Combustion Instabilities in Gas Turbine Engines (Progress in Astronautics and Aeronautics) PDF
Preview Combustion Instabilities in Gas Turbine Engines (Progress in Astronautics and Aeronautics)
Combustion Instabilities in Gas Turbine Engines: Operational Experience, Fundamental Mechanisms, and Modeling Editedby TimothyC.Lieuwen SchoolofAerospaceEngineering GeorgiaInstituteofTechnology Atlanta,Georgia VigorYang DepartmentofMechanicalEngineering ThePennsylvaniaStateUniversity UniversityPark,Pennsylvania Volume 210 PROGRESS IN ASTRONAUTICS AND AERONAUTICS FrankK.Lu,Editor-in-Chief UniversityofTexasatArlington Arlington,Texas Publishedbythe AmericanInstituteofAeronauticsandAstronautics,Inc. 1801AlexanderBellDrive,Reston,VA20191-4344 Copyright(cid:1)C 2005bytheAmericanInstituteofAeronauticsandAstronautics,Inc.Printed intheUnitedStatesofAmerica.Allrightsreserved.Reproductionortranslationofanypart ofthisworkbeyondthatpermittedbysubsections107and108oftheU.S.CopyrightLaw withoutthepermissionofthecopyrightownerisunlawful.Thecodefollowingthisstatement indicatesthecopyrightowner’sconsentthatcopiesofarticlesinthisvolumemaybemade forpersonalorinternaluse,onconditionthatthecopierpaytheper-copyfee($2.00)plusthe per-pagefee($0.50)throughtheCopyrightClearanceCenter,Inc.,222RosewoodDrive, Danvers, Massachusetts 01923. This consent does not extend to other kinds of copying, forwhichpermissionrequestsshouldbeaddressedtothepublisher.Usersshouldemploy thefollowingcodewhenreportingcopyingfromthisvolumetotheCopyrightClearance Center: 1-56347-669-X/05 $2.50+.50 Dataandinformationappearinginthisbookareforinformationalpurposesonly.AIAAis notresponsibleforanyinjuryordamageresultingfromuseorreliance,nordoesAIAA warrantthatuseorreliancewillbefreefromprivatelyownedrights. ISBN1-56347-669-X ProgressinAstronauticsandAeronautics Editor-in-Chief FrankK.Lu UniversityofTexasatArlington EditorialBoard DavidA.Bearden RichardC.Lind TheAerospaceCorporation UniversityofFlorida JohnD.Binder RichardM.Lloyd viaSolutions RaytheonElectronicsCompany StevenA.Brandt AhmedK.Noor U.S.AirForceAcademy NASALangleyResearchCenter FredR.DeJarnette AlbertC.Piccirillo NorthCarolinaStateUniversity InstituteforDefenseAnalyses PhilipD.Hattis BenT.Zinn CharlesStarkDraperLaboratory GeorgiaInstituteofTechnology AbdollahKhodadoust PeterH.Zipfel TheBoeingCompany AirForceResearchLaboratory Preface Gasturbineshavemadesubstantialgainsinperformancesincetheirinitialdemon- strationinjetpoweredaircraftandpowerturbines.Theperformance,noisechar- acteristics, and pollutant emissions of gas turbines for propulsive applications continue to improve. On the ground, contemporary gas turbines produce higher operatingefficienciesandemitfewerpollutantsthanothermajorchemical-energy conversiondevices.Inaddition,thelowcapitalinvestment,easeofpermitting,and quickinstallationhavemadethemattractivetoinvestors.Asaresult,gasturbines have become a dominant technology for new power generating capacity in the UnitedStatesandworldwide. Avarietyoffactorshavecontributedtothepopularityofgasturbinetechnology. Financing considerations are the key high-level driver. Pollutant emissions play anotherimportantrole,particularlyinmotivatingthespecifictechnologyimprove- mentsandinnovationsoverthelastdecade.Forexample,intheUnitedStates,the Clean Air Act Amendments of 1990 imposed strict guidelines on the control of nitrogenoxides,NOx,which,alongwithSO ,isamajorcontributortoacidrain 2 Thisbookfocusesonaparticularlyseriousdifficultyinlowemissionsgastur- bines: combustion-driven oscillations. These instabilities routinely constrain the operatingenvelopeandpoweroutputoffieldedmachinesand,insomecases,leadto seriousdamageofhotsectioncomponents.Gasturbineusershavefoundthatcom- ponentssuchascombustorliners,transitionpieces,andfuelnozzlesneedroutine examinationforpartcrackingorexcessivewearingbecauseofvibration-induced fretting. At a minimum, this requires downtime for inspections and part repair, therebyreducingmachineavailability.Attheworst,acrackedpiecemaybeliber- atedintothehotgaspath,potentiallyrequiringreplacementofexpensiveturbine components.Inaddition,usersincertaingeographicareashavefoundthatengines must be seasonally retuned to eliminate oscillations due to ambient temperature changes.Thecostfortherepairandreplacementofhotsectioncomponents,much of which is directly attributable to the combustion instability problem, exceeds $1billionannuallyandconstitutesupto70%ofthenonfuelcostsofF-classgas turbines.Majorpowergeneratingcompanieshavesufferedlossesinthehundreds ofmillionsofdollarsbecauseoflostrevenuefromforcedoutages,resultingina numberoflawsuits. Althoughinstabilitieshavenotbeennearlyassevereaprobleminnonpremixed aero engine combustors, they have appeared in a few cases and posed serious challengesinthedevelopmentstage.Militaryengines,however,haveexperienced majorproblemswithlow-frequencyinstabilitiesinaugmentors.Alarge-scaleef- fortiscurrentlyunderwayatseveralgasturbinemanufacturersintheUnitedStates, incooperationwiththeU.S.AirForce,toovercomesuchdifficulties. Over