Introduction of

the Solar Turbines

Titan 250
Gas Turbine System
Design, Development and Validation Testing
a New 22.4 MW Gas Turbine

VGB Fachtagung Ulrich Stang

24-JUN-2009 Manager
Mannheim, Germany Turbine Aerodynamics
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 Solar Turbines

Solar Turbines Inc.

• History
• Founded in 1927 As Prudden Airplane Company
• Full Transition to Industrial Gas Turbines in 1970’s
• Caterpillar Subsidiary Since 1981
• 6000 Employees in 96 Countries Worldwide
• Products
• Over 12,500 Units Installed Worldwide (3100 in EAME)
• Over 5,900 Compressor Sets and Mechanical Drive Units
• More than 1.2 Billion Operating Hours (350 Million in EAME)
• Titan 250 Timeline
• Program Kick-Off - 2004
• Hardware Delivered - 2008
• New Test Cell Commissioned - 2008
• First Light-Off – 2008
• Customer Delivery - 2009

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 Pedigree

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 Overall Performance

Parameter CS/MD GS
SYSTEM DESIGN GOALS
Power Output 22,400 kW 21,745 kWe
• Highest-Efficiency Gas Turbine in Class
Heat Rate 8993 kJ/kW-hr 9259 kJ/kW-hr
• Design for Long-Life Industrial Applications
• Common Modular Design Throughout Efficiency 40.0% (shaft)
38.9%
(generator)
• Minimum Package Footprint
• Advanced Aerodynamics, Optimized Cooling Exhaust Flow 245664 kg/hr

• High Availability, Maximum Life-Cycle Benefits Exhaust Temperature 463 °C

• Wide Application Range for Compressors
Pressure Ratio 24:1
• Packaged Generator Set for High Efficiency
• Simple Cycle and Heat Recovery Installations Power Turbine Speed
6,300 rpm (optimum)
7,000 rpm (maximum)

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 Titan 250 General Arrangement

16-STAGE 2-STAGE
ACE COMPRESSOR GAS PRODUCER TURBINE

DRY LOW EMISSIONS 3-STAGE POWER TURBINE

(DLE) COMBUSTOR ALL-SHROUDED BLADES

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 Titan 250 Features
Compressor

Variable
Geometry Vanes
COMPRESSOR FEATURES
PERFORMANCE
• “Clean Sheet” Design
• 16-Stages of High-Efficiency Aerodynamics
• 2 Stages More Than Titan 130
• Built on Taurus 65 Success
• 6 Stages of Variable Guide Vanes COMPRESSOR (IGV-EGV)
• Optimized Airflow For Full Operating Range • N = 10500 RPM
• Sets New Standard for Compressor Efficiency • W = 67.7 kg/s
• PR = 24:1
• Within Experience Base
• Unsurpassed Attention to Detail INLET DIFFUSER
• Multi-Stage CFD Code • Δp/p = .75% • Δp/p = 1.6%
• Blockage < 1.5% • Cp > .70
• Validated by Rig Testing • Minimum Distortion • Ma < .10
• Mercury 50, Centaur 50 and Taurus 65 • α = +/- 3.0 deg
• Optimized for Wide Range of Operation
• Low-Loss, Minimum Distortion Inlet
• Compressor- Discharge and Inter-Stage Bleed

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 Titan 250 Features
Compressor

COMPRESSOR FEATURES
DURABILITY
• Welded Drum Design for Rigidity, Long Life
• Modular Annular Design
• Bearing Support Optimized - Rotor Dynamics
• Extensive Vibration Analyses
• Latest Variable Guide Vane Bushing Design
• Based on In-House Corrosion Testing
• Prevent Lock-up in Field
MAINTAINABILITY
• Designed for Long Life and Maintainability
• Anti-Corrosion Aluminide Coating (Stages 1-12)
• In-Situ Two-Plane Trim Balancing
• All Airfoils Individually Field Replaceable
• 4-Piece Compressor Case (Mars, Titan 130)

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 Titan 250 Features
Combustor

COMBUSTOR FEATURES
PERFORMANCE
• Proven SoLoNOx Technology
• Canted Diffuser for Optimized Airflow
• Optimized Outer Dome For Good Swirler Flow
• Extensive CFD Used to Design
• Diffuser
• Liner
• Injector
• Emissions (NOx/CO/UHC) ppm CFD Predictions of Internal Flow field

