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Jim DownsDirector of Technology
Florida Turbine Technologies, Inc.561-427-6250
Turbomachinery Technology Development at FTT
3 November 2015
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.
University Turbine Systems Research (UTSR) WorkshopAtlanta, Georgia, November 3-5, 2015
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
OutlineOutline
• FTT company overview
• DOE-sponsored turbomachinery technology programs at FTT
• Opportunities for collaboration with UTSR universities
Turbomachinery Technology Development at FTTCopyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.November 3, 2015 2
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
3Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.November 3, 2015
Independent Know-How of Industry Systems (Industrial and Aero)Design practice, design criteria, and lessons learnedFast iteration conceptual designDetailed design know-howExpert knowledge of material systems and manufacturing processes
Calibrated Analysis Tools and Design SystemInternal and external softwareContinuously improved with new information/data
Technology PortfolioIntellectual propertyGovernment-sponsored technology programs
Proven Supply Chain for Prototype HardwareManufacturing engineering to support delivery
Validation and Field ExperienceProduction as-manufactured hardware verificationField issue root causePower producer engineering support
OEM Capability – Innovation EmphasisOEM Capability – Innovation Emphasis
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
DOE-Sponsored Technology ProgramsDOE-Sponsored Technology Programs
4Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.
• TurboGTTM Gas Turbine with ARTICReturnTM Cooling (FE-0023975)
– 18 month Phase I program Wraps-up early next year
• Air Riding Seal Technologies for Gas Turbines (DE-SC0008218)
– 2 year program Concludes next year
November 3, 2015
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
DOE Advanced Turbines ProgramDOE Advanced Turbines Program
5Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.
R&D Activities to Accelerate Turbine Performance and Efficiency Beyond Current SOA and Reduce the Risk to Market for Novel and Advanced Turbine-Based Power Cycles
Goals:• Efficiency – High, 65% (LHV) or Greater in Combined Cycle
• Operability – Support Load Following Capabilities to Meet Demands of Modern Power Grid
• Higher Firing Temperatures (1700C/3100F)
• Emissions – Low NOx and other Criteria Pollutants
• Cost – ? … FTT Primary Goal = Lower Cost
Ref: DOE NETL Web SiteNovember 3, 2015
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
Path to High Efficiency GoalPath to High Efficiency Goal
6Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.
Combined Cycle Power Plant
A lot of pieces, but the efficiency is predominantly driven by the gas turbine(s)
Focus here is on gas turbine performance
November 3, 2015
Ref:http://tse1.mm.bing.net/th?&id=OIP.Meed81da2ead7c689b2dbf71a16d1f9b6o0&w=300&h=300&c=0&pid=1.9&rs=0&p=0
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
Gas Turbine PerformanceGas Turbine Performance
7Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.
What’s the Limit? How Good Can it Get?
Understanding the fundamentals of the ideal thermodynamic cycle:
Tem
pera
ture
, T
Entropy, s
Compressor: Isentropic compression from low pressure to high pressure
Combustor: Increasing temperature at constant pressure
Turbine: Isentropic expansion from high pressure to low pressure
PH
PL
A lot of emphasis is placed on this value - the turbine inlet temperature
But, What is the Efficiency of this Cycle?
November 3, 2015
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
Gas Turbine PerformanceGas Turbine Performance
8Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.
Ideal Simple Cycle Efficiency – As Good as it Gets
Tem
pera
ture
, T
Entropy, s
1
2
4
3
Efficiency () = Useful Output
Total Energy Input PH
PL
≈ (T3 – T4) – (T2 – T1)
(T3 - T2)
1
1L
H
PP
With Some Mathematical Manipulation:
November 3, 2015
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
Gas Turbine PerformanceGas Turbine Performance
9Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.
Reality – Real Component Performance Reduces Efficiency
Tem
pera
ture
, T
Entropy, s
1
2
4
3PH
PL
• 4 Power Generation IGT Manufacturers
Aeroderivative
Simple Cycle Efficiency
November 3, 2015
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
Gas Turbine PerformanceGas Turbine Performance
10Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.
Increased Pressure Ratio Needed to Reach Goals
FTT Goal
DOE Program Objective
• 4 Power Generation IGT Manufacturers
Simple Cycle Efficiency
Combined Cycle Efficiency
November 3, 2015
Ref:http://tse1.mm.bing.net/th?&id=OIP.Meed81da2ead7c689b2dbf71a16d1f9b6o0&w=300&h=300&c=0&pid=1.9&rs=0&p=0
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
FTT Design SolutionsFTT Design Solutions
11Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.
