CAME-GT 2nd International Symposium, April 29-30, Bled, Slovenia 1 /22

Industrial Gas
Industrial Gas Turbines
Turbines
and Related
and Related Research
Research Activities
Activities
in Japan
in Japan
1. Introduction
2. Industrial Gas Turbines
in dawning ages of development
3. National Project of “ Moonlight”,
and Industrial Gas Turbines Today
4. “Sunshine” and various project activities
5. Current and prospective CFD Technology
for Compressor, Turbine, and Combustor
6. Concluding Remarks
Department of Mechanical Engineering,
Eisuke OUTA Waseda University
Okubo 3-4-1, Shinjuku, Tokyo, Japan
Phone: +81-3-5286-3246, e-mail: outa@waseda.jp
 CAME-GT 2nd International Symposium, April 29-30, Bled, Slovenia 2 /22

1. Introduction
Industrial gas turbines and their systems
developed and utilized in Japan over these
50 years are overviewed.

► The activity started in 1949; i.e. a base

Engine that was developed for a high speed
war-boat during the World War II came back
as the first industrial GT of 1.6MW. First GT in Japan produced by
Since then, various types of GT were Toshiba Corporation, 1949 †1
produced by various GT manufacturers, in order to develop the related technology
and to demonstrate their advantages as power generators.
► In 1978, the 10 years national project of “Moonlight” was organized aiming at a
high efficiency 100MW class GT.
The activity gave great technology innovations towards the modern GT in Japan.
► The “Moonlight” was followed by various projects such as on IGCC, Ceramics
GT, Hydrogen GT, utilization of Melt Growth Composite Ceramics, and so on.
► Technology of large scale, accurate and efficient CFD has promoted researches
on GT components. Latest activities and a “Virtual Turbine” system are introduced.

†1) “Photo-Album of Gas Turbines in Japan” , edited by the Gas Turbine Society of Japan (2002-5)
 CAME-GT 2nd International Symposium, April 29-30, Bled, Slovenia 3 /22

2. Industrial Gas Turbines in Dawning Ages

Most of the heavy Industrial companies
Generator 0.23MPa
had started their own projects in the ages 8000 563C
AIR
8500
of 1950th, and various GTs were produced min -1
min-1
Starter
partly by their own technology and partly by IPT LPT LPC
0.33MPa
introducing technologies from abroad. 0.49MPa
17000 153C
554C
min-1
The pictures shows typical research GTs, HPT HPC
intending respectively for future applications Combustor 0.99MPa Starter
1MPa
to ship propulsion and electric power generation. 700C
200C

Heat
exchanger

First open cycle twin-shafts GT produced by Mitsui 3-shafts, inter-cooled, reheated, recuperated
Engineering and Shipbuilding Co. (1953) .†1 1.86MW GT, produced by Mitsubishi-Nihon
1.63MW, (C):13(L)/ 8(H) stages, pressure ratio=5.15, Heavy Industries. (1951~57) .†1 Max. TIT=700C,
(B): Straight can type, (T): TIT=650C, 5(H)/ 1(L) stages. pressure ratio=10, Efficiency=31%.

†1) “Photo-Album of Gas Turbines in Japan” , edited by the Gas Turbine Society of Japan (2002-5)
 CAME-GT 2nd International Symposium, April 29-30, Bled, Slovenia 4 /22

First practical use twin-shafts GT, manufactured by Jet-powered emergency GT, manufactured
Toshiba Corporation. (1956) .†1 2MW, Heavy oil, by Toshiba Corporation. (1968) .†1 10MW,
(C):9(L)/ 8(H) stages, (B): Straight double cylindrical, Gas-generator: GE/IHI-J79, (P.T): TIT=560C,
(T): TIT=650C, 3(H)/ 3(L) stages. Starting duration up to full load=210 sec.

