fluid mechanics

JK/HJK

Turbines for Sustainable

Power

Topic 01

Current Energy Scenarios and

Challenges

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This is a VERY Important Topic, and will continue to

be so for quite some time

Not a single day seems to pass by when we do not hear about

some reference to energy!!

US News & World Report: in 2008

http://www.usnews.com/articles/education/best-graduate-schools/2008/03/26/mechanical-engineering-is-on-the-rise.html In article titled Mechanical Engineering Is on the Rise; The classic

discipline is cutting-edge again says

"The coming decade is going to be the decade of energy, and when you

think energy, you think mechanical engineering," says Pritchard, 35. That's

because, as Iowa State University M.E. Prof. Robert C. Brown explains,

mechanical engineers are not only experts in thermodynamics-the study and

uses of energy-they know how to apply its laws to bring machines to life.

This is equally true today if not more. To b

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This is a VERY Unique Course

Not just at UCF, Perhaps anywhere around country

Materials from Multiple Academic Disciplines or Stems

are presented in order to explain a particular (and by far

the MOST dominant) approach for energy conversion: Mechanical systems

Thermal fluids or energy systems

Aerospace E.

Materials Sc & E.

Industrial E.

Statistics

Chemistry or Chemical/Environmental E.

Examples are taken from real life experience of many

years.

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Different Principles for

Conversion into Electricity

Primary

Energy

Sources

Electricity

Coal, Natural Gas, Oil

Nuclear materials

Solar radiation

Wind Energy

Ocean Tidal Energy

Etc.

Physical Principles for Conversion

Shaft power - generator

through Turbomachineries through Reciprocating engines

Photovoltaics (e.g. solar cells)

Electrochemical (e.g. fuel cells)

Thermoelectric

Thermo-ionic

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Energy: From acquisition to consumption

Primary

Sources

Conversion

Technique

Carrier and/or

Storage

Final

consumption

Coal

Petroleum

Natural Gas

Nuclear fuel

Biomass

Hydro

Wind

Solar

Ocean Tidal

Geothermal

Electricity (grid)

Liquid Fuel

Gaseous Fuel

such as natural

gas

Hydrogen

Pumped Hydro

Compressed Air

Battery

Thermal

TurboM/C: >90% of electricity IGCC/clean coal

w/carbon capture;

Nuclear; Wind; Solar

thermal; Hydro; Ocean

~100% of person

miles Aviation Engines

IC Engines

PhotoVoltaic

ElectroChemical SOFC; PEMFC

PhotoChemical

Chemical

Industrial

Residential

Commercial

Transportation

Portable

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What is a Turbomachinery?

Turbomachinery based

Conversion Component

Working Fluid In (state 1)

Mass flow rate = m

Working Fluid Out (state 2)

W

21

2

2

2

1212

1ZZgCChhmWout

e.g. hydro-turbine e.g. wind turbine

e.g. gas turbine

burning natural gas

Components Frame Plant

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Means of Conversion to Shaft Power Primary (in bold) or secondary energy

sources

Turbomachines Non

Turbo

Machines

Carbon

foot-print Thermal TurboM/C Non-

thermal Gas Turb Steam Turb

Coal X +

Oil x (x) X +

Natural Gas X (X) x +

Hydrogen X (X) X 0 (**)

SynGas (IGCC) w/ or w/o carbon capture X (X) 0 or +

Nuclear (X) X 0 or +?

Solar (PV or thermal) w/ or w/o storage X X (PV) +(*) or 0

Biomass (including synthetic gas) (X) X 0 or -

Wind (on/off shore) w/ or w/o storage X +(*) or 0

Hydro X 0

Ocean tidal w/ or w/o storage X +(*) or 0

Ocean stream X 0

Geothermal X 0

Pumped Hydro X 0 (**)

Compressed Air Energy Storage X + (**)

Battery X 0 (**)

** depends on the primary source; ? Why?? ( ) in CC plant

* depends on storage, if used

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Conventional Power

Generation

Natural Gas

Air Turb

Comb

Comp Gen

Gen

Boiler

Cond

Pump

Coal

Turb

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Conventional Power

Generation

Natural Gas

Air

Comb

Gen

Gen

HRSG

Cond

Pump

Turb Comp

Turb

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Solar Energy

atmosphere

~ 1354 W/m2*

~ 0 to 1000 W/m2*

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Turbines are involved in generation of about 98% of all electricity (kW-hr) added to US Grid (according to Energy Information Administration, US DOE) Almost 100% of all commercial passenger miles in air transportation is powered by turbines, as well.

