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1 Research sponsored by the U.S. Department of Energy’s Federal Energy Technology Center, under contract DE-FC21-95MC31173and the Chicago Operations Office, under contract DE-AC02-92CE40960 with Solar Turbines Incorporated, 2200 Pacific Highway,P.O. Box 85376, San Diego CA 92186-5376.
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Industrial Advanced Turbine Systems Program Overview1
S. Gates (619) 595-7428([email protected])
Solar Turbines IncorporatedP.O. Box 85376
San Diego CA 92186-5376
IntroductionEarly in this decade, the U.S.Department of Energy (DOE)recognized the fact that gas turbineswere playing an ever-expanding role inthe power generation industry. Despitethe fact that such machines have been inexistence for more than 50 years, theirimprovements in efficiency, emissions,cost and reliability have been largelyincremental, having typically followedimprovements in materials and otherenabling technologies. In response tothis dichotomy, DOE initiated the fourphase Advanced Turbine Systemsprogram in 1990 and chartered theprogram with the following goalsrelative to then state-of-the-art industrialturbine products:
• 10% improvement in busbar cost ofelectricity.
• 15% improvement in efficiency.• Single-digit NOx emissions.• Reliability equal to or greater than
currently available products.
Now, more than 8 years into the future,the development program undertaken bythis unprecedented public-privatepartnership is entering its fourth andfinal phase. The design phase of theprogram is behind us and thecomprehensive field evaluation phase ofSolar Turbines’ ATS program is nowwell underway and will continue for thenext year. With one field evaluation
machine in operation and 5 morescheduled to follow in short order, wewill address the status of the Solar’sMercury 50 program and its progress vs.the four fundamental goals that were setforth more than 8 years ago.
The Mercury 50 was introduced to thepublic in December 1997 at the ASMETurbomachinery symposium in Orlando,Florida as a single shaft, optimizedrecuperated engine, nominally sized at4.3 MWe with better than 40%efficiency at the busbar. Thisenvironmentally superior systemincorporates a highly flexiblecombustion system that can beconfigured for either ultra-lean premixedor catalytic combustion. The Mercury50 is targeted to meet the rapidlyexpanding demand for highly efficient,environmentally superior turbine-basedpower systems in the industrial powergeneration and emerging distributedgeneration markets.
Development EffortsFormal development of the Mercury50 began in September 1995 andemphasized the use of system-leveldesign solutions that take advantage of awide variety of demonstratedtechnological advancements, eachproviding sufficient margin to assure thesuperior durability and availability thatare required by industrial gas turbineusers. A combination of innovative
1 Research sponsored by the U.S. Department of Energy’s Federal Energy Technology Center, under contract DE-FC21-95MC31173and the Chicago Operations Office, under contract DE-AC02-92CE40960 with Solar Turbines Incorporated, 2200 Pacific Highway,P.O. Box 85376, San Diego CA 92186-5376.
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primary and backup design solutionshave been carefully blended to offermaximum cycle efficiency andemissions reductions with minimal risk,as adequate design margin is maintainedwithin each selected technology. Thematerials used in the manufacture of theMercury 50 turbine are a key elementin the durability equation and represent amix of current turbine materials as wellas next-generation alloys that arerelatively new to industrial turbines.One of the most significant Mercury50 innovations is the layout of the coreengine, around which the package hasbeen synergistically designed. Theresulting design offers significantadvantages in terms of cost, performanceand maintainability and is central to itsability to meet the key product goalsstated at the beginning of the program.
Solar’s Mercury 50 engineering designactivities were concluded in July 1998.The engine test phase of the programcommenced in December 1998 toevaluate the performance and durabilitycapabilities of this unique engine prior tothe commencement of field evaluationtests. The fourth and final industrialsystem demonstration phase of theprogram begins in December 1999 andwill be marked by startup of the DOEHost Site demonstration machine atRochelle Municipal Utilities. This
machine is scheduled to run for 8,000hours, during which time it willdemonstrate its capability to meet thefour fundamental goals of the program.As a precursor to this milestone event,evaluation of an early pre-commercialversion of the Mercury 50 began inSeptember of 1999, coincident withstartup of the machine at a remotemining site in Australia.
