Energy RD Performance: Gas Turbine Case Study

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were marked by a large breakthrough during their introduction, followed by great strides forward as computer codes and modeling improved. This contrast may be modified in the future if material developments lead to the widespread use of ceramic components, which would be the first real breakthrough in turbine material engineering. Finally, mechanical and cooling advancements have differed somewhat in their sources and methods of technology transfer. For turbine materials, initial blade structures and material specifications were transferred from the military turbojet industry. Major turbine manufacturers such as GE and Westinghouse Electric Corporation got their start in the gas turbine industry by developing gas turbines for applications in military aviation. These turbojets became the first crude models for power generation gas turbines. As gas turbines became accepted in the field of power generation, engineering and manufacturing companies began to split teams of gas-turbine engineers into “aviation” side and “power generation” sides. (GE also separated its steam turbine engineering groups from its gas turbine engineering groups, whereas Westinghouse kept them together until the 1980s.)18 The power generation groups then began developing and applying their own lessons for power-producing turbines as opposed to thrust-producing turbines. The power generation engineering efforts let to independent advances in materials applications, including improved heat tolerance and distribution for turbine inlet components. Both power and aviation engineering efforts led to the applications of protective coatings on the high-temperature turbine components. Advances in cooling technology have four identified sources. The first is development in the aviation industry, which has led to technology transfer to the power generation field. The first cooled turbine concepts were applied to military aircraft and then spread to civil aviation and power generation. A second source of cooling technology transfer is the drilling industry, which also requires that rapidly rotating metal be cooled to prevent damage.19 A third major resource for cooling advancements came through design codes and programs pioneered by both turbine design engineers and other groups in unrelated fields, such as NASA. Finally, the power generation industry itself has pioneered some efforts in keeping its own product temperatures cool enough to allow inlet temperature increases without the thermal breakdown of turbine components. Despite their differences, both material improvements and cooling advancements helped to increase the RITs of gas and combined cycle plants. These higher RITs helped to boost the efficiencies shown earlier in this section. Figures 6 and 7 demonstrate this trend. Figure 6 shows how the rotor inlet temperatures increased with time for one manufacturer’s specific family of turbines, in this case the Westinghouse 251 series. It shows its biggest jump in RIT as cooling was introduced in the late 1960s and early 1970s. In this chart, improvements can be seen in differences between the models. The AA model turbines only had their first row stationary vanes cooled. The B model turbines also had the first row blade cooling and compressors similar to earlier versions, but also included second row vane segment cooling. The B8 model included an improved combustion system and temperature profile as well as fine advancements to the first row blade cooling. The B12 model hallmarked considerably improved air flow which allowed 18 Interview with Lee McLurin, Westinghouse. 19 Interview with Craig Tedmon, ABB. 13

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