Problem – For Single Shaft Architecture, High Pressure Ratios Decrease the Size of the Core Hardware … Reduces Component Efficiencies
http://www.netl.doe.gov/scng/projects/end-use/at/images/at31176HseriesTurbine.jpg
• Today’s IGT operates on a single shaft
• Size is limited due to last stage turbine blade pull stress as quantified by AN2
• Requires Innovation to Mitigate Effects of Shrinking Core Size
• FTT Offers New Solutions to Historical IGT Problems
November 3, 2015
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
FTT InnovationFTT Innovation
12Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.
Aircraft Engine-Derived Multi-Shaft Architecture – TurboGTTM
*FTT Patents Pending*
HPTurbomachinery
LPTurbomachinery
To Bottoming Cycle
Air In
Generator
2X pressure permits 2X flow through expensive core partsExtended operability• Downturn to 10% power
FTT-Proprietary Shaft Arrangement
November 3, 2015
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
OperabilityOperability
13Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.
Variable Turbine Geometry • Improves responsiveness to
intermittent power demands caused by increased use of renewables
• Enables substantial expansion of turn-down envelope
November 3, 2015
Vane Gapping Patent Pending
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
Turbine CoolingTurbine Cooling
14Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.
Benefits of Internal Convection Cooling are Well-Established
• Enables rotor inlet temperature to be increased 200F/111C• Mitigates emissions impact
Ref: GE ATS Final Report, June 2001
Independent Assessment/Conclusion:
Problem: C/A Dilution Increases Turbine Inlet Temperature
November 3, 2015
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
Turbine CoolingTurbine Cooling
15Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.
Enhanced Cooling to Address Increased Turbine Inlet Temperature
*FTT Patents Pending*
ARTIC CoolingHP
Turbomachinery
LPTurbomachinery
To Bottoming Cycle
Air In
Generator
ARTICReturnTM Cooling System
ARTICReturnTM
November 3, 2015
Iteration #1 Geometry
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
Turbine CoolingTurbine Cooling
16Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.
Demonstrator Hardware Produced• Rapid prototype technologies Demonstrated in Full-Scale IGT
• Engine ran from March to April, 2014 with ARTICTM parts installed
• Total estimated run time ~ 115 hours
• ~25 hours at maximum power temperature rating
• Total estimated number of cycles ~ 50
• All objectives of planned test campaign were completed
*FTT Patents Pending*
Fundamentals of ARTIC Vane 1 Cooling Technology Demo’d Under DOE Contract DE-FE0006696
New Application in TurboGTTM as ARTICReturnTM
November 3, 2015
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
17Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.November 3, 2015
Advanced Leakage Control TechnologyAir Riding Seal Concept (Jake Mills, Principal Investigator)
• Non-contacting static-to-rotating seal • Hydrostatic balance of forces• Ability to follow rotor to maintain close clearances
0
Clearance
Desired Gap
Bal
anci
ng F
orce
Restorative Forces
Outer Seal Land
Inner Seal Land
Seal Clearance
Rotating Surface
Secondary Seals
Piston
Secondary Seal
Outer Seal Land
Inner Seal Land
Piston
Static Housing
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
18Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.November 3, 2015
Advanced Leakage Control TechnologyAir Riding Seal (ARS) Concept
PhAh
Pl Al
Pl Al Equilibrium ΣFx = 0
PcAc
Pl AlPh Ah + = Pc Ac
Reduced Clearance ΣFx = Pl AlPh Ah + < Pc Ac
Increased Clearance ΣFx =
Pl AlPh Ah + > Pc Ac
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
19Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.November 3, 2015
ARS Technology Demo’d in Phase I20,000rpm Seal Pressurization/Activation
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
20Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.November 3, 2015
ARS ApplicationARS Application
Compressor Interstage
Seals
Turbine Interstage
Seals
Bearing Compartment
Seals
Compressor Bleed Seal
ARS technology applicable to a variety of rotating to static seals
• Large utility scale engine performance model created to assess benefits of retrofitting an engine with the ARS technology
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
21Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.November 3, 2015
Rig TestingDesign-to-Test Operating Considerations• Testing centered around engine operating conditions• Rig allows for variation of a variety of design variables to understand the ARS
design space and to calibrate/validate the analytical tools.
