This paper describes the most important factors affecting the industrial gas turbine engine performance deterioration with service time and provides some approximate data on the prediction of the rate of deterioration. Recommendations are made on how to detect and monitor the performance deterioration. Preventative measures, which can be taken to avoid or retard the performance deterioration, are described in some detail.

This paper describes the most important factors affecting the industrial gas turbine engine performance deterioration with service time and provides some approximate data on the prediction of the rate of deterioration. Recommendations are made on how to detect and monitor the performance deterioration. Preventative measures, which can be taken to avoid or retard the performance deterioration, are described in some detail.

In cooperation with the U.S. Department of Energy’s Morgantown Energy Technology Center, Westinghouse is working on Phase 2 of an 8-year Advanced Turbine Systems Program to develop the technologies required to provide a significant increase in natural gas-fired combined cycle power generation plant efficiency. In this paper, the technologies required to yield an energy conversion efficiency greater than the Advanced Turbine Systems Program target value of 60 percent are discussed. The goal of 60 percent efficiency is achievable through an improvement in operating process parameters for both the combustion turbine and steam turbine, raising the rotor inlet temperature to 2600°F (1427°C ), incorporation of advanced cooling techniques in the combustion turbine expander, and utilization of other cycle enhancements obtainable through greater integration between the combustion turbine and steam turbine.

Integrated Gasification Combined Cycle (IGCC) technology makes possible the utilization of low cost coal and opportunity fuels, such as petroleum coke, residual oil and biomass, for clean efficient and cost effective electricity generation. Siemens is a leading supplier of products and services for IGCC plants and it is adapting its most advanced gas turbines for successful integration into IGCC plants. To expedite this, Siemens is pursuing combustion system development for application in IGCC plants operating on syngas/hydrogen fuels. Detailed combustion system testing has been carried out during 2005 and 2006 on syngas/hydrogen fuels derived from different feed stocks and gasification processes. The test programs addressed both the F- and G-Class firing temperatures and operating conditions. Fuel transfer capability to and from natural gas, which is the startup and backup fuel, and syngas was explored over the operating range. Optimization studies were carried out with different diluent (H2O and N2) addition rates to determine the effect on emissions and operability. The focus of this development was to ensure that only combustion system modifications would be required for successful enriched hydrogen syngas fuel operation. This paper summarizes the results from the Siemens combustion system development programs to demonstrate that low emissions and wide engine operating range can be achieved on hydrogen fuel operation in advanced 50 Hz and 60 Hz gas turbines in IGCC applications with carbon dioxide capture.

The U.S. Department of Energy (DOE) has awarded Siemens Power Generation the first two phases for the Advanced Hydrogen Turbine Development Program. The 3-phase, multi-year program goals are to develop an advanced syngas, hydrogen and natural gas fired gas turbine fully integrated into coal-based Integrated Gasification Combined Cycle (IGCC) plants. The Program objectives are to demonstrate 3–5 percentage points efficiency improvement over current state of the art, less than 2 ppm NOx @ 15% O2 and reduction in plant capital cost. An additional objective is to show how the advanced gas turbine – IGCC plant can be configured for CO2 sequestration readiness. These objectives represent the overall DOE Advanced Power System goal to conduct Research and Development necessary to produce fuel flexible, CO2 sequestration ready advanced IGCC power systems for FutureGen type applications. Phase 1 entails advanced technologies identification, research and development Implementation Plan preparation and new gas turbine component conceptual designs. Phase 2 focuses on novel technologies development, validation, down selection and advanced gas turbine detail design. Phase 3 involves advanced gas turbine and IGCC plant construction and validation testing to demonstrate that efficiency, emissions and cost goals will be achieved and to prove the system’s commercial viability. The end objective is to validate the advanced gas turbine technology by 2015. The SGT6-6000G was selected as the basis for this development effort, due to its high firing temperature, output power and efficiency, as well as its advanced secondary air and steam cooling systems. It will be adapted for operation on coal, refinery residue and biomass derived hydrogen and syngas fuels, as well as natural gas, while achieving high performance levels and reduced plant capital costs in $/kW. New or enhanced technologies required to achieve high plant efficiency, while minimizing emissions and capital cost, will be developed and gas turbine design changes needed for optimum integration into the IGCC plant will be carried out. The main development thrust will be in the combustion, turbine cooling, materials/coating technologies and engine integration/operational flexibility. Several combustion systems will be investigated and the most successful candidate down selected. To minimize cooling air consumption, novel cooling concepts will be investigated, and validated in rig tests. Advanced bond coats, thermal barrier coatings, superalloys and airfoil architectures will be developed to minimize cooling air use. This paper describes the first year’s Phase 1 activities in advanced concepts, technologies identification and development, plant thermal performance evaluation, gas turbine IGCC plant integration studies and new gas turbine component conceptual designs.