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Unrestricted © Siemens Energy Inc. 2016 All rights reserved. http://siemens.com/energy/power-generation/gas-turbines

“Ceramic Matrix Composite AdvancedTransition for 65% Combined Cycle Efficiency”DE-FE0023955

UTSR 2016 Conference

01-Nov- 2016

Unrestricted © Siemens Energy Inc. 2016 All rights reserved.

Jonathan Shipper / Siemens Energy Inc.CMC Advanced Transition

CMC Advanced Transition for η > 65% CCProgram Overview

Content of Today’s Presentation

CMC Technology Development33

22

11 Towards a 65% CC efficient power plant

Proposed CMC AT for high TIT / Low NOx

Conclusions & Next Steps44

01-Nov- 2016



Towards a 65% CC system

SGT6-8000HSGT6-5000F

SGT6-2000E

SGT6-6000G

DOE targets are driving a step change in GT combustion technology

DOE FOA:R&D complete by 2020

with deployment by 2025

Silocombustor

ULNCombustor

Next GenCombustor

* 60Hz Demonstrated Commercial operation

01-Nov- 2016



Towards a 65% CC system

4

65% CC efficiency targets Firing Temperature > 1700ºC

Source: Ibrahim et. al (2012)

Brayton Cycle

• Plant output and efficiencyimproved by raising the top ofthe cycle

• i.e. Higher firingtemperature and pressure.

Rankine Cycle• Plant output and efficiency

improved with betterutilization of GT Exhaustenergy.

• i.e. Higher bottoming steamtemperature and pressure.

Brayton Cycle Rankine Cycle

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Combustion Technology “jumps” are required to shift NOx curve right

Siemens Solution to Program Challenge:Combustion Development

w/diluent

65% CCtargetcurve

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Parallel Combustion approaches for NOx reduction


65% CCtargetcurvew/diluent

Enablers:• Increase premixing quality• Decrease residence time• Diluents

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• Focus of this program is on Cooling & Leakage Air Reduction for Low NOx• Lower required flame temperature for a given TIT⇓ Reduced NOx


Original65% CCtargetcurve

New65% CCtargetcurve

Enablers:• Reduced Cooling &

Leakage Air

01-Nov- 2016



Enablers: Advanced Transitions (AT)

Advanced Transition (AT) ⇓Reduced Cooling air consumption

AHE + AT

• Developed during DOE-H2program (DE-FC26-05NT42644)

• Allows for reduction ofcooling air

• Low NOx at J-classconditions

• System residence time notoptimized for 65% CCoperating conditions

AdvancedTransition (AT)

01-Nov- 2016



Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencyIntroduction

ƒ Objective:ƒ Phase 2: Design a CMC inlet for

Siemens Advanced Transition

ƒ Benefits:ƒ Reduction in Cooling Air⇓ NOx

reduction or RIT increaseƒ CO reduction (eliminate wall quenching)ƒ Reduced aero losses

• Due to cooling air mixing• Due to cooling air ducting

ƒ Premise:ƒ Existing Siemens’ CMC materialƒ No through-wall cooling (backside only)ƒ Shape conducive to CMC manufactureƒ Durability demonstrated in 25K hr testƒ Readily tested in combustor rigs

Concept schematic

Experience base

01-Nov- 2016



Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencyBenefits: Cooling Air Reduction

⇓ NOx emissions reduction at High Firing Temperatures

CMCInlet

CMC Inlet& Exit

01-Nov- 2016



Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencySiemens’ Hybrid CMC Technology

>

Reduction in coolingvs. TBC/metal

Increased surfacetemperature limit

01-Nov- 2016



Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencyCMC Technology Status

Combining two high pay-off technologies individually developed & tested

Siemens’AdvancedTransitionBlade Tip

Seals enginetested

Airfoils demonstratedin rig testing

+

01-Nov- 2016



Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencyCMC Component Testing Summary

ƒ Bench testingƒ Mechanical, thermal, fatigue,

impact, etc.

