Fluid Mechanics

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Turbines for Sustainable

Power
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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
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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
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In article titled Mechanical Engineering Is on the Rise; The classic

discipline is cutting-edge again says
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"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.

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This is a VERY Unique Course

Not just at UCF, Perhaps anywhere around country
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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:
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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
6
Primary
Energy
Sources
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Ocean Tidal Energy
Etc.
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To
Wind Energy
fo
Nuclear materials
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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Coal, Natural Gas, Oil
Solar radiation
Electricity
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Petroleum
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Electricity (grid)
Thermal
TurboM/C:
>90%
Liquid Fuel
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of electricity
IGCC/clean coal
w/carbon capture;
Nuclear; Wind; Solar
thermal; Hydro; Ocean
~100% of person
miles Aviation
Engines
Natural Gas
Nuclear fuel
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Biomass
Hydro
IC Engines
fo
Wind
Final
consumption
Industrial
Coal
Carrier and/or
Storage
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r
Conversion
Technique
Primary
Sources
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Energy: From acquisition to consumption
Residential
Gaseous Fuel
such as natural
gas
Commercial
Hydrogen
Transportation
Pumped Hydro
Portable
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PhotoVoltaic
Solar
be
Ocean Tidal
ElectroChemical
To
Geothermal
SOFC; PEMFC
Compressed Air
PhotoChemical
Chemical
Battery
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Mass flow rate =
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Working Fluid In (state 1)
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What is a Turbomachinery?
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Turbomachinery based
Conversion Component
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Working Fluid Out (state 2)
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1 2
Wout m h1 h2 C1 C2 g Z1 Z 2
2
To
e.g. gas turbine

burning natural gas
e.g. wind turbine
Components Frame Plant
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e.g. hydro-turbine
Means of Conversion to Shaft Power

Turbomachines
Non
Turbo
Thermal TurboM/C NonGas Turb Steam Turb thermal Machines
X
Coal
Oil
x
(x)
X
Natural Gas
X
(X)
x
Hydrogen
X
(X)
X
SynGas (IGCC) w/ or w/o carbon capture
X
(X)
Nuclear
(X)
X
Solar (PV or thermal) w/ or w/o storage
X
X (PV)
Biomass (including synthetic gas)
(X)
X
Wind (on/off shore) w/ or w/o storage
X
Hydro
X
Ocean tidal w/ or w/o storage
X
Ocean stream
X
Geothermal
X
Pumped Hydro
X
Compressed Air Energy Storage
X
Battery
X
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Primary (in bold) or secondary energy

sources
** depends on the primary source;

* depends on storage, if used
? Why??
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Carbon
foot-print
+
+
+
0 (**)
0 or +
0 or +?
+(*) or 0
0 or +(*) or 0
0
+(*) or 0
0
0
0 (**)
+ (**)
0 (**)
( ) in CC plant
Air
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Comb
Natural Gas
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Conventional Power
Generation
Turb
Gen
Boiler
Turb
To
Pump
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Coal
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Comp
Cond
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Gen
Air
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Comb
Natural Gas
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Conventional Power
Generation
Turb
Gen
Turb
To
Pump
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Comp
Cond
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Gen
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O
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Solar Energy
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~ 1354 W/m2*
~ 0 to 1000 W/m2*
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atmosphere
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Why Turbines?
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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.
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Renewables, 9% see the inset
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Genset, 1.5%
(non-turbines)
From AEO, USCurrent