SummarySolar’s Mercury 50 is the culminationof a development effort that has beenmore than 8 years in the making andrepresents a revolutionary approach inan industry that has long depended uponevolutionary solutions. It has beendesigned to offer superior performanceand operating flexibility at a price that iscompetitive with alternative powergenerating technologies. It represents abalanced approach to the tradeoffbetween the benefits of new technology,low cost and high reliability that istargeted directly at the needs of theindustrial power generation marketplace.This report highlights Solar’s ATSprogram progress over the past year andwill discuss the design activities, testresults and field evaluation preparationsalong with a brief overview of futureplans, commercialization efforts andmarketplace activities.
Dave Dave EsbeckEsbeck Vice President, Engineering
Dave Dave EsbeckEsbeck Vice President, Engineering
ATS99-002
Program SponsorshipProgram Sponsorship
• Chicago Operations Office− Steve Waslo - Contracting Officer’s Technical
Representative
• Washington Headquarters
− Denise Swink - Deputy Assistant Secretary,Industrial Technology
− William Parks - Director, Cross-Cutting Technologies
− Patricia Hoffman - ATS Program Manager
• FETC - Morgantown
− Mary Gabrielle - Contracting Officer
ATS Program Management ATS Program Management DOE Office of Industrial TechnologyDOE Office of Industrial Technology
ATS99-003
IntroductionIntroduction
• Introduction & Overview Dave Esbeck
• Review of Accomplishments Steve Gates
− Mercury Engine Design
− 2nd Generation Hardware
− Package Design
− Summary of Test Results
• Commercialization Activities- Overview
• Update - Rochelle Site Mr. Ray Schwartz Preparations Rochelle Municipal Utilities
ATS99-004
Mercury 50 LayoutMercury 50 Layout
• Industrial Single-ShaftGenerator Set
• Optimized RecuperatedCycle
• Modular Construction− 10-Stage Axial
Compressor− 2-Stage Axial Turbine− Annular Combustor
• 4.2 MWe
• 40% Busbar Efficiency
ATS99-005
Program GoalsProgram Goals
• Efficiency
• Environment
• Fuel Flexibility
• Reliability and Maintainability
• Cost of Power
ATS99-006
15% Improvement in Efficiency15% Improvement in Efficiency
Program Goals - EfficiencyProgram Goals - Efficiency
• Based on Lower Heating Value (LHV)of Natural Gas
• Compared to Best Available 1991 IndustrialTurbomachinery Technology
• Comparable in Size Range
ATS99-007
Program Goals - EnvironmentProgram Goals - Environment
• Environmental SuperiorityUnder Full- and Part-LoadConditions
• No Post-CombustionCleanup Devices
• Emissions Acceptable inSevere Non-Attainment Areas- NOx, CO, UHC
• “Single-Digit” NOx
ATS99-008
Program Goals - Fuel FlexibilityProgram Goals - Fuel Flexibility
• Natural Gas Fired ATS Systems
• Adaptable to Biomass andCoal-Derived Fuels
ATS99-009
Program Goals - ReliabilityProgram Goals - Reliability
• Reliability and Maintainability- Equivalent to Best Available Circa 1991
• Addressing “RAM-D”
ATS99-010
Program Goals - Cost of PowerProgram Goals - Cost of Power
• Busbar Energy Costs at 10% Less than 1991State-of-the-Art Turbine Systems
−Total Cost of Ownership (Fuel,Maintenance, Amortization)
ATS99-011
Steve Gates Steve Gates Director,
Developmental Engineering
Steve Gates Steve Gates Director,
Developmental Engineering
ATS99-015
Mercury 50 EngineMercury 50 EngineDesign OverviewDesign Overview
Mercury 50 EngineMercury 50 EngineDesign OverviewDesign Overview
ATS99-016
Mercury 50 LayoutCenter Frame
Mercury 50 LayoutCenter Frame
RECUPERATOR
TURBINE
COMBUSTOR