the last decade, substantial efforts have been expended in the industrial, government,andacademiccommunitiestounderstandtheuniqueissuesassociated withcombustioninstabilitiesinlow-emissionsgasturbines.Theobjectiveofthis book is to compile these results into a series of chapters that address various xiii xiv PREFACE facets of the problem. In planning this volume, it was decided to include a few comprehensive chapters, rather than a large number of more narrowly focused contributions.Assuch,itwasnotpossibletosolicitarticlesfromeverycontributor tothefield,althoughitiscertainlyourhopethatallrelevantworksareappropriately representedinthebook. Following the overview, the book is organized into four basic sections: The CaseStudiessectioncompileschaptersfromgasturbinemanufacturersandusers that detail specific experiences with combustion instabilities in the development stageandinfieldedturbineengines.Thesechaptersdescribethebasicinstability mitigationapproachesthatweredevelopedandthetradeoffsencounteredbetween instabilitiesandotherperformancemetrics,suchasNOxemissions.TheFunda- mental Processes and Mechanisms section addresses the basic phenomenology ofcombustioninstabilitiesinpremixedandnonpremixedcombustors,themech- anismsthroughwhichunsteadyheatreleaseprocessesmaybecomeself-excited, andmeasurementtechniquesforcharacterizingthem.Next,theModelingandDi- agnosticssectiondescribesanalyticalandcomputationalapproachestomodelthe complexacousticcharacteristicsofcombustorgeometriesandtheinteractionsbe- tweenflamesandacousticwaves.Finally,theCombustionInstabilityandControl sectionaddressesactiveandpassivecontrolofcombustioninstabilities,including anindustryperspectiveintoapproachesforincorporatinginstabilityconsiderations intothedesignprocess. Publication of this volume was made possible through the substantial contri- butions of a number of individuals. We would like to first thank the authors for sharingtheirtimeandtalentinpreparingtheirmanuscriptsandcarefullyrevising them.TheinvaluableassistanceofRodgerWilliams,HeatherBrennan,andJanice SayloroftheAIAAinthepreparationofthevolumeforpublicationisgratefully acknowledged. Last, but by no means least, we wish to thank Danning You and YanxingWangforprovidingthetechnicaldrawingservices. TimothyC.Lieuwen VigorYang July2005 TableofContents Preface .................................................................. xiii I. Overview Chapter1. CombustionInstabilities:BasicConcepts ................. 3 BenT.ZinnandTimothyC.Lieuwen,GeorgiaInstituteofTechnology, Atlanta,Georgia Introduction .......................................................... 3 HistoricalOverview ................................................... 5 CausesofInstabilities ................................................. 8 GrowthandSaturationofInstabilities ................................... 16 Conclusion ........................................................... 22 References ........................................................... 24 II. CaseStudies Chapter2. CombustionInstabilitiesinIndustrialGasTurbines: SolarTurbines’Experience........................................... 29 KennethO.SmithandJamesBlust,SolarTurbines,Inc., SanDiego,California Introduction .......................................................... 29 LeanPremixedCombustionSystemConfigurationsand OperatingConditions ................................................ 30 CommercialIntroductionat42ppmvNOx ............................... 33 EmissionsReductionto25ppmvNOx .................................. 35 CombustorPressureOscillationModel .................................. 37 CentaurCPOReduction ............................................... 37 MarsCPOReduction .................................................. 38 RecentExperience .................................................... 40 Conclusion:NeedsandFutureChallenges ............................... 40 References ........................................................... 41 vii viii Chapter3. IncorporationofCombustionInstabilityIssuesinto DesignProcess:GEAeroderivativeandAeroEnginesExperience... 43 H.C.Mongia,T.J.Held,G.C.Hsiao,andR.P.Pandalai,GETransportation, Cincinnati,Ohio Introduction .......................................................... 43 FundamentalCausesofCombustionDynamics ........................... 45 ControlStrategies ..................................................... 45 ExamplesofCombustionDynamics ..................................... 46 Combustion–AcousticModeling ........................................ 51 AcousticModelingResults ............................................. 57 Conclusion ........................................................... 61 References ........................................................... 61 Chapter4. CombustionInstabilityandItsPassiveControl: Rolls-RoyceAeroderivativeEngineExperience ...................... 