The 2MW GT shown is the first GT that was utilized for independent power plant
using heavy oil. It was developed under joint research with a petroleum company.
Performance defect was experienced due to adhesion of burned ashes.
The first jet powered GT was installed in a power station of Kansai Electric Power
Co. for emergency power supply. GE/IHI aeroengine was employed as the gas
generator, because of its high reliability and rapid start capability. The GT is still
working with one real experience at an occasion of heavy storm.
Fuji Electric Co. constructed a 2MW electric power plant using an imported single
shaft GT (EscherWyss) in 1957, and a 12 MW closed cycle system in 1961.
†1) “Photo-Album of Gas Turbines in Japan” , edited by the Gas Turbine Society of Japan (2002-5)
 CAME-GT 2nd International Symposium, April 29-30, Bled, Slovenia 5 /22

3. National Project of “ Moonlight”

and Industrial Gas Turbines Today
- Advanced GT Project †2 (1978-1987)
The project was involved in the national “Moonlight Project”, and executed by an
research association that was participated with six major GT manufacturers. The
target was to develop a combined cycle system with overall efficiency of 55%.
Pilot GT( AGTJ-100A): The two-stage combustion reheat GT produced 93MW
at TIT of 1280C. Combined plant efficiency was 52.3%(LHV).
The pressure ratio was 55, LPC
was composed of full variable
SV, and the turbine stages were
air-cooled. High temperature
resistant ceramics and Ni-based
alloy were investigated.
Prototype with TIT of 1400C:
Full scale models of HPT
and combustor were tested,
introducing TBC on directionally
solidified blades, steam injection
and other high technologies. AGTJ-100A (Courtesy of Prof. Emer. Matsuki, Nippon Institute
of Technology)
†2) Yamagishi, K. “Development of advanced Gas Turbine in Japan”, Proceedings of
the 1987 Tokyo International Gas Turbine Congress, (1987-11), p.I-1.
 CAME-GT 2nd International Symposium, April 29-30, Bled, Slovenia 6 /22

- Product Activity of Industrial Gas Turbines Today

Production statistics †3 published by GTSJ indicates that number of units produced
in Japan took the peak in 2000, I.e. 300 units of small range (<735kW), 250 units of
middle range (<22MW) and 220 large units were produced
for base load and emergency electric power generation.
Approximately 120 small units were
supplied for miscellaneous use
Including water pump drive in 1998.
Typical GT engines †1 ranging
between kW and highest MW are
shown in these two slides. NMGT-2.6DX, 3.3KW : AT2700 integrated 2 MW unit:
Nissan / IHI Aerospace Yanmar Diesel Engine Co.

SB5, 1.2 MW:

Mitsui Engineering and Shipbuilding Co.. M501G, 254 MW, TIT 1500C: MHI
†3) Bulletin of GTSJ, the Gas Turbine Society of Japan (1998, 1999, 2001, 1002)
 CAME-GT 2nd International Symposium, April 29-30, Bled, Slovenia 7 /22

Specifications of typical Heavy Duty Middle Class GT for

Cogeneration and Combined Cycle are compared in the table:
HITACHI - H25 †4 KHI - L20A †3 MHI - MF221
S/C out put 27.5 MW 18 MW 30 MW
Efficiency 33.8 % 35 % 32 %
TIT 1250 degC 1250 degC
Exhaust T. 555 degC 545 degC 533 degC
C/C output 39.8 MW 24 MW 46.0 MW
Efficiency 49 % >47 % 49.0 %
Emission Nox 20 ppm < 23 ppm 25 ppm vd@15%O2
CO HITACHI- H25 < 25 ppm
(B): Lean premixed (B): Lean-premixed (B): Lean-premixed
+ Steam injection (C): MCA-wide chord (C): MCA/CDA / 17 stgs
(C): Supercritical- / 11stgs. (T): 1st vane cooling:
MCA/CDA / 17 stgs. (T ): NI-based super-alloy Impingement +Film + Pin-fin
Particular (T): 1st: multipath / TBC 1st blade: Serpentine with
features turbulence promoter
cooling / High efficiency
+Pin-fin cooling
+ turbulence cooling
2nd vane: Impingement
promoter Design Life T. 40000 hrs
+ Pin-fin
2nd, 3rd: shroud
2nd blade: Multipath + Pin-fin
covered KHI – L20A

†4) Takehara, I., “Application of Middle Class Gas Turbine for Combined Cycle”,
J. of Gas Turbine Society of Japan, Vol.31, No.3 (2003-5), p. 151.
 CAME-GT 2nd International Symposium, April 29-30, Bled, Slovenia 8 /22