Why Turbines?

Current Total (2006)

Coal, 52%

(turbines)

Natural Gas,

16% (turbines)

Nuclear, 21%

(turbines)

Renewables, 9% see the insetGenset, 1.5%

(non-turbines)

Solar Thermal,

0.013%

(turbines)

Solar PV,

0.0003% (non-

turbines) Wind, 0.7%

(turbines)

Hydro, 7.6%

(turbines)

Geothermal,

0.4%

(turbines)

Biomass,

0.6%

(turbines)

From AEO, US DOE EIA (not the latest)

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Fleet with state-

of-the-art

technology

- 5 bn t CO2/a

10

30

50

70

2020 1940 1960 1980 2000

- 2 bn t CO2/a

Gas-

fired

CCPP

Coal-fired

steam power

plants

Efficiency of existing

coal-fired power

plant fleet

6 bn t CO2/a

8.0 bn t CO2/a (2005)

2.0 bn t CO2/a

Efficiency %

CO2 reduction potentials in power & heat

Worldwide CO2 emissions: emission reductions through

use of high-efficiency state-of-the-art power plants

Coal-fired power plants produce roughly 28% of the worlds CO2 emissions

CO2 reduction, while maintaining competitiveness, can be achieved by replacing old coal power

plants with:

State-of-the-art coal power plants: minus 2.0 billion t CO2/yr

i.e. minus 25%

Gas-fired combined cycle power plants: minus 5.0 billion t CO2/yr

i.e. minus 63%

Coal-

fired

steam

power

plants

Coal fired fleet-CO2 emissions

Source: IEA, Siemens Energy GS Source: Siemens Energy

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Competition among fuels driven by prices

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Market Prices: Scarcity of engineering capacity and cost

increase for raw materials drive power plant cost.

Global stainless steel price

0

2000

4000

6000

8000

10000

Apr 06 Jun 06 Aug 06 Oct 06 Dec 06 Feb 07 Apr 07 Jun 07

US$/tonne

Source: MEPS

Doubling of price

within 1 year

Tight engineering capacities

Engineers needed

Active staff gap

2005 2015 2010

Source: BCG, RWE 2006

High steel demand has driven prices to record levels, which impacted power plant cost substantially.

Manufacturing capacity for power plant equipment like forgings, HRSGs and boilers is currently insufficient to satisfy world demand.

Engineering capacity can be a bottleneck.

Lead time for power projects has increased significantly.

Investors delay projects despite a need for new power plants.

Scarcity of raw materials and scarce

engineering capacity

high grade steel

low grade steel

Source: Siemens Energy

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Summary Fossil fuels remain primary energy

source

Renewables increase attractiveness

Clean energy environmental awareness

Economics more comprehensive

Reliability of utmost importance

Engineering bottleneck endangers growth

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Units Conversion

Fuel Prices

Appendix

Energy Units

$/EUR 1,35

Oil

EUR/GJ $/mmBtu $/bbl $/mmBtu (HHV) $/1000cft EUR/tce $/tce

1,00 1,40 7,90 1,25 1,35 29,30 39,60

1,50 2,10 11,80 1,90 2,00 44,00 59,40

2,00 2,80 15,80 2,55 2,70 58,60 79,10

2,50 3,60 19,70 3,25 3,35 73,30 99,00

3,00 4,30 23,70 3,90 4,05 87,90 118,70

4,00 5,70 31,60 5,15 5,40 117,20 158,20

5,00 7,10 39,50 6,40 6,70

6,00 8,50 47,40 7,65 8,05

7,00 10,00 55,30 9,00 9,40

8,00 11,40 63,20 10,30 10,75

9,00 12,80 71,10 11,55 12,10

10,00 14,20 79,00 12,80 13,45

11,00 15,70 86,80 14,15 14,80

12,00 17,10 94,70 15,45 16,15

13,00 18,50 102,60 16,70 17,50

General CoalNatural Gas

MWh GJ toe mmBtu

MWh 1 3,6 0,086 3,41

GJ 0,278 1 0,0239 0,948

toe 11,63 41,87 1 39,67

mmBtu 0,293 1,055 0,0252 1

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Coal still fuels the world in 2035

Renewables grow fastest (but from a low level)

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Increased energy use impacts climate change and endangers economical development.