ƒ Rig testingƒ Simulated engine conditionsƒ Durability under combined

loadingsƒ Subscale & Full Scale

components

ƒ Engine testingƒ Customer site / durabilityƒ BTF engine

Ring segments (4 types), airfoils, subelements

Combustors, Airfoils, Ring segments (4 types)

Combustor Ring Segment

01-Nov- 2016



ƒ Siemens Hybrid Oxide CMCsystem (FGI thermal barrier)

ƒ Filament wound combustorouter liner (made by COIC)

ƒ Operated in Solar Centaur 50™engine.ƒ 25,404 hours / 109 cycles;ƒ Bakersfield, CAƒ Still serviceable

ƒ Surface & CMC temperaturesrepresentative of AT inlet

This test demonstrated CMC durability in a turbine engineenvironment for representative component lifetime

Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencyHybrid Oxide CMC Combustor Liner

01-Nov- 2016



Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencyCMC Manufacturing Options

Fabric Lay-up Vs. Filament Winding

• Both manufacturing approaches are feasible for most AT inlet concepts• Concepts with out-of-plane features more conducive to fabric lay-up

01-Nov- 2016



Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencyCMC Ring Segment Engine Test

Features:

Reduced Cooling from metalbaseline design

Tip seal improvement features

Retrofittable design

High temperature sealing

Full engine set: Tested successfully for > 50 hours

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Siemens Project Team

Siemens has assembled a multi-disciplinary team of internal experts andexternal vendors and partners to successfully execute this program.

01-Nov- 2016



Schedule & Major Milestones

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Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencyTechnology Development

PHASE 2Technology Development & Testing

PHASE 1Concept Feasibility

PHASE 3Technology Demonstration

Conceptual Design

Manufacture & Combustor Rig Testing

Engine Testing

Technology Progression for Future Phases identified

01-Nov- 2016



Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencyCMC AT Concept Down-selection Process

49

9Milestone Sept 2015⇓ Two Concepts

Structural CMC’s Heat Shields

5

01-Nov- 2016



Two Cooling Options:1. Shell air circulation⇓ feasibility shown with 1D heat transfer2. Radiation cooling⇓ used on Solar combustor liner design

Both eliminate active (chargable) cooling

Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencyHeat Transfer⇓ CMC with backside cooling

Shell Air Circulation Radiation Cooling

Radiation cooling method proven effective inprevious combustion testsInsulating characteristic of Hybrid Oxide CMC

enables use of low cooling coefficients(similar to levels in engine midframe)

01-Nov- 2016



Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencySupporting CMC Data & Remaining Challenges

Coupon Test Data Damage Accumulation & Life Prediction Tools

Remaining Design / Materials Challenges• Sealing methods for high temperature

• Metal-to-CMC Interfaces:• Wear resistance (anti-wear coatings)• Contact stresses / inserts / compliant layers

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Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencyMicromechanics Modeling (MAC/GMC)

• Model calibrated and matches test data• Works interactively with FEA

• Constitutive model (fiber & matrix properties)• Iteratively best-fit to a series of test data (different geometries)• Matches stress-strain behavior of simple (uniaxial) and complex shape (multiaxial stress)

test data

Stre

ss

Strain

01-Nov- 2016



Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencyCMC Structures and Numerical Modeling

Bi-Directional DesignOptimization

Hi-Fidelity DamageSimulation

• Advanced Simulation Methods Calibrated to Lab and Sub ComponentTesting to Provide Accurate and Robust Design Rules.

Solid Mesh

NXR CAD

Workbench

ANSYS ACP

Production Layup

FE BestPractices

ConstitutiveModels &

FailureCriteria

01-Nov- 2016



Objective:Simulate TBC failure under pseudo enginecondition (high heat flux, backside cooling)

Application of HHFT:• Down select coating• Characterize CMC/Coating system behavior

TBC Testing

Monitor hot sidetemperature

Monitor cold sidetemperature

TBC coated sample

Heat input(Flame or laser)

01-Nov- 2016



Combustor Rig Testing

Siemens Clean Energy CentreAdvanced Transition test rig

CMC Advanced Transition Inlet section will be tested in this dedicated rigfacility (full scale; full pressure; full flow; full temperature)

01-Nov- 2016



Acknowledgements

• This work is performed under US Department of Energy Award Number DE-FE0023955.

• This program is based upon prior work supported by the US Department of Energy,under Award Number DE-FC26-05NT42644.

• The Siemens team wishes to thank Dr. Seth Lawson, NETL Project Manager and Mr.Rich Dennis, NETL Turbine Technology Manager for the opportunity to collaborate on thedevelopment of these novel technologies.

&

01-Nov- 2016



Answers for Energy.

Thank You. Questions?

Jay MorrisonProgram Manager - Ceramic Matrix CompositeAdvanced Transition for 65% Combined CycleEfficiency

Siemens Energy Inc.4400 Alafaya TrailOrlando, FL 32826Phone: +1 (407) 736-2000

E-mail:[email protected]

01-Nov- 2016



Hybrid Ox-Ox CMC RationaleReference ASME GT 2007-27532

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