4. “Sunshine” and Various Projects Activities

National projects of energy included two large scale projects of Moonlight and
Sunshine; Moonlight related to advanced GT, Stirling engine, fuel cell and
power storage, and the Sunshine covers utilizations of coal, hydrogen, solar, etc.
1980 1990 2000 2010
Integrated Coal Gasification Melt Growth Composite GT
Combined Cycle -New-Sunshine-
- Sunshine Project - 2001-2005
1986-1996
H2O Fuelled GT CO2 Recovery
Advanced GT -New Sunshine - Closed Cycle GT
- Moonlight - 1993-1998 1999-2001
1978-1987 Ceramics GT Application to
- New Sunshine - Industrial Cogeneration
1988-1998 1999-2003
(1972) Advanced Material
Gas Turbine Society Gas Generator
of Japan Super marine GT
1997-2002
High Temperature Materials
in the 21th Century
Aero Engine 1999-
FJR710 HYPER ESPR
1971-1984 1989-1998 1999-2003
 CAME-GT 2nd International Symposium, April 29-30, Bled, Slovenia 9 /22

- World Energy Network Using Hydrogen (WE-NET)

Hydrogen-Fuelled Turbine (1993-1998）
A topping regenerator cycle was designed, aiming at an efficiency higher
than 60 %（HHV) at TIT of 1700C and pressure of 4.8 MPa.
4H2 / O2 combustion in steam, TBC rotor blade, and TBC stator vanes with
“Film cooling + recycle type internal cooling”, “Recycle type internal
cooling” and “Water cooling with internal cooling”,
are verified for applications by tests under actual temperature.
Prior to the WE-NET, research on Internal Reheat Hydrogen Gas Turbine
was conducted at the Ship Research Institute
(1980 – 1997). †5 Internal cooling
by Hydrogen Working gas
combustor
(kerosene/Air)

Hydrogen gas
Hydrogen is discharged from nozzle trailing edge
to reheat the working gas.
4TIT:1173C, Out put power with reheat: 440 kW, without reheat : 380 kW
†5) Hiraoka, K. et al, “Research of Internal Reheat Hydrogen GasTurbine”,
Reports of Ship Research Institute, T.R. 138-2 (2001)
 CAME-GT 2nd International Symposium, April 29-30, Bled, Slovenia 10 /22

Succeeding the project of Hydrogen-Combustion Turbine, project of

Carbon-Dioxide Recovery System of Closed-Cycle GT
was formed supervised by NEDO. (1999-2001)
The 500MW system applying CH4 and O2 combustion was designed to collect
emitted CO2 and to achieve an efficiency > 60% at a TIT of 1700 deg C class.
4Subjects: system analysis, methane -oxygen combustion technology,
blade cooling technology, ultra high temperature alloy with TBC †7,
and circulation of mixture of CO2 + H2O vapor in system components.
Methane Methane/Oxygen
/ Oxygen combustor Brayton cycle
Rankine cycle

Diagram of system
concept †6 Steam High Generator
HPT Comp. Temp. LPT
- 500MW
T.

Steam CO2/H20
/CO2 Separator condenser
†6) Pamphlet , Hydrogen, Alcohol
and Biomass Energy Department, Steam Steam
/CO2 Recovered
NEDO. CO2
Heat
†7) Okada, T., et al, Proceedings exchanger
IGTC2003, IGTC2003Tokyo De-aerator CO2 - Water
TS-130 (2003-11). compressor
 CAME-GT 2nd International Symposium, April 29-30, Bled, Slovenia 11 /22

- Ceramic Gas Turbine Project †8

Pilot CGT
Ceramic-FRC -302 Power
hybrid nozzle turbine
Ceramic BLISK

To heat
exchanger
From
The 300kW CGT project started in 1988 at NEDO. heat exchanger
The pilot GT of “CGT 302” was a recuperated two-shaft engine adaptable for
fluctuating load demand maintaining high efficiency even at a partial load, and
developed by KHI, Kyocera Corporation and Sumitomo Precision Products Co.
4 Ceramic component are applied for all parts of the hot section †1,
Turbine rotor : Integrated ceramic blade with disk,
Turbine nozzle : Ceramic-FRC hybrid composite structure.
Separated nozzle segment are wounded by ceramic fiber
to form one piece turbine nozzle.
4 Engine test †1 • TIT 1396 C, power 322kW and efficiency: 42.1%,
• NOx emission: 31.7 ppm, in 300hrs of accumulated operation at TIT1350C,
• Endurance test at TIT of 1200C over 2100 hrs.
†8) Pamphlet “Ceramic Gas Turbine”, Ceramic Gas Turbine R&D Association / NEDO / AIST, MITI
 CAME-GT 2nd International Symposium, April 29-30, Bled, Slovenia 12 /22