COMPRESSOR
ATS99-019
Mercury 50 LayoutCombustor ModuleMercury 50 LayoutCombustor Module
8 ULP Injectors
Augmented Backside-Cooled(ABC) Combustor Liner
Closed-Loop CO Control
Compensating Geometry Design
Flexible Design- Accommodates Either UltraLean-Premixed (ULP) orCatalytic Combustion
Extension of SoLoNOxTechnology
ATS99-020
Mercury 50 LayoutTurbine Module
Mercury 50 LayoutTurbine Module
Vortex-Cooled Leading EdgeCooling Circuit
Film / Impingement Cooled
Unshrouded; Highly Loaded
Shrouded Blade Design
Nominal Stage Loading
Uncooled Uncooled 2nd-Stage Bladed Disk2nd-Stage Bladed Disk
2nd-Stage Design, 2125°F TRIT 2nd-Stage Design, 2125°F TRIT 1st-Stage Bladed Disk1st-Stage Bladed Disk
ATS99-021
Mercury 50 LayoutACE Compressor Module
Mercury 50 LayoutACE Compressor Module
Variable Geometry ControlVariable Geometry Control
10-Stage Axial Design
9.1 Pressure Ratio
3-D Wide Chord Airfoils
40% Reduction in Blade Count
ATS99-022
ATS Mercury 50 AccomplishmentsATS Mercury 50 Accomplishments
Commissioned Dedicated Mercury50 Development and ProductionTest Cells
Completed 1st Round ofDevelopment Testing on Engines#1 & #2
Completed On-site PackageServiceability and Installation“Kaizen” Review
Created Significant CommercialInterest in ATS Product
Built, Tested and Shipped FirstCommercial Unit on Schedule
A T S 9 9 - 0 2 4
• All Bearings in ExcellentCondition
• Thrust Bearing Like New
• Skidding Non-Existent
• No Pitt ing or Contamination
Rolling Element BearingsRolling Element Bearings
ATS99-030
Blade Z-NotchInterlock
Blade Removal
2nd Turbine Disk Assembly2nd Turbine Disk Assembly
Shrouded Blade Design
Shroud “Z-Notch” InterlockFunctioning per Design Intent
No FPI Indications at Attachments
ATS99-031
Mercury 50 Development Test SummaryMercury 50 Development Test Summary
Over 700 Hours of Test2 Phases, 4 Engines, 5 Builds300+ Start Cycles
Critical New Content FunctioningAs Designed
Mercury-50 Test Program
0
100
200
300
400
500
600
700
800
900
SN001/1 SN002/1 SN002/2 SN003/2 SN004/1
Test Engine
Ho
urs
on
Te
st
Emissions: Exceeding Goal inTest Cell
Engine Performance on Plan
ATS99-032
Mercury 50 Package MaintainabilityKaizen Demonstration
Mercury 50 Package MaintainabilityKaizen Demonstration
• Service/ Maintenance/ Safety Audit
• Review Assembly/ Installation Plans
• Evaluate Field Tooling
ATS99-044
Engine #1 Modular Disassembly Engine #1 Modular Disassembly
CompressorModule
Combustor and Turbine ModulesCombustor and Turbine Modules
My Jacket
ATS99-065
Opportunity in Current Energy MarketOpportunity in Current Energy Market
• ENERGY USERS –Requirement forCompetitive andReliable Electricity
• ENERGY PROVIDERS –Need to Optimize Profits onEnergy Sales, Whether Gasor Electricity, While DeliveringCompetitive and Reliable Energy
ATS99-074
Broad Appeal in Diverse ApplicationsBroad Appeal in Diverse Applications
• Small Utility Base Load
• Grid Support
• On-Site Generation
• Remote Power
• CHP / Cogeneration
ATS99-075
Initial Customer InstallationsInitial Customer Installations
Phosphate MineQueensland,Australia
San Diego, Cal1. Manufacturer2. Hospital
ESCOLaredo, TX
Municipal UtilityChicago, Il
UniversityS. Carolina
Rural UtilityColorado
ATS99-076
Ray Schwartz Ray Schwartz Rochelle Municipal Utilities
Ray Schwartz Ray Schwartz Rochelle Municipal Utilities
ATS99-079
972228-006
City of Rochelle, IllinoisCity of Rochelle, Illinois
• Located in North Central Illinois
• Intersection of I-39 and I-88
• Intersection of BNSF and UP - 120 Trains/Day
• Population at 10,000 and Growing
ATS99-080
