ppm
EV Burner
DLE Gas
AEV Burner
DLE Gas & Oil
50
NOx
40
40
30
30
CO
Low oxygen burner20
20
Catalytic burner
10
10
1700
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1800
Flame Temp K
1900
- Advanced DLE burners Power

- Generation
20
Our case
z The Oil&Gas customers have presently no high requirements on

emissions, but the industrial customers will have a requirement of NOx
< 10 ppm
z We will try to build a low NOx burner of lean premix type
z Our trial choice is a LP burner with a design flame temperature of 1750K
z How much air is needed for the combustion?
z We will do a heat balance calculation for the flame zone
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The combustor 2
z Now we have the basic flow data for the combustor

z Air flow to the burner: 65/426/1785 kg/s/C/kPa
z Fuel flow: 2.02 kg/s
z Wall cooling flow: 17/426/1785 kg/s/C/kPa
2.02 kg/s
84 kg/s
65 kg/s
1300C
1700kPa
17 kg/s
426C
2/9/2006
1785kPa
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Wall cooling
z The burner air is around 65 kg/s out of the 82 kg/s combustion air
z We have around 21% of the combustion air for wall cooling, which
ought to be enough for a film cooled sheet metal combustor.
438
450
500
850
14771300
If the film cooling air is on

the low side Thermal Barrier
Coating can be used.
If there is more air than
necessary for cooling, it can
be injected as dilution air in
the down stream part of the
combustor.
2/9/2006
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Wall cooling designs

The shown wall design is the traditional one for film cooled combustors.
Several similar designs with improved performance are in use
438
450
Impingement
14771300
500
850
Convection
The use of Thermal barrier coatings has been more common. Conventionally
only thin TBC (<0.5 mm) has been used. But lately also thick TBC (up to 1.5
mm) has become frequent.
In turbines with higher turbine inlet temperature, the cooling air has not been
enough for film cooling. Wall with only outside cooling and thick TBC is then
the solution.
Meal wall Bound coat

2/9/2006
TBC
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Wall heat transfer: film cooling

z For initial design we can assume a heat flux to the combustor wall in the
range of 600kW/m2 but dependent on the gas temperature. The hot side heat
transfer is a combination of convective and radiation heat flux
z qhot = *(Tgas Twall) + const*S-B*[Tgas4 Twall4]
590 when velocities are around 30 m/s and pressure 1700 kPa,
increasing at higher velocities and pressure. The radiation constant is
dependent on flame radiation and surface emissivity
In the combined impingement/convection cooled design we can assume
that the metal temperatures for one wall section starts at air temperature
and reaches 850C, with an average wall temperature of 565C.
It is then assumed that the injected cooling air will absorb the heat flow to
the surface
Q = qhot*A = m*cp*(565-tcool)
The length of a section depends of course on the design but 50 70 mm is
common
The rings are laser drilled, rolled to form and seam welded in a fixture
2/9/2006
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Wall cooling: convection cooling
z In the case when there is not enough air for

film cooling, outside convection cooling with
the combustion air has to be used.
z The cooled side heat transfer has then to
match the hot side heat flux
z Q = qhot*A = *A*(twall tair)
z When using TBC the heat flow through the wall
is reduced by the low heat conductivity of the
ceramics, = 1.1 1.6 and the lower absorption
of radiation
z The cold side heat transfer coefficient is a
function of the air velocity, pressure and the
shape of the surface. Usually the wall surface
has ribs, fins etc to enhance the heat transfer
up to 1.7 times
2/9/2006
Annular combustor with convection

cooled walls
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Combustor size
z The bulk flow velocity in the combustor can tentatively be set to
around 30 m/s, which means that there is a need for a flow area in the
combustion chamber inlet exit section of around 0.63 m2
z The turbine inlet velocity can be in the range of 100-130 m/s, which means
that there is a need for an exit area in the range of ~0.2 m2
z The length of the combustor depends on what residence time we want. This
could be investigated by combustion kinetics calculations, but a value based
on experience for natural gas and diesel oil is 1520 ms
15 ms
which gives a axial length of around 600 mm
z Now it is time to make a choice of combustor type
z Annular
z Can-annular
z Tilted or in line with the flow
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Annular versus can-annular

z The annular combustor has compared to the can-annular type
z less wall surface area to cool
z fewer auxiliaries
z Spark plugs
z Flame detectors
z Annular combustors are used in almost all jet engines and many high
temperature industrial turbines
z The can-annular design has most often
z fewer but larger burners
z transition ducts between the circular combustion chambers and sectors of
the turbine inlet, which is difficult to design and cool
z Can combustors are used in many industrial turbines by tradition and for
easier maintenance
z The can type of combustor is easier to develop since the testing can be done on
one of the combustors, while it is quite difficult to use the test results from a
sector test of an annular combustor
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A GE can combustor
Premixed Pilot
Main swirl premixers
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Transition duct
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GE Frame 5
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Siemens G30 Combustor