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
22Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.November 3, 2015
Future ARS Engine Testing
• To reduce cost and risk for future engine testing, the initial application of the ARS has been designed for the 501K
– The ARS will be tested in a rig at engine conditions under the Phase II contract
– Rig hardware has been designed to integrate into the engine
• ARS replaces the ‘thrust balance seal’ upstream of the first stage turbine
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
23Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.November 3, 2015
Project OverviewProject OverviewgRig
Rig• Designed around engine
hardware• Design requirements and
test objectives established from engine OEM
• Designed to establish a large design space centered around engine conditions
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
24Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.November 3, 2015
FY12 FY13 FY14 FY15 FY16 FY17 FY18 FY19
ARS Tech, Development RoadmapARS Tech, Development Roadmap
Pro
duct
501K ????
FTT RigFTT RigFTT Rig
TRL1 TRL2 TRL 3 TRL 4 TRL 5 TRL 6 TRL 7 TRL 8 TRL 9
Basic Technology
Research to Prove Feasibility
Technology Development
Technology Demonstration System/Subsystem
Development
System Test, Launch & Operations
Product
SBIR Phase I SBIR Phase II
OEM Partnership
Concept Test Rig Engine Like Test Rig
Low Risk Engine Test
Demo Engine Demo Engine Test
Completed Working
Concept Studies Design for Application Technology Maturation
Push Condition Push Condition Rig Testing
Technology Maturation
Phase II Sequential
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
TurboGTTM Conceptual Design StatusTurboGTTM Conceptual Design Status• Thermodynamic Performance
Model for TurboGTTM has been Created Using GateCycle Software
25Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.November 3, 2015
• High Fidelity Based On:– FTT’s fast-Iteration conceptual design system with:
• Calibrated aerodynamic and turbine design codes• Compressor aerodynamics (Component efficiencies and diffuser pressure losses)• Turbine aerodynamics (Stage pressure ratios and efficiencies in HPT and LPT)• Fast FEM• Completed analysis: Rotor dynamics, Thrust balance, SAS• Incorporation of cooling and leakage flow rates and pressure losses based on
latest mechanical arrangement
• Over past 12 months, design elements have been balanced to achieve a robust conceptual design which will be reviewed with the DOE in coming weeks
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
26Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.November 3, 2015
TurboGTTM Cost ImpactTurboGTTM Cost ImpactMulti-Pronged Approach to Reduce COE
• Low Equipment First Cost– More Steel, Less Nickel, per Megawatt
• Low Operating Cost– High Efficiency Maintained Over Wide Operating
Range– Increased Utilization (Turn-Down to 10% Load)
On Track For: CC cost reduction > 25% SC cost reduction > 30%
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TurboGTTM Development RoadmapTurboGTTM Development Roadmap
27
Goal is for Technology Development of a 65% Combined Cycle to be Complete by 2017, with Commercial Rollout by 2022
27Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.November 3, 2015
DOE Studies Leading to High P/P Cycle Definition
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Opportunities for UTSR Collaboration
28
• System-Level – Operability and controls validation
– Controls logic development
• Component-Level– High pressure low NOx combustion using gaseous fuels
– Emissions control over wide range of operating conditions
– Coatings for high pressure environment
– Cooling technology development
– Seal durability test opportunities
November 3, 2015Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
Summary
29
• TurboGTTM Addresses All of the Advanced Turbines Program Goals– Affordability– Efficiency– Operability– Increased Temperatures
• Leverages Prior Successful FTT/DOE Component Development Experience
• Following Demonstration/Validation Test Phase, Commercial Rollout Could Be Realized by 2022
• Many Opportunities for Collaboration with UTSR Universities
November 3, 2015Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
Acknowledgements
Department of EnergyNational Energy Technology Laboratory
Rich Dennis, Technology ManagerSteven Richardson, Project Manager
30November 3, 2015Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.
Proprietary information of Florida Turbine Technologies, Inc. (“FTT”). Use, disclosure, dissemination, distribution, or copying to any outside parties without express written permission of FTT is strictly forbidden.
31
Thank You & Questions?
FTT -- Affordable EfficiencyTMFTT -- Affordable EfficiencyTM
November 3, 2015Turbomachinery Technology Development at FTT
Copyright 2015, Florida Turbine Technologies, Inc. All Rights Reserved.