• Natural Gas: 15/25/10

• Liquid Fuel: 60/30/15
• Associated Gas (900–1600 WI) / 25/50/10
• Operating Range
• 40 thru 100% Load
• –29°C to 49°C (Gas/Liquid)

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 Titan 250 Features
Combustor

Main Primary
COMBUSTOR FEATURES Fuel Stem

Main Secondary
DURABILITY Fuel Stem
• Modular Annular Design
• Augmented Backside Cooled (ABC) Liner
• Simple Supported Pins
• Reduce Dome Stress
• Independently controlled fuel flows
• Main Primary, Main Secondary, Pilot Bullet Nose
Heat Shield
• Extensive Experience with HAST-X Material
• Modal Frequencies Per Design Criteria
Pilot Fuel Stem
• Injector Barrel Features Helmholtz Resonator
• Oscillation Abatement
MAINTAINABILITY
• Designed for Long Life and Maintainability
•14 Radial-Inflow Injectors – Offset Stems
• Proven Taurus 65 Experience
• Easy Installation
• Field Replaceable and Repairable

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 Titan 250 Features
Gas Producer Turbine

GAS PRODUCER TURBINE

PERFORMANCE
• Two-Stage Design, Similar to Titan 130
• Leveraged Taurus 65 Experience
• High Aspect Ratio Airfoils
• Optimized Work Split, High Stage Loading
• Designed for Uncooled 2nd Blade
• Jump Cooling Experience Applied
• Extensive Application of Advanced CFD
• Airfoil Design
• Combustor Interface
• Cooling Support
• Passive Tip Clearance Control

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 Titan 250 Features
Gas Producer Turbine

GAS PRODUCER TURBINE

DURABILITY
• Advanced 1st Stage Nozzle and Blade Cooling
• Showerhead Film Cooling
• 2nd Nozzle Cooled for Minimum Performance Impact
• Internal Convection Cooling
• Optimized Cooling Passages (Advanced CFD)
• Under-platform Dampers
• Advanced Materials
• Nozzles - MAR-M-247
• Blades - SCRY-4
• TBC Pt-Al Coatings (1st Stage Airfoils)
MAINTAINABILITY
• In-Situ Repair and Replacement Capability
• Borescope Access
• 2-Plane Trim Balance in Field
• Low-Speed Turning Gear (Cool down)
• Avoid Rotor-Lock-up Issues

With Turning
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Vanes
 Titan 250 Features
Power Turbine

POWER TURBINE
PERFORMANCE
• Three-Stages
• Low RPM Design (6300 / 7000)
• Moderate Endwall Slope
• All Blades Shrouded
• Reduced-Leakage Geometry
• Increased Knife-Count
• High Efficiency, 3-D Airfoils
• Optimized Axial Gaps
• High Fidelity, Detailed CFD Models Used
• Tip Gap Analysis
• Purge Cavity Effects Captured

• Flat Power Curve across Speed Range

• Highest Efficiency Solar PT

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 Titan 250 Features
Power Turbine

POWER TURBINE
DURABILITY
• Shrouded Blade Experience
• Titan-130, Taurus-65
• Low to Moderate AN2 Levels
• Clearances Set for Durability
• Extensive Experience with Materials
• Nozzles : IN 939
• Blades : IN792
• Vibration Testing on Shrouded Blades
• Proven, Reliable High-Time Bearings
• Field-Retrofittable
MAINTAINABILITY
• Modular Design for Field Maintenance
• Advanced Rail System
• Dedicated Lubrication System
• Borescope Access

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 Validation

VALIDATION
• New Test Cell Commissioned in 2008
• Test Program Initiated in Sep-08
• >250 Hours of Operation
• Advanced Instrumentation
• Start Power Minimized
• Guide Vane Optimization
• Component Performance Validated
• Compressor Mapping 35

100% NGP

• Power Turbine Mapping 30

TEMPERATURE, °F(000)
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• Load Modulation 20
95% NGP

• Emissions Verified 15

10 90% NGP

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85% NGP
0
40 50 60 70 80 90 100 110
POWER TURBINE SPEED (% of Max)

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 Summary

SUMMARY
• Methodology
• Lean, Interactive Processes
• State-of-the-Art Design Tools
• Experience From Prior Designs
• Industry Design Experience
• Maximum Commonality
• Design
• Advanced Technology
• Detailed Analyses
• Highest Efficiency, Durable Components
• Focus On Ease of Maintenance
• Validation
• Attained Performance
• Verification With Calibrated CFD
• Extensive Engine Testing

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