www.siemens.

com


NOX COMBUSTION
Power-Gen International 2008Orlando, Florida
ULTRA LOW
TECHNOLOGY

PowerGen International | Orlando, Florida | December 2008 2
ULTRA LOW NOX COMBUSTION TECHNOLOGY

9

h


)
-
ur-
eli-
g
's
d
is-
s-
ixed combustion proc-
ss that employs a premixed pilot stage.
h-
to
m
x-
s recently dem-
onstrated at Idaho Power's Evander Andrews site.
Clifford Johnson, Barton Pepperman, Michael Koenig, Khalil Abou-Jaoude,
Anil Gulati, Ali Moradian
Siemens Power Generation Inc., 4400 Alafaya Trail, Orlando, FL 32826-239
Greg Hall
Idaho Power, Boise, Idaho
Abstract

Siemens Power Generation combustion technology has under-
gone a significant transformation over the past 20 years. Evolv-
ing from the 1980's diffusion flame combustor technology, whic
produces a very stable flame, but is associated with relatively
higher levels of emissions output of some constituents, Siemens
Power Generation incorporated material and technological design
advancements, industry-leading design engineers, and state of
the art design tools to develop a successful Dry Low NOx (DLN
combustion system in the 1990's. Dry Low NOx technology pro-
vides reduced NOx emissions through a staged combustion proc
ess and unique temperature and heat release strategy. This fo
stage premixed combustion process is designed to produce r
able and stable combustion, with lower level emissions and is
currently installed in over 100 Siemens GT's. Further improvin
the environmental compatibility of Siemens Power Generation
fleet of gas turbines, the Dry Low NOx technology has evolve
into a combustion system, commercially offered as Ultra Low
NOx (ULN), which is designed to achieve sub 9 ppm NOx em
sions. In addition to stable combustion, the Ultra Low NOx sy
tem is characterized by a five stage prem
e

Demonstration of Siemens Power Generation's combustion tec
nology is typically extensive, following a detailed design, rig and
field test, and then full scale engine testing process, which lead
commercial introduction. The Ultra Low NOx combustion syste
has been introduced into the commercial fleet, and operating e
perience with it has included high GT efficiency and sub 9ppm
NOx emissions, across a wide operating range, a

Siemens Power Generation, Inc. 2008. All rights reserved.


PowerGen International | Orlando, Florida | December 2008 3
Siemens Power Generation, Inc. 2008. All rights reserved.
4
5
7
8
r ..........................................................9
..........................................................................................
Permission for Use ..........................................................................10
References.......................................................................................11
Contents


Introduction .......................................................................................
Combustor Design Features..............................................................
Operation ...........................................................................................
Testing and Verification.....................................................................
Field Validation Idaho Powe
Summary 10


PowerGen International | Orlando, Florida | December 2008 4
Introduction
s, Siemens
flexible, reli-
requirements
mixed combustion
The ULN de-
ting fleet.
obust Dry
ng in SGT6-
501F, and W501G)
combustion
nd opera-
]
ns, Siemens has
lopment of the
onstrated
w NOx emis-
ustor design produces lower CO, VOC and particulate
emissions. In combination with the Siemens low load CO system, this combus-
tion system is capable of producing single-digit CO emissions down to 40% load.
Additionally, the ULN design can meet these requirements for a wider range of
fuels, including LNG. [2].


Building upon its history of advanced gas turbine combustion system
has developed a robust Ultra-Low NOx (ULN) combustor design for
able power generation is designed to meet the stringent emissions
in the U.S. and abroad. This configuration utilizes a highly pre
system that was designed for SGT6-5000F and W501F engines.
sign is applicable for new units and is also retrofittable to the exis
The Siemens ULN technology is derived from the well-proven and r
Low NOx (DLN) combustion system design that has been operati
3000E, SGT6-5000F, and SGT6-6000G (W501D5/D5A, W
engines for more than 10 years. Recent enhancements to the DLN
system have contributed to the world-class reliability, performance a
tional flexibility of the newest Siemens SGT6-5000F gas turbines. [1
In response to market requirements for even lower NOx emissio
leveraged this DLN design and operating experience into the deve
next-generation ULN combustion system technology, which has dem
sub-9ppm NOx emissions for F-class engines. In addition to the lo
sions, the ULN comb

Siemens Power Generation, Inc. 2008. All rights reserved.