The rapid growth of the world population

corresponds with the broad 20th century

industrialization.

The availability of cheap fossil energy and

increased concern for social welfare increased

specific energy consumption by a factor of 2,

reaching a level of 1.8 toe/capita.

There is a good reason to assume a correlation

between use of fossil energy, higher CO2 concentrations in the atmosphere, and a

corresponding temperature increase.

Political, financial, and industrial leaders have

acknowledged the danger of significant human-

caused climate change.

Technological innovation and industry response

can significantly help to stabilize CO2 concentrations to avoid possibly catastrophic

results. It is estimated that this would cost less

than 1% of the world GDP.

Year1500 200013.5

C

15.0

14.5

14.0

w

o

r

l

d

a

v

e

r

a

g

e

t

e

m

p

e

r

a

t

u

r

e

1900

0.6

Energy consumption

per capita (toe)

bubble size1.8

0.9

0.3


Fleet with state-

of-the-art

technology

- 5 bn tCO2 /a

10

30

50

70

20201940 1960 1980 2000

- 2 bn tCO2 /a

Gas-

fired

CCPP

Coal-fired

steam power

plants

Efficiency of existing

coal-fired power

plant fleet

6 bn t CO2 /a

8.0 bn t CO2 /a(2005)

2.0 bn t CO2 /a

Efficiency %

CO2 reduction potentials in power & heat

Worldwide CO2 emissions: reductions through use of high-efficiency state-of-the-art power plants

Coal-fired power plants produce roughly 28% of

the worlds CO2 emissions

CO2 reduction, while maintaining competitiveness,

can be achieved by replacing old coal power

plants with:

State-of-the-art coal power plants:

minus 2.0 billion t CO2 /yr

i.e. minus 25% of power generation from

coal-fired steam power plants

Gas-fired combined cycle power plants:

minus 5.0 billion t CO2 /yr i.e.

minus 63% of power generation from

coal-fired steam power plants

Coal-

fired

steam

power

plants

Coal fired fleet-CO2 emissions

Source: IEA, Siemens Energy GS

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Increase of combined cycle net efficiency to over 60%

Reduced emissions per produced kWh

High efficiency and low emissions also in part-load operation

Fast start-up capability and operational flexibility

Reduced investment costs per kW

High reliability and availability

Lowest life cycle costs

Gas Turbine and Gas Turbine Power Plant

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Natural Gas Production Shale Gas reservoirs

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Richard Newell, March 2, 2010

20

Since 1997, more than 12,000 gas wells completed in Barnett shale, USA

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Turbines for Sustainable Power JK/HJKRichard Newell, March 2, 2010 22

U.S. shale gas plays

Success in the Barnett prompted companies to look at other shale formations in the U.S.

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Typical Areas of Application of different Power Plant Types and Requirements

Peak load:

Simple-cycle GTPP,

Hydro storage plants

Base-load:

Nuclear, Hydro Running

Water, Coal Steam Plants

Intermediate-load:

Combined Cycle PP,

Coal Plants

0 4 8 12 16 20 24

Daily cycling of units

Renewables replace base load units because of must feed-in obligations, but must be backup for wind shortfall

Competition between gas and coal fired plants:high gas prices shift CCPP to lower load factors

High Start-up ReliabilityLow start-up CostLoad Ramp

Best EfficiencyHigh availabilityLow Generation CostsShort Outage Period

Regulation

loadWeighting of ProductRequirements:

FlexibilityPart Load Efficiency

Time of day

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Accelerating renewables raises a new issue Ramp-up & rump-down capability

more wind does not always result in more power generation

Wind is not always there when it is needed e.g. it is temperature dependent

Source: RWE 9/2009

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As Evidence: RWE is planning to invest in less CO2 and more operationally flexible technologies.

