Cp1

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

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Industrial Gas Gas Turbines Turbines Industrial and Related Related Research Research Activities Activities and in Japan Japan in 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

Eisuke OUTA

Department of Mechanical Engineering, Waseda University Okubo 3-4-1, Shinjuku, Tokyo, Japan Phone: +81-3-5286-3246, e-mail: [email protected]

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

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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 First GT in Japan produced by as the first industrial GT of 1.6MW. Toshiba Corporation, 1949 †1 Since then, various types of GT were 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

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2. Industrial Gas Turbines in Dawning Ages Most of the heavy Industrial companies Generator had started their own projects in the ages 8000 min of 1950th, and various GTs were produced IPT partly by their own technology and partly by introducing technologies from abroad. 0.49MPa -1

0.23MPa 563C

LPT

554C

The pictures shows typical research GTs, intending respectively for future applications to ship propulsion and electric power generation.

HPT Combustor

AIR 8500 min-1

17000 min-1 0.99MPa 700C

Starter LPC 0.33MPa 153C

HPC Starter 1MPa 200C

Heat exchanger

First open cycle twin-shafts GT produced by Mitsui Engineering and Shipbuilding Co. (1953) .†1 1.63MW, (C):13(L)/ 8(H) stages, pressure ratio=5.15, (B): Straight can type, (T): TIT=650C, 5(H)/ 1(L) stages.

3-shafts, inter-cooled, reheated, recuperated 1.86MW GT, produced by Mitsubishi-Nihon Heavy Industries. (1951~57) .†1 Max. TIT=700C, 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

First practical use twin-shafts GT, manufactured by Toshiba Corporation. (1956) .†1 2MW, Heavy oil, (C):9(L)/ 8(H) stages, (B): Straight double cylindrical, (T): TIT=650C, 3(H)/ 3(L) stages.

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Jet-powered emergency GT, manufactured by Toshiba Corporation. (1968) .†1 10MW, Gas-generator: GE/IHI-J79, (P.T): TIT=560C, 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

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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.

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- 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.

SB5, 1.2 MW: Mitsui Engineering and Shipbuilding Co..

NMGT-2.6DX, 3.3KW : Nissan / IHI Aerospace

AT2700 integrated 2 MW unit: Yanmar Diesel Engine 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

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Specifications of typical Heavy Duty Middle Class GT for Cogeneration and Combined Cycle are compared in the table: HITACHI - H25 †4 S/C out put Efficiency

KHI - L20A †3

MHI - MF221

27.5 MW 33.8 %

18 MW 35 %

TIT Exhaust T.

555 degC

1250 degC 545 degC

1250 degC 533 degC

C/C output Efficiency

39.8 MW 49 %

24 MW >47 %

46.0 MW 49.0 %

Emission Nox CO

20 ppm

< 23 ppm < 25 ppm

25 ppm vd@15%O2

(B): Lean-premixed (C): MCA-wide chord / 11stgs. (T ): NI-based super-alloy / TBC / High efficiency cooling Design Life T. 40000 hrs

(B): Lean-premixed (C): MCA/CDA / 17 stgs (T): 1st vane cooling: Impingement +Film + Pin-fin 1st blade: Serpentine with turbulence promoter +Pin-fin cooling 2nd vane: Impingement + Pin-fin 2nd blade: Multipath + Pin-fin

Particular features

HITACHI- H25 (B): Lean premixed + Steam injection (C): SupercriticalMCA/CDA / 17 stgs. (T): 1st: multipath cooling + turbulence promoter 2nd, 3rd: shroud covered

KHI – L20A

30 MW 32 %

†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.

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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

Integrated Coal Gasification Combined Cycle - Sunshine Project 1986-1996

H2O Fuelled GT

Advanced GT - Moonlight 1978-1987 (1972)

-New Sunshine 1993-1998

Ceramics GT

- New Sunshine 1988-1998

2010

Melt Growth Composite GT

-New-Sunshine2001-2005

CO2 Recovery Closed Cycle GT 1999-2001

Application to Industrial Cogeneration 1999-2003

Advanced Material Gas Generator Super marine GT

Gas Turbine Society of Japan

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

- 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)

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

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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 / Oxygen

Diagram of system concept †6

HPT

Methane/Oxygen combustor

Steam Comp.

