Flexible Micro Gas Turbine Rig for Tests on Advanced Energy Systems

The Thermochemical Power Group (TPG) of the University of Genoa, Italy, has developed a new flexible laboratory to study advanced energy systems based on micro gas turbine technology. In the laboratory a general-purpose experimental rig, based on a modified commercial 100 kW recuperated micro gas turbine, was installed and fully instrumented. The main objectives of the laboratory is to perform experimental activities related to gas turbine based cycles in both steady-state and transient conditions. The rig layout was defined to include the effects of interaction between the turbomachines (especially the compressor) and further components. This approach is extremely significant for innovative cycle analyses, such as recuperated, humid air, and hybrid (with high temperature fuel cells) configurations. The facility was partially funded by two Integrated Projects of the EU VI Framework Program (Felicitas and Large-SOFC) and the Italian Government (PRIN project). It was designed with a high flexibility approach including: flow control management, co-generative applications, downstream compressor volume variation, grid-connected or stand-alone operations, recuperated or simple cycles, and room temperature control. In the new EU VII Framework (E-HUB Project), the test rig has been improved with the installation of an absorption cooler to operate the system in tri-generative configuration. The layout of the whole system, including connection pipes, valves, and instrumentation (in particular mass flow meter locations) was carefully designed to measure all the significant properties with high accuracy performance. Particular attention was devoted to component design, using CFD tools (Fluent), to perform emulation tests on high temperature fuel cell hybrid systems. For this reason, the facility was equipped with a modular cathodic vessel, an anodic recirculation loop (including a vessel and an ejector), and a steam injection system for chemical composition emulation. To compare tests affected by a significant influence of the ambient temperature variation, such as the performance tests on the machine maximum electrical power and electrical efficiency or on the recuperator effectiveness, the rig was integrated with a compressor inlet temperature control system. This equipment is composed of three air/water heat exchangers located at the air intake, controlled valves and a variable speed pump operating in a closed loop. This circuit was designed to couple the machine air inlet with the absorption cooler. The large number of experimental data available for the high flexibility test rig design is also used to validate both steady-state (design and off-design) and transient (also real-time) theoretical models. A good level of consistency can be achieved thanks to the complete knowledge of the test rig dimensions, volumes, masses, shaft inertia, thermal capacitances, and operating procedure. Such completeness is difficult to obtain in industrial plants, where details about equipment are often missing or confidential. This facility is also essential to introduce undergraduate students to micro gas turbine technology, and Ph.D.s to advanced experimental activities in the same field. With this experimental rig, in addition to learning about the thermodynamic cycles and plant layouts, students can also become familiar with their materials, piping, gaskets, technology for auxiliaries, and instrumentation.