Source: RWE 9/2009

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Energy Conversion in a Steam Power Plant (SPP) Principal Layout

Chemical Energy

Boiler

Thermal Energy

Steam Turbine

Mechanical Energy

Generator

Electrical Energy

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SST-3000 Series Turbine

Barrel type HP casing

Combined journal-thrust

bearing

Internally cooled balance piston

Compact combined IP/LP section

with straight-flow design

High-performance LP blades for different sizes

of exhaust area

Welded IP/LP- shaft design

Single flow LP with axial exhaust for

a range of different exhaust areas

Efficient erosion protection measures

for LP blades

Fully 3-dimensional high performance variable reaction

blade path (3DVTM)

Combined stop and control valves

in single valve arrangement

SGen-1000A series for 50 Hz

and 60 Hz

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SST-5000 Series Turbine

Spring back seals

Fully 3-dimensional high performance variable reaction blade path

(3DVTM)

Push rod arrangement for reduced axial

clearances

High-performance LP blades for different sizes

of exhaust area

SGen-1000A series or SGen-2000H series for 50 Hz and 60 HzSGen-1000A series

or SGen-2000H series for 50 Hz and 60 Hz

Fabricated welded design for optimized material application

Efficient erosionprotection measures

Single cross-over pipe

Combined stop andcontrol valves in single

valve arrangement

Compact HP/IP design

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Energy Conversion in a Combined Cycle Power Plant (CCPP) Principal Layout

GT Exhaust Energy

HRSG

Thermal Energy

Steam Turbine

Mechanical Energy

Generator

Electrical Energy

Gas turbine system Heat-recovery boiler Steam turbine system

Electric

power

Air Natural gas,

Fuel oil, etc.Main Steam

Feedwater

Condensate

Circulating

water

Cooling

tower

Cooling

air

Electric

power

12

11

9

10

11 11

1413

Fresh water

Gas turbine system1 Air intake duct

2 Compressor

3 Gas turbine

4 Steam generator

5 Exhaust stack

6 Bypass stack

7 Generator

8 Transformer

Steam turbine system9 Steam turbine

10 Condenser

11 Pump

12 Feedwater tank

13 Generator

14 Transformer

8 7 1 2 3 4

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Single Shaft CC Power Train Layout

Combustion Turbine Generator Exciter Clutch

Steam Turbine

Foundation

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Trent 800

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ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

JK/HJK Turbines for Sustainable PowerBBC - ABB - Alstom Gas Turbines - ML - 03 Aug 2010 - P 1

Gas Turbines in Baden, Switzerland, Forever

1969-1974

1990-1999

2000+

1891-1969

1974-1990

1999-2000

+

ASEAAllmnna Svenska

Electricitets-

Aktiebolag, Schweden

+

+

+

gas turbines gas turbines

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1st Utility Gas Turbine Plant in the World 4 MW, Neuchtel, Switzerland 1939

Plant Country ordered in operation last reading OH S

Neuchatel CH 1938 1940 1997 7020 1807

Single Stage Gas Turbine without Recuperator from BBCPlantgen. power

kW

spec pow.

kW/kg/s

Th. Efficiency

%type rpm

air inlet

C

air inlet

kg/s

Thg

CTexh C PR Fuel

comp

stages

turb

stages

Neuchatel 4021 62.8 17.4 12 3020 23.4 64 552 313 4.4 light fuel oil 23 7

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Evolution: Single Shaft GTs with Recuperator

GTs for electricity

(2 x Pertigalete 1.6 MW, Alexandria 1.2 MW,)

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Revolution: First two shaft reheat GT 10 MW, Filaret, Rumania 1945*)

Intercooler

LP compressorLP turbine

HP turbine

El. Generator

HP compressor Starting motor

Starting motor

Plant Country ordered in operation last reading OH S

Filaret Rumania 1944 1951 1959 9700 572

Plantgen. power

kW

spec pow.

kW/kg/s

Th. Efficiency

%type rpm

air inlet

C

air inlet

kg/s

Thg

CTexh C PR Fuel

Filaret 12567 138.1 24 12/8* 3997/3000 13.4 91 564/563 296 11.8 Natural gas

*) Test in Baden

1st Combustor

2nd

Combustor

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*) Test in Baden factory


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Test results: above guarantees

1945: public demonstration *) Test in Baden

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Evolution: Standard two shaft reheat GTs

1961, Korneuburg CC Plant, Austria

ETAcc = 32.6 %,

Pcc = 2 x 30 (GT) + 25 (ST) = 85 MW

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Revolution: First Sequ. Comb on 1 Shaft 300 MW Air Storage Plant, Huntdorf, Germany 1977

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1st Sequential Combustion Gas Turbine for 60 Hz on one Shaft, 1995

GT24 Gilbert, USA, with 165 MW

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Base

load

Full Speed

No load

Relative GT Load

Inlet Air flow

(Inlet Guide Vane Position)

0% 25% 100%

Base

load

Full Speed

No load

Relative GT Load

Inlet Air flow

(Inlet Guide Vane Position)