- Application of Melt Growth Composite Ceramics (MGC)

to High Efficiency GT †9
2001 – 2005 NEDO: IHI, KHI and Ube Industries, LTD.
Application of MGC to hot parts of GT will provide a breakthrough technology in
improving gas turbine efficiency with increased TIT, improved combustor design,
reduced cooling air flow, improved aerodynamic performance of turbine blades
with reduced coolant injection, and so on.
4 The MGC keeps high strength at high temperature even up to 1700 deg. C.
4 A preliminary research on 5MW class engine implies
an efficiency gain of 9%, at TIT of 1700 C and Super alloy-
SXMarM-247
pressure ratio of 30 without cooling. 1200

Flexural strength MPa

1000
Al2O3/GAP
800

600 Si3N4
Linear stacked vane 400
Al2O3/YAG
200

MGC/GAP 0
0 500 1000 1500 2000
Bow stacked vane Temperature deg. C
Courtesy of Mr. Yokoi, S
(Engineering Association for †9) Kobayashi, K. et al , IGTC2003, Tokyo, TS-125 (2003-11),
High Performance Gas Turbine) Hagari, T. et. al. IGTC2003 Tokyo, TS143 (2003-11)
 CAME-GT 2nd International Symposium, April 29-30, Bled, Slovenia 13 /22

- Coal Utilization
IGCC: Lime-
The research project and system will be Stone/
Water/
presented in the session of “Combustion”. Coal
(Dr.Sato, M. )
GT
PFBC †10 : ST
Specifications of PFBC combined cycle
plant working at three electric power
stations are compared in the table †x. PFBC at Osaki Power Station

Hokkaido E. P. Chugoku E. P. Co. Kyusyu E. P. Co.

Facility
Co. -Tomato St. - Osaki St. - Karita St.
Operation Y1998 Y2000 Y2001
Plant output 85MW 2×250MW 360MW
Efficiency 40.1% 41.5% 42.5%
11.1MW 2 × 44MW 75MW Data are quoted from pamphlets
GT MHI-M151P Mod. GE-F7EA-P ABB-GT140P of respective power stations.
S. shaft -S. Cycle S. shaft -S.Cycle T. shaft -S.Cycle
73.9MW 2×215MW, 290MW
†10) Sato, T., “The Large Capacity
ST 16.6MPa, 16.6MPa, 24.1MPa, Gas Turbine for Pressurized
566/538C 566/593C 566/593C Fluidized Bed Combustion Boiler
2-stage cyclone Combined Cycle Power Plant”,
cyclone 2-stage cyclone
Soot + dust + electro-static Bull. GTSJ 2003.
+ ceramic filter + bag filter
precipitator
 CAME-GT 2nd International Symposium, April 29-30, Bled, Slovenia 14 /22

5. Current and Prospective CFD Technology for

Compressor, Turbine, and Combustor
Large scale, accurate and efficient CFD incorporated with multiple fields of
mechanics and dynamics will play more Important role to improve efficiency, size,
reliability and emission of GT. Some of the targets to be studied are shown in the
slide with quoting to various activity results.
- Optimized for stage
interaction and clocking,
- Unsteady whole stage - 3-D. automatic inverse
3-D. N.S. design

Off-design performance Optimum blade profile

COMPRESSOR
Control of Control of
instability and stall blade vibration

- Boundary layer - Aero-mechanical

aspiration, Control of multi-stage 3-D. simulation,
- Real-time sensing, acoustic noise - Real-time sensing,
- Active control - aero engine - Active control
 CAME-GT 2nd International Symposium, April 29-30, Bled, Slovenia 15 /22

Tandem Profile of Cascade †11 Unsteady 3-D N-S Analysis †12

Significant aerodynamic performance Predicts efficiency gain due to new
is achieved through aggressive loading. variable-stator-vane setting in 2.5-stage.
(Courtesy of KHI) (Courtesy of IHI)