DOE Total
EIA (not
(2006)the latest)
Coal, 52%
(turbines)
To
be
Nuclear, 21%
(turbines)
Natural Gas,
16% (turbines)
Solar PV,
0.0003% (nonturbines)
Biomass,
0.6%
(turbines)
Geothermal,
0.4%
(turbines)
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Solar Thermal,
0.013%
(turbines)
Wind, 0.7%
(turbines)
Hydro, 7.6%
(turbines)
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Worldwide CO2 emissions: emission reductions through

use of high-efficiency state-of-the-art power plants
Coal fired fleet-CO2 emissions
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CO2 reduction potentials in power & heat
Efficiency %
70
Fleet with stateof-the-art

technology
Coal-fired power plants produce roughly 28% of

the worlds CO2 emissions
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Gasfired
CCPP
- 5 bn t
CO2/a
6 bn t CO2/a
- 2 bn t
CO2/a
50
2.0 bn t CO2/a
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Coal-fired
steam power
30 plants
Gas-fired combined cycle power plants:

minus 5.0 billion t CO2/yr
i.e. minus 63%
be
Coal- Efficiency of existing

coal-fired power
fired
steam plant fleet
power
plants
To
10
State-of-the-art coal power plants:

i.e. minus 25%
(2005)
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8.0 bn t CO2/a
CO2 reduction, while maintaining competitiveness,

can be achieved by replacing old coal power
plants with:
1940
1960
1980
2000
2020
Source: Siemens Energy
Source: IEA, Siemens Energy GS
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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.
Tight engineering capacities
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Scarcity of raw materials and scarce

engineering capacity
High steel demand has driven prices to record
levels, which impacted power plant cost
substantially.
Active staff
Engineers needed
Manufacturing capacity for power plant

equipment like forgings, HRSGs and boilers is
currently insufficient to satisfy world demand.
Source: BCG, RWE 2006
2015
Global stainless steel price

10000
fo
US$/tonne
2010
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2005
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gap
Lead time for power projects has increased

significantly.
Investors delay projects despite a need for new
power plants.
se
d
8000
Engineering capacity can be a bottleneck.
high grade steel
6000
low grade steel
To
2000
be
4000
Doubling of price
within 1 year
Source: MEPS
0
Apr 06
Jun 06
Aug 06 Oct 06 Dec 06 Feb 07
Apr 07
Source: Siemens Energy
Jun 07
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Summary
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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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Appendix
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Units Conversion
1,35
Oil
$/1000cft
EUR/tce
1,50
1,40
7,90
1,25
1,35
29,30
39,60
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
5,40
117,20
158,20
4,00
5,70
31,60
5,15
5,00
7,10
39,50
6,40
6,00
8,50
47,40
7,65
7,00
10,00
55,30
9,00
8,00
11,40
63,20
10,30
10,75
8,05
12,80
71,10
11,55
12,10
14,20
79,00
12,80
13,45
11,00
15,70
86,80
14,15
14,80
12,00
13,00
17,10
18,50
94,70
102,60
fo
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9,40
9,00
15,45
16,70
16,15
17,50
toe
0,086
0,0239
1
0,0252
mmBtu
3,41
0,948
39,67
1
se
d
$/tce
6,70
10,00
GJ
3,6
1
41,87
1,055
To
MWh
1
0,278
11,63
0,293
be
Energy Units
MWh
GJ
toe
mmBtu
1,00
Coal
$/mmBtu (HHV)
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$/mmBtu
Natural Gas
$/bbl
General
EUR/GJ
ou
r
$/EUR
se
Fuel Prices
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Coal still fuels the world in 2035
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Renewables grow fastest (but from a low level)
Page 14
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Turbines for Sustainable Power
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Increased energy use impacts climate change

and endangers economical development.
12
Energy consumption
per capita (toe) 1.8
bubble size
fo
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14.5
se
350
300
U
se
0.9
400
1800
800
be
13.5
1500
250
1900
1950
2000
Year
1550
2400
6500
Population
(millions)
To
0.3
<0.1
0.6
ou
r
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 humancaused climate change.
14.0
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.
ppmv
Danger of irreversible changes
MEnergy
L
consumption
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CO -concentration in atmosphere
45
6
C
bn. toe
world average temperature
15.0
Energy consumption, CO2 concentration and

temperature increase, are they correlated?
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.
Sources: Stern report 2006, Siemens Energy GS
Page 15
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Worldwide CO2 emissions:

reductions through use of high-efficiency
state-of-the-art power plants
Coal fired fleet-CO2 emissions
ou
r
se
CO2 reduction potentials in power & heat
Efficiency %
70
Fleet with stateof-the-art