High Temp. T.

†7) Okada, T., et al, Proceedings IGTC2003, IGTC2003Tokyo TS-130 (2003-11).

Steam Heat exchanger

Generator - 500MW CO2/H20 Separator condenser

Steam /CO2 †6) Pamphlet , Hydrogen, Alcohol and Biomass Energy Department, NEDO.

LPT

Brayton cycle Rankine cycle

Steam /CO2 De-aerator

Recovered CO2 CO2 compressor

Water

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- Ceramic Gas Turbine Project †8 Ceramic-FRC hybrid nozzle

Pilot CGT -302

Power turbine

Ceramic BLISK

From heat exchanger

To heat exchanger

The 300kW CGT project started in 1988 at NEDO. 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

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- Application of Melt Growth Composite Ceramics (MGC) to High Efficiency GT †9 2001 – 2005 NEDO: IHI, KHI and Ube Industries, LTD.

Linear stacked vane

MGC/GAP Bow stacked vane Courtesy of Mr. Yokoi, S (Engineering Association for High Performance Gas Turbine)

Flexural strength MPa

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 Super alloyan efficiency gain of 9%, at TIT of 1700 C and SXMarM-247 1200 pressure ratio of 30 without cooling. 1000

Al2O3/GAP 800

Si3N4

600 400

Al2O3/YAG

200 0 0

500

1000

1500

2000

Temperature deg. C †9) Kobayashi, K. et al , IGTC2003, Tokyo, TS-125 (2003-11), Hagari, T. et. al. IGTC2003 Tokyo, TS143 (2003-11)

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

- Coal Utilization IGCC:

The research project and system will be presented in the session of “Combustion”. (Dr.Sato, M. )

PFBC

†10

Operation Plant output Efficiency GT

LimeStone/ Water/ Coal

GT

:

Specifications of PFBC combined cycle plant working at three electric power stations are compared in the table †x. Facility

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ST

PFBC at Osaki Power Station

Hokkaido E. P. Chugoku E. P. Co. Kyusyu E. P. Co. Co. -Tomato St. - Osaki St. - Karita St. Y1998 85MW 40.1% 11.1MW MHI-M151P

Y2000 2×250MW 41.5% 2 × 44MW Mod. GE-F7EA-P

Y2001 360MW 42.5% 75MW ABB-GT140P

S. shaft -S. Cycle

S. shaft -S.Cycle

T. shaft -S.Cycle

ST

73.9MW 16.6MPa, 566/538C

Soot + dust

cyclone + ceramic filter

2×215MW, 16.6MPa, 566/593C

2-stage cyclone + bag filter

290MW 24.1MPa, 566/593C 2-stage cyclone + electro-static precipitator

Data are quoted from pamphlets of respective power stations. †10) Sato, T., “The Large Capacity Gas Turbine for Pressurized Fluidized Bed Combustion Boiler Combined Cycle Power Plant”, Bull. GTSJ 2003.

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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 design 3-D. N.S.

Off-design performance

Control of instability and stall - Boundary layer aspiration, - Real-time sensing, - Active control

Optimum blade profile

COMPRESSOR

Control of acoustic noise - aero engine

Control of blade vibration - Aero-mechanical multi-stage 3-D. simulation, - Real-time sensing, - Active control

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

2.4 2.2 2.0 1.8 1.6 1.4 1.2 1.0

Tandem rotor Loading

200 250 300 350 400 450 500 Corrected Speed Um m/sec

†11) Sakai, Y., et al, “Design and Test of Transonic Compressor Rotor with Tandem Cascade”, Proc. IGTC2003Tokyo TS-108 (2003-11).

Predicts efficiency gain due to new variable-stator-vane setting in 2.5-stage. (Courtesy of IHI)

Isentropic efficiency

Pressure ratio

Significant aerodynamic performance is achieved through aggressive loading. (Courtesy of KHI)

Unsteady 3-D N-S Analysis †12

Pressure ratio

Tandem Profile of Cascade †11

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VSV new VSV old

Efficiency gain ~ 3 Pts

100%speed

90%speed

Inlet mass flow †12) Imanari, K., Proceedings of GTSJ Lecture Meeting, (2002-5)p. 129

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-Inverse Design Method †13 has various advantage in improving turbo-machinery performance: e.g. 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, 4

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

Strong shock

Reduced shock

-1

TURBOdesign

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

Distorted exit flow

L.E. shock

Elimination of L.E. shock

Uniform exit flow

†13) Collaboration work between University College London and Ebara Research Co. Ltd.