2.4
2.2

Isentropic
VSV new

efficiency
2.0 Tandem rotor
Pressure ratio

Loading
100%speed
1.8 Efficiency
VSV old gain ~ 3 Pts
1.6
1.4 90%speed
Pressure
1.2
1.0 ratio
200 250 300 350 400 450 500
Corrected Speed Um m/sec
†11) Sakai, Y., et al, “Design and Test of Transonic Inlet mass flow
Compressor Rotor with Tandem Cascade”, †12) Imanari, K., Proceedings of GTSJ Lecture
Proc. IGTC2003Tokyo TS-108 (2003-11). Meeting, (2002-5)p. 129
 CAME-GT 2nd International Symposium, April 29-30, Bled, Slovenia 16 /22

-Inverse Design Method †13 has various advantage

in improving turbo-machinery performance: e.g.
4 Detail control of 3-D. flow by using flow related design parameters,
4 Efficient optimization by logical feedback of the CFD results to the input,
4 High performance design beyond our past experience,

4Centrifugal compressor redesign at pressure ratio = 5.5

(Courtesy of Advanced Design Technology LTD)
4Splitter blade is aft-loaded with zero L.E. loading to reduce shock.

Conventional TURBOdesign
-1
Strong shock Reduced shock

Blade loading
is specified for
both of full and
splitter blades.

Distorted L.E. shock Elimination of Uniform

exit flow L.E. shock exit flow
†13) Collaboration work between University College London and Ebara Research Co. Ltd.
 CAME-GT 2nd International Symposium, April 29-30, Bled, Slovenia 17 /22

Targets of subject to improve the turbine performance will be such as shown here.
Turbulent high energy flow is the key point to be solved.
Are processes of starting and variable load possible to be simulated in future?

- Unsteady whole stage N.S., with - Minimum pressure loss,

cooling and sealing air flow, - 3-D. automatic inverse
tip leakage flow, design
and inlet distortion
of temperature and velocity.
- Instantaneous gas temperature, Highly loaded cooled
- Matching of last stage flow and blade profile
diffuser flow

Performance and Reliability

TURBINE
Cooling technology
Blade heat transfer Blade vibration
for TIT=1350 1500

- Suppress local - Accurate prediction of - (CFD + FEM) multi-

hot spot, turbulence, transition, stage simulation,
- Low cooling air flow roughness effect, etc. - Real-time sensing
 CAME-GT 2nd International Symposium, April 29-30, Bled, Slovenia 18 /22
In developing advanced design of high temperature turbine blades, it is essential
to know the details of internal flow pattern and gas temperature distribution by
employing unsteady 3-D. CFD.
Parallel super computing
4 Activity at MHI 4 CENSS at NAL/JAXA
(Courtesy of Tsukagoshi, K., MHI) toward a virtual rig test of whole GT
(Courtesy of Dr. Nozaki, S., JAXA)

Contour of entropy
in 4-Stage LPT
84.5M grid points,
4k CPU hours,
85 PE

Exhaust
strut cover
Tangential
strut cover
Gas temperature Mach number contour
Inlet gas temperature Distortion of turbine Contour of total pressure
distribution exit flow in 7-Stage HPC
+ Blade surface cooling flow + exhaust diffuser flow 70 M grid points,
+ Disc cooling flow + strut flow 2KCPU hours, 182 PE
 CAME-GT 2nd International Symposium, April 29-30, Bled, Slovenia 19 /22

- “Virtual Gas Turbine” †14 involved in Project of

“High Temperature Materials in the 21 Century” 1999-
A simplified simulation system has been formed
by JAXA (NAL), Toshiba and NIMS, in order
to estimates the temperature capabilities of
new material developed by the HTM21, and
the composed gas turbine performance.