technology
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Gasfired
CCPP
- 5 bn t
CO2/a
44
6 bn t CO2/a
- 2 bn t
CO2/a
50
Coal-fired power plants produce roughly 28% of

the worlds CO2 emissions
2.0 bn t CO2/a
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Coal-fired
steam power
30 plants
8.0 bn t CO2/a
CO2 reduction, while maintaining competitiveness,

can be achieved by replacing old coal power
plants with:
State-of-the-art coal power plants:
i.e. minus 25% of power generation from
coal-fired steam power plants
(2005)
Gas-fired combined cycle power plants:

i.e.
minus 63% of power generation from
coal-fired steam power plants
To
10
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Coal- Efficiency of existing

coal-fired power
fired
steam plant fleet
power
plants
1940
1960
1980
2000
2020
Source: IEA, Siemens Energy GS
Page 17
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Gas Turbine and Gas Turbine Power Plant
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Increase of combined cycle net

efficiency to over 60%
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Reduced emissions per produced

kWh
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High efficiency and low emissions

also in part-load operation
Page 18
Fast start-up capability and

operational flexibility
Reduced investment costs per kW
High reliability and availability
Lowest life cycle costs
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Natural Gas Production

Shale Gas reservoirs
Page 19
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Since 1997, more than 12,000 gas wells

completed in Barnett shale, USA
Richard Newell, March 2, 2010

Page 20
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Turbines for Sustainable Power 20
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Success in the Barnett prompted companies

to look at other shale formations in the U.S.
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U.S. shale gas plays
Page 22Richard Newell, March 2, 2010
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Turbines for Sustainable Power 22
Regulation
load
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Typical Areas of Application of different

Power Plant Types and Requirements
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Daily cycling of units
ou
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Weighting of Product
Requirements:
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Peak load:
Simple-cycle GTPP,
Hydro storage plants
44
Intermediate-load:
Combined Cycle PP,
Coal Plants
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Flexibility
Part Load Efficiency
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Base-load:
Nuclear, Hydro Running
Water, Coal Steam Plants
To
be
Competition between
gas and coal fired
plants:
high gas prices shift
CCPP to lower load
factors
12
16
High Start-up Reliability

Low start-up Cost
Load Ramp
20
24
Renewables replace
base load units because
of must feed-in
obligations, but must be
backup for wind shortfall
Best Efficiency
High availability
Low Generation Costs
Short Outage Period
Time of day
Page 23
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Accelerating renewables raises a new issue

Ramp-up & rump-down capability
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Wind is not always there when it is

needed e.g. it is temperature
dependent
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more wind does not always

result in more power
generation
Source: RWE 9/2009
Page 24
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As Evidence:
RWE is planning to invest in less CO2 and more
operationally flexible technologies.
Source: RWE 9/2009
Page 26
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Energy Conversion in a Steam Power Plant

(SPP) Principal Layout
Chemical Energy
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Boiler
44
Thermal Energy
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Steam Turbine
Mechanical Energy
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Electrical Energy
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Generator
Page 27
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Efficient erosion
protection
measures
for LP blades
ou
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Fully 3-dimensional
high performance
variable reaction
blade path (3DVTM)
Combined stop
and control valves
in single valve
arrangement
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SST-3000 Series Turbine
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SGen-1000A
series for 50 Hz
and 60 Hz
Single flow LP with

axial exhaust for
a range of different
exhaust areas
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Welded IP/LPshaft design
To
be
Internally cooled
balance piston
Page 28
Barrel type
HP casing
Combined
journal-thrust
bearing
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Compact combined
IP/LP section
with straight-flow
design
High-performance
LP blades for
different sizes
of exhaust area
Fabricated welded
design for optimized
material application
ou
r
Efficient erosion
protection measures
Single cross-over pipe
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SST-5000 Series Turbine
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Combined stop and

control valves in single
valve arrangement
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Compact HP/IP design
be
High-performance LP
blades for different sizes
of exhaust area
Page 29
To
Spring back seals
Fully 3-dimensional high

performance variable
reaction blade path
(3DVTM)
SGen-1000A series
or SGen-2000H series
for 50 Hz and 60 Hz
SGen-1000A series
or SGen-2000H series
for 50 Hz and 60 Hz
Push rod arrangement

for reduced axial
clearances
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Energy Conversion in a Combined Cycle Power