0% 25% 100%

GT24/GT26 Gas Turbine Operation Concept

EV temperature maintained

high from ~10 - 100% load- low emissions over a

wide load range

High exhaust temperature

maintained between

~ 25% - 100% load- high CC part-load efficiency

- quick CC start-up time

High performance and low NOx emissions

over wide load range

GT Exhaust

Temperature

EV Combustor Temperature

SEV Combustor Temperature

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GT24/GT26 Gas Turbines Cooling Air Coolers

LP-

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HP-

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GT24 (60 Hz): +20.6 MWth Heat Release in OTC*) = +9.7 MWe via Steam Turbine

GT26 (50 Hz): +27.8 MWth Heat Release in OTC*) = +13.1 MWe via Steam Turbine

GT24/GT26 Gas Turbines Once Through Coolers in CCPP

*) converted at 47% into el. Power

ISO conditions (gross at generator terminals)

Gas Turbine GeneratorSteam

Turbine

Heat

Recovery

Steam

Generator

HP Steam

Feed

Water

Once Through Coolers

Cooling Air

9.7 MW

13.1 MWGT24: 184.1 MW

GT26: 279.7 MW

193.8 MW

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4

Increased efficiency SFC with increased turbine inlet temperature

Current demands require ever higher turbine inlet temperatures

Combined cycle efficiencies pushing 60%, gas cycle efficiencies ~ 40%

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Topic1_A.pdfSlide Number 1IntroductionTurbines for Sustainable PowerAgendaNuclear: renaissance with improved reactor types.Biomass: locally available energy source.Offshore wind: Installations increasing in near futurePhotovoltaic: large scale production and new technologies promise improvements.Solar thermal: New plant installations Slide Number 82008 Electricity generation costPower generation growth factorPower generation growthRelative power generation growth factorRenewables gaining importance but fossil fuels will continue to be the mainstayCoal still fuels the world in 2035Increased energy use impacts climate change and endangers economical development. Climate change: An widely accepted factWorldwide CO2 emissions: reductions through use of high-efficiency state-of-the-art power plantsSlide Number 18Natural Gas Production Shale Gas reservoirsSince 1997, more than 12,000 gas wells completed in Barnett shale, USA Resulting in accelerated increase of production from the Barnett fieldSuccess in the Barnett prompted companies to look at other shale formations in the U.S.Typical Areas of Application of different Power Plant Types and RequirementsAccelerating renewables raises a new issueRamp-up & rump-down capabilityTherefore also modernization of conventional power plants is necessaryAs Evidence:RWE is planning to invest in less CO2 and more operationally flexible technologies.Energy Conversion in a Steam Power Plant (SPP) Principal LayoutSST-3000 Series TurbineSST-5000 Series TurbineEnergy Conversion in a Combined Cycle Power Plant (CCPP) Principal LayoutSingle Shaft CC Power Train LayoutSlide Number 32Slide Number 33Slide Number 34Slide Number 35Slide Number 36Slide Number 37Growth in pressure ratio and exhaust temperature

Topic1_B.pdfGas Turbinesin Baden, Switzerland, Forever1st Utility Gas Turbine Plant in the World4 MW, Neuchtel, Switzerland 19391st Utility Gas Turbine Plant in the World4 MW, Neuchtel, Switzerland 19391st Utility Gas Turbine Plant in the World4 MW, Neuchtel, Switzerland 1939Evolution:Single Shaft GTs with RecuperatorEvolution:Single Shaft GTs with RecuperatorEvolution:Single Shaft GTs with RecuperatorRevolution: First two shaft reheat GT10 MW, Filaret, Rumania 1945*)Revolution: First two shaft reheat GT10 MW, Filaret, Rumania 1945*)Revolution: First two shaft reheat GT10 MW, Filaret, Rumania 1945*)Evolution:Standard two shaft reheat GTsEvolution:Standard two shaft reheat GTsEvolution:Standard two shaft reheat GTsRevolution: First Sequ. Comb on 1 Shaft300 MW Air Storage Plant, Huntdorf, Germany 19771st Sequential Combustion Gas Turbinefor 60 Hz on one Shaft, 1995GT24/GT26 Gas Turbine Operation ConceptGT24/GT26 Gas TurbinesCooling Air CoolersGT24/GT26 Gas Turbines Once Through Coolers in CCPP

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fluid mechanics