Concept
Pilot Burner
Main Burner
Double Skin Impingement

Cooled Combustor
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Annular combustor for

Siemens SGT-600
.
18 DLE burners
Sheet metal (HastX),
annular combustor
with film cooled
walls and
impingement cooled
front panel
Number of cooling
holes 5800
Outer diam ~ 1 m
Power ~ 75 MWth
Manufactured by
Trestad Svets in
Trollhttan (now a
Siemens Company)
DLE combustor for 25 ppmv with EV burners since 1991

2/9/2006
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Flows in conventional annular

combustor
Primary injection
Secondary injection
Primary zone
2/9/2006
Turbulence and mixing by primary and secondary Power

jets Generation
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Annular combustor types
Tilted annular combustor

with removable burners
for easier maintenance
In line annular combustor

with burners fixed to the
combustion chamber
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Annular combustor dimensions

z Assume tentatively
The philosophy for the wall

contour differs. There are e.g.
parallel walls and pear like forms.
inner radius
400
390
height
200
60
Combustor wall design

700
600
CFD calculations on
the velocity and temperature
distribution at the combustor exit
500
Radius mm
z at the combustor front panel:

z at combustor exit:
outer radius
600
450
Outer wall
300
Inner wall
200
the recirculation pattern

are important aspects as well as
manufacturing aspects.
400
100
0
-200
200
400
600
Axial position mm
2/9/2006
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Combustor re-circulating flow
Combustor wall design

700
600
ignition of the flame

lowering of NOx by reducing
the O2 content in the flame
The recirculation can be
achieved in different ways, but
the most common is to use
swirling flows.
Swirling jet aerodynamics is
important and a lot of research
is done in that field
2/9/2006
500
Radius mm
The recirculation of hot gases

in the combustor is necessary
for
400
300
200
100
0
-200
200
400
600
Axial position m m
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Exit temperature profile

The radial temperature
profile is very important
for the rotating blade
life. Due to the wall
cooling flows a peaky
profile can be expected,
which is good for the
blades (cold root and tip
sections), if it is not too
hot in the centre.
Dilution air can be used
to shape the exit profile.
The tangential profile is
important for the
stationary vanes.
2/9/2006
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DLE evolution, GT 15-50 MW

- history
Residence time reduced by using many small burners,

with short flames:
introduced 1986, NOx 75 ppmv on gas
1st gen. DLE
Single burner
Lean premix combustion in two-slotted cone, multiple

burners:
introduced 1991, NOx 25 ppmv on gas
Lean premix combustion in four-slotted cone + mixing
tube, multiple burners:
introduced 1999, NOx < 15 ppmv on gas
2nd gen. DLE
3rd gen. DLE
GT10B
(Annular
combustor)
Used in:
GTX100
GT10B&C
GT35C
GT35 (Can-annular
combustor)
Silo Combustors
2/9/2006
Annular Combustors
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Dual fuel Injector
Water inlet
STD PARTPOSITIONABLE ELBOW
HCV GAS HOLES
PURGE HOLES
STEAM INLET
Gas inlet
Oil inlet
2/9/2006
Dual fuel Injector with

water and steam
injection
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39
The burner 2
z There is one basic philosophy for the lean premix burner: the fuel and air has
to be mixed as evenly as possible. The better mixing, the lower NOx.
z Choice of swirl strength for good ignition and recirculation
z Low swirl and weak recirculation is providing an unattached flame with
low pressure drop. The mixing in of oxygen depleted recirculation
products is quite low. Ignition has to secured by zones with higher fuel
concentrations. The flow out from the combustor is quite even.
z High swirl burners has often flames attached to a flame holder. The
recirculation is strong, but in many cases the mixing in of the recirculation
flow is not as good as it could be. The exit profile is often distorted by the
swirling flows reaching all the way to the turbine.
2/9/2006
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Swirl Burner Operation

1.
2.
Gas fuel
Air
3.
2/9/2006
4.
1)
Gas fuel is injected along the air

inlet slots and is immediately mixed
with the air.
2)
At the burner exit a lean mixture

enters the flame zone, which is
stabilised by the vortex breakdown
in the inner core of the exit flow
3)
The high air flow velocity inside of

the burner protects the burner wall
against flame flashback
4)
Operation with oil No2