PowerGen International | Orlando, Florida | December 2008 5
Combustor Design Features
or basket, pilot
fuel is injected
to two fuel
etween the C-
premix pilot stage.
) utilize swirler
es this com-
injection holes in the swirler vanes, enhanced fuel/air mixing is achieved, thus reducing
the peak temperature of local hot spots that contribute to NOx production. In addition to
improved emissions, this design is capable of handling a wide range of fuel composition
and fuel temperature.


The ULN combustion system shown in Figure 1 comprises a combust
nozzle, support housing, C-stage fuel nozzle, and transition. Most of the
through eight main fuel nozzles in the support housing, which is divided in
stages of four main nozzles each. The remainder of the fuel is divided b
stage and the pilot. The pilot nozzle includes a diffusion stage and a
The premix pilot (D-stage) and the two main fuel stages (A and B stages
fuel injection (SFI) technology, which is the key design feature that enabl
bustor design to achieve sub-9ppm NOx emissions. By injecting fuel through multiple



Figure 1: Ultra-Low NOx combustor cross-section




Siemens Power Generation, Inc. 2008. All rights reserved.

PowerGen International | Orlando, Florida | December 2008 6
.
sing was up-
tested in 2004
he mechanical
nozzle bodies were
esign, the main fuel
he pilot nozzle
bustor basket (Figure 5) are very similar to the design that was
tested in 2004. The ULN combustor basket incorporates design features from the
proven DLN combustion system that has demonstrated the ability to operate at ex-
tended service intervals.

Since the original engine test of this system in 2004 [3], the support hou
graded to add dual fuel capability. The original gas only design that was
is shown in Figure 2. To accommodate the fuel oil tubing and increase t
robustness of the fuel nozzles, the production support housing main
redesigned as shown in Figure 3. As in the initial support housing d
nozzles were designed to minimize CO production during loading. T
(Figure 4) and com

Figure 2: Original Gas Only Suppor

t Housing

Figure 3: Dual Fuel Support Housing



Production
nozzle body

Siemens Power Generation, Inc. 2008. All rights reserved

PowerGen International | Orlando, Florida | December 2008 7

Figure 4: Dual Fuel Pilot Nozzle


Figure 5: Combustor Basket

Operation
Table 1 shows the fuel staging used for the ULN combustion system. S
ignition is performed with fuel split between the diffusion pilot and main
adjusted between these two stages to maintain stability during accelera
speed. Near synch sp
imilar to DLN,
A-stage. Fuel is
tion to synch
eed, the D-stage fuel is added. Below 25% load, the CO emis-
sions are minimized by inje only the pilot, A and D-stages. B-stage
fuel is introduced at 25% load to provide more uniform thermal loading and lower NOx
emissions. Above 45% load, C-stage fuel is introduced to provide additional stability in
the high load range. At high loads, 70-90% of the fuel is injected through the main fuel
nozzles, with the remainder of the fuel being divided between the other fuel stages to
provide the optimum tuning for low NOx and CO emissions while maintaining combus-
tion dynamics below limits.
Table 1: Fuel Staging
cting fuel through


Siemens Power Generation, Inc. 2008. All rights reserved.

PowerGen International | Orlando, Florida | December 2008 8

Engines with the ULN combustion system are equipped with an active c
namics protection system (CDPS SPPA-D3000) that continually monitor
tion dynamics levels and the engine emissions. After initial tuning of the
commissioning, the engine controller makes automatic real-time adjustm
fractions to maintain low emissions while protecting the engine against
namics. If the dynamics and NOx readings are within the allowable ran
taken. If NOx emissions exceed the target value (e.g., due to a change
position or ambient temperature change), then the contro
ombustion dy-
s the combus-
engine during
ents to the fuel
combustion dy-
ge, no action is
in the fuel com-
ller automatically modulates
y changes to A
value, then the
in dynamics levels within limits.
Dual fuel operation with a ULN combustion system is very similar to DLN dual fuel op-
eration. The engine can be started with either gas fuel or oil fuel. Transfers between
gas and oil can be performed up to 70% load.
a combination
mbustion rig testing and
performed
e was success-
ribed above,
ber of design
an high pressure
ility, a highly in-
The verification
NOx and sub-10ppm CO emissions were demonstrated for part load as well as base
load operation. On oil fuel, sub-42ppm NOx and sub-10ppm CO emissions were dem-
onstrated over the same load range. Fuel transfers between gas and oil were per-
formed over a wide range of part load operation.
More than 500 operating hours of validation and verification were performed between
the first ULN demonstration and the final engine verification at the Siemens Berlin Test
Facility prior to commercial release of the ULN design for production.
the D-stage fraction to reduce NOx, with the balance of the fuel offset b
and B stages. If the combustion dynamics levels exceed the threshold
D-stage fraction is adjusted to mainta