65 TomasScarinci,Rolls-RoyceCanada,Quebec,Canada OverviewoftheTrent60Aeroderivative ................................. 66 OscillatoryCombustionintheTrent60DLE ............................. 68 CombustionSystemDesignModifications ............................... 87 Acknowledgments ..................................................... 87 References ........................................................... 88 Chapter5. ThermoacousticDesignToolsandPassiveControl: SiemensPowerGenerationApproaches .............................. 89 WernerKrebs,SvenBethke,JoachimLepers,PatrickFlohr,andBerndPrade, Siemens AG, Mu¨lheim, Germany and Cliff Johnson and Stan Sattinger, SiemensAG,Orlando,Florida Introduction .......................................................... 89 SiemensGas-TurbineProducts ......................................... 89 PhenomenologicalDescription .......................................... 90 SolutionMethods ..................................................... 93 Application .......................................................... 100 Conclusion ........................................................... 110 References ........................................................... 111 Chapter6. CharacterizationandControlofAeroengineCombustion Instability:Pratt&WhitneyandNASAExperience ................. 113 JeffreyM.CohenandWilliamProscia,Pratt&Whitney,EastHartford, ConnecticutandJohnDeLaat,NASAGlennResearchCenter, Cleveland,Ohio Introduction .......................................................... 113 EngineCombustionInstability .......................................... 115 EngineAcousticAnalysis .............................................. 116 FuelInjector–AirSwirlerDynamicResponse ............................. 118 SubscaleCombustorExperiment ........................................ 127 ix Active-ControlDemonstration .......................................... 135 Conclusion ........................................................... 143 Acknowledgments ..................................................... 144 References ........................................................... 144 Chapter7. MonitoringofCombustionInstabilities: Calpine’sExperience.................................................. 147 JesseB.SewellandPeterA.Sobieski,CalpineTurbineMaintenanceGroup, Pasadena,Texas Introduction .......................................................... 147 Combustion-DynamicsMonitoringSystem ............................... 148 GeneralInstabilityCharacteristicsandTuningConsiderations .............. 151 DetrimentalImpactsofCombustionDynamics ........................... 153 CDMforCombustorHealthMonitoring:CaseStudies .................... 154 References ........................................................... 162 Chapter8. MonitoringCombustionInstabilities:E.ON UK’sExperience ...................................................... 163 CatherineJ.Goy,StuartR.JamesandSuzanneRea,E.ONUK,England, Nottingham,UnitedKingdom Introduction .......................................................... 163 WhyMonitorCombustionDynamics? ................................... 163 DescriptionoftheOn-LineCombustion-MonitoringSystem ............... 164 BenefitsofCombustion-DynamicsMonitoring ........................... 165 CaseStudies .......................................................... 166 ImpactofAmbientConditionsonDynamicResponse ..................... 166 ImpactofOperatingRegimeonDynamicResponse ....................... 167 CombustionLinerFailure .............................................. 168 BurnerAssemblyFailure ............................................... 171 Conclusion ........................................................... 175 References ........................................................... 175 III. FundamentalProcessesandMechanisms Chapter9. CombustionInstabilityMechanismsin PremixedCombustors ................................................ 179 Se´bastien Ducruix, Thierry Schuller, Daniel Durox, and Se´bastien Candel, CNRSandEcoleCentraleParis,Chaˆtenay-Malabry,France Introduction .......................................................... 179 AcousticsforReactingFlows ........................................... 183 HeatReleaseasaPressureSource ....................................... 187 Heat-ReleaseFluctuationsDrivenbyWaves .............................. 197 Conclusion ........................................................... 206 References ........................................................... 207 x Chapter10. FlowandFlameDynamicsofLeanPremixed SwirlInjectors ........................................................ 213 YingHuang,ShanwuWang,andVigorYang,PennsylvaniaStateUniversity, UniversityPark,Pennsylvania Introduction .......................................................... 213 ColdFlowCharacteristicsofSwirlInjectors .............................. 216 FlameDynamicsofAxial-EntrySwirlInjector ........................... 250 Conclusion ........................................................... 