An oil-water emulsion is injected in
the center of the EV cone. The oilwater jet is atomised and partly
evaporated; ignition of the vapour
occurs in the vortex breakdown
zone. NOx formation is reduced and
remains below 42 ppm
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41
A 2nd generation premix burner
z Most lean premixed burners have

z A swirl generator which can be axial, radial or tangential
z A device to mix in the fuel as evenly as possible often integrated in the
swirl generator
Most lean premixed burners has a pilot flame that is supporting the
main flame at part load, when the flame temperature tends to be too
low
2/9/2006
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A 3rd generation dual fuel burner
Main gas
Pilot oil
Pilot gas
Main oil
Concentric tubes for fuel supply
2/9/2006
Power Generation
- A burner for 10 -15 ppm NOx
43
The DLE dual fuel burner function
Mixing tube
Cone
Main liquid fuel injection
Gas fuel and

Liquid fuel
Combustor wall
Combustor hood
Flame
Compr. discharge air
Pilot gas fuel injection

Pilot liquid fuel injection
Main gas fuel injection
Dry Low Emissions on gas and oil
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A high swirl burner

Radial Swirler
with Main fuel
injection
Quarl
Pilot fuel
injection with
Igniter
Flame Holder
2/9/2006
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Emissions and pulsations

z In a burner with very good mixing it is theoretically possible to come done in
NOx to around 5 ppm at 1750K, but
z It is hard to do the mixing that well
z A very well mixed flame has a tendency to be weak and sensitive to
disturbances
z Instable flames can induce pulsations and acoustic phenomena in the
combustion chamber
z In order to have stable combustion a fuel richer zone is arrange somewhere
to anker the flame, often designed as a pilot diffusion flame that can be
controlled by its own fuel supply. That flame is often producing quite a lot of
NOx, maybe 12 ppm/% pilot fuel, so even a small pilot can supply an
additional 5 ppm NOx
z The pilot flame is often arranged in the centre of the burner, but also at the
exit ring
2/9/2006
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46
Pulsations
z The combustion pulsations are generally of two types

z High frequency acoustics (1000-3000 Hz) generated by the instationary
heat release in the turbulent shear layers of the swirling jet
z Low frequency combustion dynamics (50-500Hz) generated by the
movements of the flame front
z It is possible to design combustion systems without pulsations, often after a
period of testing and tuning of the aerodynamics and fuel distribution
z But if not successful
z the high frequency can be damped by Soft walls
z the low cycle frequencies can be damped by Helmholds dampers
Helmholds
damper
Soft wall
2/9/2006
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The fuel system
z The piping system for distribution of fuel to the burners has basically three
pressure drops caused by
z The control valve
z The fuel injector flow area and calibration nozzle
z The piping system losses in bends or due to wall friction
The minimum pressure drop over the control valve must be around 200 kPa to
achieve a stable control
z The total pressure drop over the burner depends somewhat on the injector
design, but a calibration nozzle is most often used to provide
z Even flow to all burners
z A safety against too high gas flow in case of an injector failure
2/9/2006
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48
A typical gas fuel system for a 18

burner combustor with main and pilot
Gas fuel unit 2, located inside the GT enclosure
Quick shut-off valves

Gas control valves
Enclosure wall
From gas fuel unit 1
To atmosphere
Ventilation valves
2/9/2006
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Fuel system pressure losses
z The main pressure drops occurs over the

z burner
z control valves
z The losses in pipes, bends, shut off valves etc are calculated by
p = **c2/2
z The burner pressure drops are calculated by
p = {m/Aeff}2*1/(2)
Aeff,main = 30 60 mm2
Aeff,pilot = 1015 mm2
z The required pressure drop over the valves is then calculated from the
available pressure or
z the required gas pressure is calculated for a minimum valve pressure drop of
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50
2/9/2006 200 kPa on the coldest day (max power output)
Fuel system and valves