Testing and Verification
As discussed in [3], the ULN combustion system was developed through
of modeling with computational fluid dynamics, high pressure co
engine verification. A series of high pressure combustion rig tests were
throughout the development of the first engine hardware. This hardwar
fully demonstrated in an engine test on a SGT6-5000F in 2004. As desc
the production design incorporated dual fuel capability as well as a num
enhancements. These design enhancements were tested in a single c
combustor test rig to assess impacts on emissions and combustion dynamics.
Final engine verification was performed at the Siemens Berlin Test Fac
strumented full scale SGT6-5000F engine, which operates at full load.
test at Berlin Test Facility included both gas and oil operation. With gas fuel, sub-9ppm

Siemens Power Generation, Inc. 2008. All rights reserved.

PowerGen International | Orlando, Florida | December 2008 9
Field Validation Idaho Power
Following the final engine verification testing at the Berlin Test Facility en
commercial application of the ULN combustion system was commissio
Power Evander Andrews project, Mountain Home, Idaho, a simple cycl
First fire of this unit occurred in February, 2008. The unit ha
gine, the first
ned at the Idaho
e SGT6-5000F).
s performed as expected
ellent starting
ulty.
nd part load per-
ormance re-
emissions for
le combustor dynamics operating range. Figure 7
shows the turndown from 60% to base load. This performance has been consistently
demonstrated at the Evander Andrews project for a period of over 6 months, totaling
more than 250 EBH and 25 ES. During this time, operation has been validated over a
wide range of ambient operating conditions.
based upon Berlin Test Facility results. In particular, the engine has exc
reliability, and base load was achieved without any operational diffic
During commissioning, the unit successfully demonstrated base load a
formance with NOx emissions < 9ppm and meeting all contractual perf
quirements. Figure 6 demonstrates that the ULN system meets <9ppm
base load operation in the acceptab
6 7 8 9
NOx (ppmvd @ 15% O2)
C
o
m
b
u
s
n
a
m
i
c
s

A
m
p
l
i
t
u
d
e
Acceptable Combustion Dynamics Operating Range
Combustion Dynamics Alarm Limit

Figure 6: Combustor Dynamics at Base Load
t
o
r

D
y

Siemens Power Generation, Inc. 2008. All rights reserved.

PowerGen International | Orlando, Florida | December 2008 10

0
3
6
9
12
15
50 60 70 80 90 100 110
Load %
E
m
i
s
s
i
o
n
s


p
p
m
v
d

@

1
5
%
O
2
NOx CO

Figure 7: ULN Emission Results
eing offered
commercially. The first commissioning effort of this engine at the Idaho Power Evan-
der Andrews project was very successful, meeting all contractual performance guar-
antees. Emissions levels below 9ppm NOx and 10ppm CO were achieved for part
peration. The lessons learned and methodology applied in the
ent of new Sie-
Permission for Use
The content of this paper is copyrighted by Siemens Power Generation, Inc. and is
licensed only to PennWell for publication and distribution. Any inquiries regarding
permission to use the content of this paper, in whole or in part, for any purpose must
be addressed to Siemens Power Generation, Inc. directly.





Summary
The Siemens ULN combustion system has been validated and is now b
load and base load o
development of this combustion system are being used for developm
mens gas turbine products.



Siemens Power Generation, Inc. 2008. All rights reserved.


PowerGen International | Orlando, Florida | December 2008 11
Siemens Power Generation, Inc. 2008. All rights reserved.
1. Kovac, J., Xia, J., SGT6-5000F Technology Enhancements, POWER-GEN Interna-
., Nag, P., Abou-Jaoude, K., Wu, J., LaGrow, M., Liquefied Natural Gas
-GEN Interna-
3. Bland, R., Ryan, W., Abou-Jaoude, K., Bandatu, R., Haris, A., Rising, B., 2004,
F Gas Turbine : Ultra Low NOx Combustion System Development,
POWER-GEN International 2004.




References
tional 2007.
2. Engel, J
(LNG) Flexibility Solutions for Large-Scale Gas Turbines, POWER
tional 2007.
Siemens W501