269 Acknowledgments ..................................................... 270 References ........................................................... 270 Chapter11. Acoustic-Vortex-FlameInteractionsinGasTurbines.... 277 SureshMenon,GeorgiaInstituteofTechnology,Atlanta,Georgia Introduction .......................................................... 277 LengthandTimeScales ................................................ 278 TheoreticalConsiderations ............................................. 280 FactorsAffectingAVFInteractions ...................................... 287 Conclusion ........................................................... 310 Acknowledgments ..................................................... 310 References ........................................................... 310 Chapter12. PhysicsofPremixedCombustion-Acoustic WaveInteractions..................................................... 315 TimothyC.Lieuwen,GeorgiaInstituteofTechnology,Atlanta,Georgia Introduction .......................................................... 317 Background .......................................................... 318 Heat-ReleaseResponsetoFlowandMixturePerturbations ................ 323 Conclusion ........................................................... 361 Acknowledgments ..................................................... 362 References ........................................................... 362 IV. ModelingandDiagnostics Chapter13. AcousticAnalysisofGas-TurbineCombustors........... 369 AnnP.DowlingandSimonR.Stow,UniversityofCambridge,Cambridge, England,UnitedKingdom Introduction .......................................................... 369 LinearizedEquationsofMotion ......................................... 371 One-DimensionalDisturbances ......................................... 374 ModalSolutions ...................................................... 389 ApplicationtoGas-TurbineCombustors ................................. 394 ModalCoupling ....................................................... 401 AcousticAbsorbers .................................................... 403 xi Limit-CyclePrediction ................................................. 406 Conclusion ........................................................... 409 Appendix:DerivationofEq.(13.41) ..................................... 410 References ........................................................... 411 Chapter14. Three-DimensionalLinearStabilityAnalysisofGas TurbineCombustionDynamics....................................... 415 DanningYou,VigorYang,andXiaofengSun,PennsylvaniaStateUniversity, UniversityPark,Pennsylvania Introduction .......................................................... 417 TheoreticalFormulation ............................................... 418 SolutionProcedure .................................................... 433 SampleStudies ....................................................... 433 Conclusion ........................................................... 442 Acknowledgments ..................................................... 442 References ........................................................... 442 Chapter15. ImplementationofInstabilityPredictioninDesign: ALSTOMApproaches ................................................ 445 ChristianOliverPaschereit,Hermann-Fo¨ttinger-Institute,Berlin UniversityofTechnology,Berlin,GermanyandBrunoSchuermans,Valter Bellucci,andPeterFlohr,ALSTOMPowerLtd,Baden,Switzerland Introduction .......................................................... 445 NetworkRepresentationofThermoacousticSystems ...................... 447 ExperimentalDeterminationofTransferMatricesandSourceTerms ........ 449 ModelingtheBurnerTransferMatrix .................................... 454 Reduced-OrderModelingofComplexThermoacousticSystems ............ 461 ApplicationtoaGas-TurbineCombustor ................................ 475 Conclusion ........................................................... 478 References ........................................................... 479 Chapter16. ExperimentalDiagnosticsofCombustionInstabilities... 481 JongGuenLeeandDomenicA.Santavicca,PennsylvaniaState University,UniversityPark,Pennsylvania Introduction .......................................................... 481 PressureMeasurements ................................................ 482 ChemiluminescenceMeasurements ..................................... 485 Infrared-AbsorptionMeasurements ...................................... 500 Laser-InducedFluorescenceMeasurements .............................. 506 LaserMieScattering .................................................. 517 PhaseDopplerParticleAnalysis ........................................ 521 Conclusion ........................................................... 522 Acknowledgments ..................................................... 524 References ........................................................... 524
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