The fuel valve calculations uses the basic equation
m = *Av*p1/rot(RgTg)
Critical flow
Sub critical flow
The critical pressure ratio
2/9/2006
crit
2
=
1
+
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51
Fuel valves
The fuel valves can of different designs but they generally has an
effective flow area as a function of shaft position
but with a small influence of the pressure ratio
Main valve matrix
1200
p2/p1=
0.2
0.3
1000
0.4
800
0.5
Effective area mm2
1400
600
0.6
400
0.7
200
0.8
0
0
10 20 30 40 50 60 70 80 90 10 11
0 0
0.9
Actual
Position %
2/9/2006
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The factor
Psi overall
0.750
0.650
0.600
1.25
1.3
0.550
1.35
psi
0.700
0.500
1.4
1.4 approx
0.450
1.35
Psi register
0.400
Psi register
p2/p1
0.00
0.50
0.55
0.60
0.65
0.70
0.75
0.80
0.85
0.90
1.00
psi 1.35
0.6761
0.6761
0.6759
0.6700
0.6562
0.6338
0.6017
0.5582
0.5002
0.4217
0.2500
Kkap
0.1751
0.1751
0.1576
0.1401
0.1226
0.1051
0.0876
0.0700
0.0525
0.0350
0.0000
0.350
Psi = psi1.35+Kkap*(kappa-1.35)
0.300
0.250
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.1
Pressure ratio
2/9/2006
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The operation
z The gas turbine is very flexible
z The gas turbine plant is very compact and contains everything needed
for the operation, which means that there are a number of systems in the
plant (lubrication, fuel distribution and control, ventilation, fire detection
and control..)
z Quick to start and take up load by a number of preset sequences:
zpush the button for start and stop of fuel change over
z Controlled from a PC
z Can be controlled by power turbine load or speed or generator frequency
z Has built in safety systems for protection of
zPersonnel (explosions from fuel leaks or flame out)
zThe unit (overheating of critical parts, over speed etc)
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The start procedure

z The start procedure goes like this
z The gas turbine is rotated by an electric motor in order to get an air flow
through the combustor
z The igniter is activated (spark plug or torch burner)
z The fuel valve is put in a preset start value and the shut off valve is
opened. Ignition has to occur within seconds, otherwise shut down.
z Speed is increased and fuel flow is ramped up
z At some point the turbine is making enough power to accelerate the
compressor; the unit is self sustained and the electric motor is phased
out
z Acceleration continues up to idle, where the generator is phased into the
grid
z Loading up to full load in 5 10 minutes depending on requirement
zFast loading means lower lifetime on critical parts
zThe combustor often contains parts that are sensitive to thermal fatigue,
but the life of a combustor is mostly limited by oxidation or buckling
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Mechanical drive start
Exhaust temp
Self-sustaining
GG speed
Fuel flow
Cross ignition
Torch ignition
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Part load operation

z When the power (fuel flow) is reduced from full load the air flow is also going
down and so is the pressure and air temperature
z On a single shaft unit the rotor speed is constant and the air flow can be
controlled by the inlet guide vanes of the compressor so that the flame
temperature is kept high in a wide load range
z On a twin shaft unit the rotor speed is going down, but not as much as
one could wish. The flame temperature drops and flame stability has to
be kept up by increasing the pilot flame
z There are a number of ways to keep the flame temperature high at part
load e.g.
zBleed off of compressor air
zBypass of air
zStaging of burners (reducing the number of burners that are fueled)
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Combustion supervision
z The combustor is supervised by flame

detectors, usually two separate systems to
prevent explosions
z fuel must not be injected when there is no
flame
z The burners are usually checked with the
turbine exhaust temperature measurements
z Deviation in temperatures can indicate
burner problems
z Some combustors have differential pressure
and pulsation measurement (fast pressure
transducers)
z Some burner have temperature measurements
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Calculation tasks
z The task is to design a gas turbine combustion system with certain data
z It is advisable to use the Excel program GTZ-Combustor`s manual
version, which can be improved by introduction of a number of iterations
and modifications if you like to
z You will be assigned a small set of data and from that you have to make
some choices, as discussed in this presentation
z You will be assigned
za power out put: 18, 26 or 35 MW
zan application for which you have to discuss and decide on NOx level,
burner type and combustor type
gas pipe line compressor driver
industrial heat &power generation
peak&reserve power
zThen you have to go through the design procedure and come up with a
combustor wall design, burner type and number/size of burners, cooling
and dilution flows
zThe result will be your Excel sheet!
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The Excel program

z The Excel program consists of a number of sheets
z Termo 1: Gas turbine thermodynamic lay out calculations
z Termo 2: Gas turbine thermodynamic part load calculation: (fixed
geometry)
z Combustor 1: Film cooled combustor geometry and wall cooling
Combustor 2: Convection cooled combustor geometry and wall cooling
z Burners 1: Nominal design of burners coupled to Termo1
z Diffusion, DLE, low oxygen and catalytic burner flows
z Burner 2: Part load operation coupled to Termo 2