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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 cooling and sealing air flow, tip leakage flow, and inlet distortion of temperature and velocity. - Instantaneous gas temperature, - Matching of last stage flow and diffuser flow

Performance and Reliability

- Minimum pressure loss, - 3-D. automatic inverse design

Highly loaded cooled blade profile

TURBINE

Cooling technology for TIT=1350 1500

Blade heat transfer

- Suppress local hot spot, - Low cooling air flow

- Accurate prediction of turbulence, transition, roughness effect, etc.

Blade vibration - (CFD + FEM) multistage simulation, - Real-time sensing

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

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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 toward a virtual rig test of whole GT (Courtesy of Tsukagoshi, K., MHI) (Courtesy of Dr. Nozaki, S., JAXA) Contour of entropy in 4-Stage LPT 84.5M grid points, 4k CPU hours, 85 PE

Tangential strut cover Gas temperature Inlet gas temperature distribution + Blade surface cooling flow + Disc cooling flow

Exhaust strut cover

Mach number contour Distortion of turbine exit flow + exhaust diffuser flow + strut flow

Contour of total pressure in 7-Stage HPC 70 M grid points, 2KCPU hours, 182 PE

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

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- “Virtual Gas Turbine” †14 involved in Project of “High Temperature Materials in the 21 Century” 1999A 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.

Thermal Cycle Design Program

Limiting streamlines Surface temperature on rotor blade and vortex flow induced by ejected coolant

INPUT GT Conditions, Materials OUTPUT GT conditions Coolant consump. Fuel consumption Plant Efficiency CO2 emission, etc.

GT Design Database GT Design Program - Aerodynamics - Cooling blade structural design - GT heat transfer / blade cooling - Rotor / Disc structural design

- GT structure - Cooling efficiency / Film cooling effectiveness - Nozzle / blade thermal / mechanical stress

Alloy Design Program

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

Thermal stress distribution (TMS alloy)

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

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Example of Virtual Turbine Performance †14 Combustor It was found that the combination of sophisticated cooling system, high temperature materials and Compressor TBC gave the only possibility to realize a 1600C class GT with low CO2 emission.

Evaluated Turbine

Input Data Item GT Output TIT

Unit MW ℃

Output VT Performance 17.6 1700

Material Base New 1st V FSX414 TMS-82+ 1st B Mar-M247 TMS-82+ 2nd V FSX414 TMS-82+ 2nd B Mar-M247 TMS-82+ 3rd V FSX414 TMS-82+ 3rd B Mar-M247 TMS-82+ 4th V FSX414 TMS-82+ 4th B Mar-M247 TMS-82+ 5th V TMS-82+ 5th B TMS-82+ Stage

1700C Virtual Turbine

Matetial Variation Base New (%) GT Output MW 12.4 12.2 -1.07 MW C/C Output 19.6 18.6 -5.22 GT Therm. Efficiency % 31.5 36.1 14.7 GT % C/C Therm. Efficiency 49.0 53.8 9.85 Fuel Flow Rate kg/s 0.92 0.8 -13.7 kg/s/MW 0.24 0.21 CO2 Emission -12.9 kg/s Compressor Inlet 52.7 35.6 Pressure Ratio 16.5 25.6 Stage Number 4 5 rpm Rotating Speed 8089 9704 Turbine kg/s Total Cooling Air 17.2 14.3 -17.0 TET ℃ 486 560 15.3 Item

Unit

†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).

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- 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 of kerosene droplet in LPP combustor †15.

Time [ms]

Er = 0.25

8000

4.5

d)

6.0 7.5

e) 250 f)

9.0

g)

11.5

h)

12.0

i)

13.5

j)

1.5

LES analysis of flame propagation †15 step 0

3.0

a) T[K] b) 2000 c)

0.0

4000

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 Society of Japan”, 30-5 (2002. 9), p.376.

†16) Murota,T. and Ohtsuka, M., ASME paper 99-GT-274 (1999).

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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/