Plant (CCPP) Principal Layout
GT Exhaust Energy
Heat-recovery boiler
Steam turbine system
Gas turbine system
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HRSG
Air Natural gas,

Fuel oil, etc.
Electric
power
8
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Gas turbine system
Mechanical Energy
Air intake duct

Compressor
Gas turbine
Steam generator
Exhaust stack
Bypass stack
Generator
Transformer
1
2
3
4
5
6
7
8
Feedwater
13
11
14
12
10
Steam turbine system

9
10
11
12
13
14
Steam turbine
Condenser
Pump
Feedwater tank
Generator
Transformer
11
Condensate
Circulating
water
Cooling
tower
11
Cooling
air
Fresh water
To
Electrical Energy
Electric
power
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Generator
Main Steam
Steam Turbine
44
Thermal Energy
Page 30
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Exciter
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Generator
Clutch
Foundation
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Combustion Turbine
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Single Shaft CC Power Train Layout
To
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Steam Turbine
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Trent 800
Page 33
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O
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ou
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C
6
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44
L
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be
To
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O
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ou
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C
6
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To
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Gas Turbines
in Baden, Switzerland, Forever
+
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1969-1974
ou
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1891-1969
gas turbines
gas turbines
44
1974-1990
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Allmnna Svenska
ElectricitetsAktiebolag, Schweden
1999-2000
To
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1990-1999
ASEA
BBC - ABB - Alstom Gas Turbines - ML - 03 Aug 2010 - P 1
2000+
JK/HJK
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.
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1st Utility Gas Turbine Plant in the World

4 MW, Neuchtel, Switzerland 1939
be
Plant
CH
To
Neuchatel
Country
gen. power spec pow. Th. Efficiency

type
kW
kW/kg/s
%
ordered
in operation
last reading
OH
1938
1940
1997
7020
1807
air inlet air inlet

C
kg/s
Thg
C
comp
stages
turb
stages
Single
Stage
Gas
Turbine
without
Recuperator
from BBC
4021
62.8
17.4
12
3020
23.4
64
552
313
4.4
23
7
light fuel oil
Plant
rpm
Texh C
PR
Fuel
Neuchatel
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Evolution:
Single Shaft GTs with Recuperator
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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*)
HP compressor
se
1st Combustor
ou
r
Starting motor
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HP turbine
El. Generator
LP compressor
Starting motor
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LP turbine
44
Intercooler
Plant
Filaret
To
be
2nd
Combustor
gen. power
kW
12567
Plant
Filaret
Country
ordered
1944
Rumania
spec pow. Th. Efficiency

type
kW/kg/s
%
138.1
24
in operation last reading
12/8*
1951
rpm
3997/3000
JK/HJK
1959
air inlet air inlet

C
kg/s
13.4
91
OH
9700
572
*) Test in Baden
Thg
C
Texh C
PR
Fuel
564/563
296
11.8
Natural gas
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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
se
ETAcc = 32.6 %,
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se
fo
rE
44
54
/5
45
ou
r
Pcc = 2 x 30 (GT) + 25 (ST) = 85 MW
JK/HJK
To
be
U
se
fo
rE
44
54
/5
45
ou
r
se
nl
y
Revolution: First Sequ. Comb on 1 Shaft

300 MW Air Storage Plant, Huntdorf, Germany 1977
JK/HJK
To
be
U
se
fo
rE
44
54
/5
45
ou
r
se
nl
y
1st Sequential Combustion Gas Turbine

for 60 Hz on one Shaft, 1995
GT24 Gilbert, USA, with 165 MW
JK/HJK
se
nl
y
GT24/GT26 Gas Turbine