z Fuel system: Fuel system calculations
z Fuel: Fuel analysis
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The program
z It is basically a manual program for educational purpose, but in order to
simplify things for you there are
z some iterations and couplings between sheets, which can go wrong.
Restart by using the Run/test 1/0 button.
z The calculated m*rotT/p values in Termo 1 must be copied to Termo 2
manually as fixed values when the nominal design is done
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The design steps
z On Termo1:
z put in your nominal data for ambient conditions, TIT and fuel flow
z make your choice of burner type 1-4
z Iterate air flow, fuel flow, pressure level until you have got what you want
in output efficiency and TET (also number of burners and burner size)
z You have now determined the main flow areas in the unit Aeff ~ m*rotT/p
z Copy those values to Termo 2 (the fixed geometry program)
z In the shaded area you have the relevant data for the combustor, which
are copied to the two combustor sheets from Termo 2
z You have to choose one of them (film cooled or convection cooled)
z If there is not air enough for film cooling you have to use convection cooling
z Set Termo 2 to combustor design conditions

zNominal or worst case?
z Make a combustor wall geometry

z Make a wall cooling configuration
z If you have done the design at nominal conditions check at worst conditions
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Fuel system
z Set Termo 2 to worst conditions = max fuel flow
z Assume a design pressure drop across the control valve, typically 200 kPa
and pressure drops in the piping system
z Find the required fuel pressure (often we want a margin of 5%)
z Choose the size of the fuel valve so that is around 85 90% open at this
condition
z If the fuel valve pressure drop is set = 0 the pressure drop is calculated and
the valve position can be used to to match the required flow area with the
valve area.
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Design sequence for turbine, burner

and combustor
Make a turbine lay out in Termo 1
considering TIT, p5, TET and efficiency
Choose a burner type considering the target NOx level.
Adjust the no of burners and/or burner diam. to get the

right flow conditions for the required burner in Burner 1
Choose a combustor type considering the cooling flow available
Transfer the m*rotT/p values to Termo 2 and
set Termo 2 to combustor design conditions
Go to Combustor 1 or 2 and adjust the dilution flow.
Design the combustor wall geometry trying to fulfill the design criteria
Design the wall cooling by adjusting number and diameter of the cooling holes in Combustor 1
Or the height of the cooling ducts in Combustor 2
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Design the fuel system

Set Termo 2 to worst conditions ambient conditions
considering the max power output
Assume that the fuel valve should be 85 -90% open with a

pressure drop of 200kPa at this condition
Adjust the necessary fuel inlet pressure
Adjust the valve size so that the valve flow area = required flow area
2/9/2006
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Design of A Gas Turbine Combustion System

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Design of A Gas Turbine Combustion System

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Design of a Gas turbine

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z The design requirements, criteria and targets

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52.2 % process heat

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Is it possible to use the same design

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z The compressor drive requires a variable speed power turbine, so we

The core engine 1

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z We have now a basic design.

Turbine Inlet Temperature

Turbine Inlet Temperature C and NOX

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Single Crystal Blades

Stationary Gas Turbines

The gas turbine cycle

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ct = (t5m - t6)/(t5m - t6s)

pt = (t6m - t7)/(t6m - t7s)

The turbine pressure levels

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m = A *rot(2*p*) = A *rot(2*p*p/RT) = *A*p/rot(RT)

the turbine constant

The flow capacity of the turbine determines the position of the

An uncooled turbine has better efficiency than a cooled turbine, which

The gas turbine cycle

ct = (t5m - t6)/(t5m - t6s)

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pt = (t6m - t7)/(t6m - t7s)

The next step is to

SGT-600, Industrial gas turbine

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Gas turbine principle & components

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The core engine 2

z For combustion high air temperature is generally better

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z Now we have basic full load data for the combustor

Burner 1: types of burners

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z The low oxygen combustors relay on a combustion process in O2-depleted gas,

Fuel/Air Equivalence Ratio

Diffusion type dual fuel Injector

STD PARTPOSITIONABLE ELBOW

HCV GAS HOLES

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Dual fuel Injector for gas

NOx and CO vs Flame Temperature

Low oxygen burner20

- Advanced DLE burners Power

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z The Oil&Gas customers have presently no high requirements on

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z Now we have the basic flow data for the combustor

If the film cooling air is on

Wall cooling designs

m = A rot(2p) = A rot(2pp/RT) = Ap/rot(RT)