Limiting streamlines Surface temperature

Thermal Cycle on rotor blade and vortex flow induced
Design Program by ejected coolant
INPUT Thermal stress
GT Design Database
GT Conditions, distribution
GT Design Program
Materials - GT structure (TMS alloy)
- Aerodynamics - Cooling efficiency /
OUTPUT Film cooling
- Cooling blade
GT conditions structural design effectiveness
Coolant consump. - Nozzle / blade thermal
- GT heat transfer / mechanical stress
Fuel consumption / blade cooling
Plant Efficiency
- Rotor / Disc
CO2 emission, etc. structural design Alloy Design Program

Profiles of the project (Courtesy of Dr. Yoshida, T. JAXA)

 CAME-GT 2nd International Symposium, April 29-30, Bled, Slovenia 20

Example of Virtual Turbine Performance †14

It was found that the combination of sophisticated Combustor
Evaluated
cooling system, high temperature materials and Compressor Turbine
TBC gave the only possibility to realize a 1600C
class GT with low CO2 emission.
Input Data
Item Unit Output VT Performance 1700C Virtual Turbine
GT Output MW 17.6
TIT ℃ 1700 Matetial Variation
Item Unit
Base New (%)
Material GT Output MW 12.4 12.2 -1.07
Stage
Base New C/C Output MW 19.6 18.6 -5.22
1st V FSX414 TMS-82+ GT Therm. Efficiency % 31.5 36.1 14.7
GT
1st B Mar-M247 TMS-82+ C/C Therm. Efficiency % 49.0 53.8 9.85
2nd V FSX414 TMS-82+ Fuel Flow Rate kg/s 0.92 0.8 -13.7
2nd B Mar-M247 TMS-82+ CO2 Emission kg/s/MW 0.24 0.21 -12.9
3rd V FSX414 TMS-82+ Compressor Inlet kg/s 52.7 35.6 -
3rd B Mar-M247 TMS-82+ Pressure Ratio 16.5 25.6 -
4th V FSX414 TMS-82+ Stage Number 4 5 -
4th B Mar-M247 TMS-82+ Rotating Speed rpm 8089 9704 -
Turbine
5th V TMS-82+ Total Cooling Air kg/s 17.2 14.3 -17.0
5th B TMS-82+ TET ℃ 486 560 15.3
†14) Saeki, H. and et. Al. “ Development of a Gas Turbine Design Program Coupled with an Alloy Design
Program- A Virtual Turbine”, Proceedings of IGTC 2003 Tokyo, IGTC2003Tokyo TS-122, (2003-11).
 CAME-GT 2nd International Symposium, April 29-30, Bled, Slovenia 21 /22

- Combustion Research
Unsteady CFD of combustion involves various physical and chemical processes,
And the accuracy significantly depends on models of turbulence, mixing of species
and reaction. Typical activities by GT manufacturers are introduced in this slide.
Activity at KHI Activity at Hitachi Ltd.
Vaporization 0.0 a) T[K]
of kerosene 1.5 b) 2000
droplet in LPP c)
3.0
combustor †15.

Time [ms]
4.5 d)
Er = 0.25 6.0 e) 250
LES analysis
of flame propagation †15 7.5 f)
step 0 4000 9.0 g)
11.5 h)
12.0 i)
13.5 j)

8000 12000 C2H4+Air, φ : 0.7 [-]

T : 288 [K], u : 27 [m/s] p :0.1[MPa]

LES analysis of combustion oscillation

in premixed combustor †16.
†15) Kinoshita, Y. et al., “Numerical Simulation for Gas
Turbine Combustor Design”, J. of the Gas Turbine †16) Murota,T. and Ohtsuka, M.,
Society of Japan”, 30-5 (2002. 9), p.376. ASME paper 99-GT-274 (1999).
 CAME-GT 2nd International Symposium, April 29-30, Bled, Slovenia 22 /22

6. Concluding Remarks
Activities of national projects and industrial efforts have been traced.
The author would like to expresses his sincere thanks to many of the
GTSJ members for their kind help in composing the slides.
Despite of an unfortunate situation that many of the projects have
been suspended to be advanced, those activity will contribute to
establish a world energy use applying clean and efficient gas turbines.
Nevertheless, subjects to be solved may still remain; e.g.
Can the high technology GT meet political and public interest ?
Can large scale CFD be validated in the depth of the physic of
the analysis through measurements and rig tests ?
Can the collaboration between university science and industrial
technology be formed in the future development ?
The Gas Turbine Society of Japan will contribute toward the solution
through “Observation Tour”, “GT Seminar”, “Education Symposium”,
“Lecture Meeting”, and “International Gas Turbine Congress”
The next IGTC will be held in Autumn, 2007!!
The Gas Turbine Society of Japan - http://wwwsoc.nii.ac.jp/gtsj/