Operation Concept
44
High exhaust temperature

maintained between
~ 25% - 100% load
54
/5
45
- low emissions over a

wide load range
ou
r
EV temperature maintained
high from ~10 - 100% load
EV Combustor Temperature
SEV Combustor Temperature
fo
rE
GT Exhaust
Temperature
- high CC part-load efficiency

Full Speed
- quick CC start-up time
No load
U
se
Inlet Air flow

(Inlet Guide Vane Position)
Base
25%
Relative GT Load
100% load
be
0%
To
High performance and low NOx emissions

over wide load range
JK/HJK
ou
r
se
nl
y
GT24/GT26 Gas Turbines

Cooling Air Coolers
54
/5
45
LPCooler
To
be
U
se
fo
rE
44
HPCooler
JK/HJK
nl
y
GT24/GT26 Gas Turbines

Once Through Coolers in CCPP
GT24 (60 Hz): +20.6 MWth Heat Release in OTC*) = +9.7 MWe via Steam Turbine
54
/5
45
ou
r
se
GT26 (50 Hz): +27.8 MWth Heat Release in OTC*) = +13.1 MWe via Steam Turbine
44
Once Through Coolers
fo
rE
Feed
Water
U
se
Cooling Air
Gas Turbine
be
Heat
Recovery
Steam
Generator
HP Steam
To
GT24: 184.1 MW
GT26: 279.7 MW
Generator
193.8 MW
292.8 MW
Steam
Turbine
9.7 MW
13.1 MW
*) converted at 47% into el. Power
ISO conditions (gross at generator terminals)
JK/HJK
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%
nl
y
To
be
se
d
fo
rE
M
44
54
/5
45
ou
r
se
To
be
se
d
rE
M
fo
44
54
/5
45
se
ou
r
nl
y

Fluid Mechanics

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Turbines for Sustainable

This is a VERY Important Topic, and will continue to

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

In article titled Mechanical Engineering Is on the Rise; The classic

This is equally true today if not more.

This is a VERY Unique Course

Materials from Multiple Academic Disciplines or Stems

Examples are taken from real life experience of many

Different Principles for

Ocean Tidal Energy

Physical Principles for Conversion

Coal, Natural Gas, Oil

Energy: From acquisition to consumption

Mass flow rate =

Working Fluid In (state 1)

Working Fluid Out (state 2)

e.g. gas turbine

e.g. wind turbine

Components Frame Plant

Means of Conversion to Shaft Power

Primary (in bold) or secondary energy

** depends on the primary source;

Turbines are involved in generation of about 98% of all

Renewables, 9% see the inset

From AEO, USCurrent

Worldwide CO2 emissions: emission reductions through

CO2 reduction potentials in power & heat

Fleet with stateof-the-art

Coal-fired power plants produce roughly 28% of

Gas-fired combined cycle power plants:

Coal- Efficiency of existing

State-of-the-art coal power plants:

CO2 reduction, while maintaining competitiveness,

Source: IEA, Siemens Energy GS

Competition among fuels driven by prices

Market Prices: Scarcity of engineering capacity and cost

Scarcity of raw materials and scarce

Manufacturing capacity for power plant

Source: BCG, RWE 2006

Global stainless steel price

Lead time for power projects has increased

Engineering capacity can be a bottleneck.

high grade steel

low grade steel

Aug 06 Oct 06 Dec 06 Feb 07

Source: Siemens Energy

Fossil fuels remain primary energy

Coal still fuels the world in 2035

Renewables grow fastest (but from a low level)

Turbines for Sustainable Power

Increased energy use impacts climate change

There is a good reason to assume a correlation

The rapid growth of the world population

Danger of irreversible changes

world average temperature

Energy consumption, CO2 concentration and

Technological innovation and industry response

Turbines for Sustainable Power

Worldwide CO2 emissions:

CO2 reduction potentials in power & heat

Fleet with stateof-the-art

Coal-fired power plants produce roughly 28% of