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facility similar in design to Shunde’s could save $22 million at 0.5 capacity factor and $36 million at 0.75 capacity factor. Savings of $264 million and $432 million respectively are indicted over the life of the plant, (US dollar figure expressed at 1995 values). Case 2: MHI steam cooling design for their highest temperature zones.5 The art of steam cooling has proved a valuable asset in the drive to maximize power per unit weight in gas turbine technology. The current limiting factor to maximum horsepower for a given rotor size is turbine inlet temperature (TIT). Internal cooling to the gas turbine vanes and blades, as well as the combustion liner, keeps those airfoils cooler for a given fuel flow rate. The steam cooling circuit can be either a “closed” or an “open” design. In the latter, the steam coolant is allowed to enter the gas path, which provides a further horsepower boost to the gas turbine. The major manufacturers compete with design modifications like steam cooling to produce effective turbines in the various horsepower size categories, “effective” in this context meaning that the turbine in question delivers its rated horsepower (and other deliverables) without leaks or other operational problems. Table 7a shows -D, -F, -G and –H category gas turbine parameters for the Mitsubishi Heavy Industries (MHI) range of gas turbines. These parameters vary for different manufacturers, but the table nevertheless provides an illustration of the effectiveness of steam cooling in raising TITs. For illustrative purposes, this article references parameters with MHI gas turbines. Readers may use this as a template for queries on or comparisons with other manufacturers’ designs. Note also that Table 5 mentions subcategories of the major horsepower size categories. These occur due to individual customer requirements or conditions that “create” a subcategory that can then be offered to other clients. For instance, the G1 is an upgraded G, with cooling steam applied to the blade ring in addition to the combustion liners. Table 5. Categories of gas turbines for the Mitsubishi Gas Turbine product line 5 GT type M501DA M501F M501F3 M501G M501G1 M501H TIT deg C 1250 1350 1400 1500 1500 1500 Cooling Type Turbine Combustor Air Air Air Air Air Air Air Steam Air Steam Steam Steam Performance (ISO: LHV) NOx Gas turbine Combined Cycle ppm 114MW 153MW 185MW 254MW 267MW 34.9% 35.3% 37.0% 38.7% 39.1% 167MW 229MW 285MW 371MW 399MW 403MW 51.4% 9 52.8% 25 57.1% 9 58.0% 25 58.4% 15 60.0% 15 -- 41 Steam cooling, like any other cooling technology helps alleviate the potential life cycle cost incurred with partial load cycling operation and frequent starts and stops. As of March 2004, MHI had 150,000 operating hours of steam cooling experience with their G units, logged. This figure includes both 50Hz and 60Hz applications. Both their G and H models have steam cooled combustion liners. The H model also has blades and vanes in the first two rows of its turbine rotor and the blade rings, steam cooled. Material selection With steam cooling, as with any design feature, wear limits and future repairability are major concerns. The steam cooling feature merits concern about corrosion rate and electrochemical reaction strength levels, which would depend on the mating materials in question and the steam purity. Although many steam cooling designers would like to claim that the steam supply conditions are no more stringent than the steam required for their steam turbines, higher steam quality standards make good economic sense at the design conditions in G and H gas turbines. Stress corrosion cracking is accelerated by long term steam exposure, particularly at high stress concentration locations like disc dovetails, bolt holes and spigots. MHI were able to use the same low alloy steel as for their F design with their G and H models which gave them a wealth of data. Further, they used scaled up but similar geometry for the hotter models. With respect to scale size after steam exposure, the actual engine tests confirmed earlier laboratory prognoses closely. See Figure 49. In MHI’s design, expensive aircraft engine type alloys such as Inconel (for the rotors) and single crystal castings (for blades and vanes) are avoided. This enhances reliability, initial capital costs and life cycle costs.PDF Image | GAS TURBINES IN SIMPLE CYCLE COMBINED CYCLE APPLICATIONS
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