Rochelle Industrial BaseRochelle Industrial Base
972228-008
• Food Processing and Distribution Center- Rochelle Foods (Hormel) Food Processing- Kraft Foods Food Processing- Erie Foods International Food Processing- Del Monte Corp Canned Food Distribution Center- Total Logistics Control Frozen Food Distribution Center- Americold Frozen Food Distribution Center
• Other Industries- Eaton Corporation Electrical Parts- Silgan Container Corp Can Manufacturing
Growth from 19 to 38 Industries in 6 YearsGrowth from 19 to 38 Industries in 6 Years
ATS99-081
Physical ProfilePhysical Profile
• Service Area 100 Square Mile - Municipal and Rural
• Population - 18,000
• Surrounded by Commonwealth Edison
• Power Generation at Three Locations- Diesel Plant 20.0 MW from 10 Oil/Gas-Fired Diesel Units- Cogen Plant 11.5 MW from Steam Turbine Generator- Peaker Plant 5.0 MW from 2 Oil/Gas-Fired Diesel Units
• Dual 138KV Transmission Connections to Com-Ed Grid
• Two 138/13.8KV Substations
ATS99-082
Power SupplyPower Supply
• Purchase 95 to 98% of Power Wholesale- Several Varying Blocks of Firm/Interruptible Power- Hourly Interruptible Power for Load Following
• Generation Assets - Current Function- Economic Dispatch (Market Hourly vs In-House Cost)- Firm Up Interruptible Power- Sales to Wholesale Market- Emergency Back-up
• Total Output 1998: 180,000,000 kW-hr
ATS99-083
Annual Load Duration CurvesAnnual Load Duration Curves
40
35
30
25
20
15
100 1000 3000 5000 7000 9000
TIME SPENT AT/ABOVE LOAD, HOURS
LO
AD
,
MW
ATS99-084
Why Distributed Generation?Why Distributed Generation?
• Places Capacity Nearer Load
• Reduces Impact of Transmission Curtailments
• Age of In-House Generation Assets
• Cost of Service
ATS99-085
Why the Mercury 50?Why the Mercury 50?
• Operational Flexibility- Base Loading for Hedge Against Supply Interruptions- Intermediate Loading for Economic Dispatch- Peak Loading for Load Following and Economic Dispatch
• Multiple Location Potential- Commercial / Industrial Sites- Existing Cogen Plant- Existing Diesel Plant- Sub-Stations
• Low Environmental Impact
• Competitive Operating Costs
ATS99-086
Mercury 50 / Rochelle Site LayoutMercury 50 / Rochelle Site Layout
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
CARON ROAD (30’-0’ ASPHALT)
EXISTING FENCE
OE OE OE OE OE OE OE OE OE OE OE OE OE OE OE OE OE OE
EXISTING OVERHEAD ELECTRICAL
FUEL GAS SKID CONTROL ROOM
SERVICE AREA
SERVICEAREA
PARKING LOT
LUBE OILCOOLER
EMISSIONSMONTIORNGTRAILER
EXISTINGSTEAMPLANT
BUILDING
NEWROAD
NEWACCESSGATE
GENERATOR SET
ATS99-087
Mercury 50 / Rochelle InterfaceMercury 50 / Rochelle Interface
• Direct Connection to 13.8KV System
• Unmanned Site
• Remote Start/Stop
• Fiber Optic Connection to SCADA
ATS99-090
Rochelle FutureRochelle Future
• Continued Steady Growth
• Intermodal Facility Strong Possibility
• Distributed Generation Role- Essential Element of Generation Fleet- Replacement for Existing Central Plant- Siting on Customer Premises Anticipated- Cogeneration Applications- Enhance Rochelle’s Competitive Edge
ATS99-091
SummarySummary
• Initial Development Activities Are Complete• Exceeded Original ATS Program Goals
−Only Durability Remains to Be Proven
• Field Evaluation Units Being Built and Shipped• Continue Further Refinements to Achieve Stretch Goals• Generated Significant Market Interest in ATS Product
Mercury 50 on Track for Full-Production Release in 2000Mercury 50 on Track for Full-Production Release in 2000
Clear Commitment to CommercializeClear Commitment to Commercialize
ATS99-092