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maximum temperature through air cooling while simultaneously increasing the mass flow with more air compressor capacity permits higher power output. To increase the final compressor pressure additional compressor stages are added on the compressor rotor assembly to give higher compression ratio thus providing additional turbine power output. Typical industrial gas turbine compression ratios are 16:1 and aeroderivative ratios are 30:1 with roughly 50 percent of the total turbine power of either type being required just to drive the compressor. Compressor blading is special stainless steel, possibly coated by electroplating with nickel and cadmium to resist pitting in salt and acid environments. Compressor designs have been quite effective, as evident by the 200,000-hour life of some early compressors installed in the 1950s. The gas turbine has the inherent disadvantage that reduced air density with high ambient temperature or high elevation causes a significant reduction in power output and efficiency, because the mass flow through the gas turbine is reduced. A 28C (50F) results in about a 25 percent output reduction and a 10 percent higher heat rate. Similarly, at 1000 meter (3300 ft) elevation the gas turbine output would be 15 percent lower than at sea level. Steam plants and diesels are not affected to the same degree by ambient air temperature and elevation changes.
systems. There is no significant difference in availability of two types of gas turbines for power use, based on the August 1990 Generation Availability Report of the North American Electric Reliability Council. For the period 19851989 the average availability of 347 jet engines (1587 unit years) was 92 percent and that for 575 industrial gas turbines (2658 unit years) was 91 percent.
Combined Cycle Modular Installations One significant advantage of combined-cycle units is that the capacity can be installed in stages with short lead time gas turbines being installed initially (1 to 2 years) followed later by heat recovery boilers with the steam turbines (3 years total). In this way each combined-cycle unit (i.e. block) can be installed in three (or more) roughly equal capacity segments. The modular arrangement of combined-cycle units also facilitates generation dispatching because each gas turbine can be operated independently (with or without the steam turbine) if part of the combined-cycle unit is down for maintenance or if less than the combined-cycle unit total capacity is required. This may give a higher efficiency for small loading than if the total capacity was operated.
Furthermore, since combined-cycle units are available in sizes of roughly 50 MW to almost 500 MW (and 600 MW are expected to be available soon with 200 MW gas turbines), there are many selection possibilities for most sizes of power system. Another point favoring staging a combined-cycle unit is that the gas turbine (or combined-cycle) per kilowatt cost does not seem to increase significantly for smaller units, as is the case for steam units due partly to the high cost of the substantial civil works necessary for steam plants regardless of steam unit size. Finally, combined-cycle units can be installed in 3 years while a steam unit typically requires 5 years, and once committed there is no power output from a steam unit until the complete unit is available.
Fuels for Combined Cycles Using present technology the combined-cycle unit can be fueled with natural gas, distillate, and even crude or residual oil with appropriate fuel treatment. Fueling with crude or residual oil, however, definitely results in extra capital costs for fuel treatment equipment. Operations suffer due to additional operating costs for additives to counteract contaminants such as vanadium, lower availability due to additional maintenance and water cleaning shutdowns to remove blade deposits, and reduced life because there is a greater tendency for hot gas path corrosion due to blade deposits and corrosion. The daily (or even more frequent) testing of the residual or crude oil for contaminants with appropriate adjustments of fuel treatment is critical to prevent damage to the gas turbine. Even with good operation there will be a reduction in efficiency with crude or residual oil fueling to reduce firing temperatures, as recommended by most manufacturers for this mode of operation, and due to the blade deposits which build up between water-washing intervals. The gas turbine has to be shut down periodically for cleaning and allowed to cool before washing can be done by injecting water while rotating the unit using the starting motor.
Operational Considerations of Combined Cycles This gas turbine is the main component that requires maintenance on combined-cycle units. All manufacturers recommend specific intervals for hotgas-path inspections and for major overhauls, which usually involve hot-gaspath part changes. During overhauls the condition of aeroderivatives may require that the complete engine or at least major components be sent to overhaul centers, while the industrial gas turbines usually will require only part changes on site.
The type of fuel and mode of operation are critical in determining both the maintenance intervals and the amount of maintenance work required. It is estimated by one manufacturer that burning residual or crude oil will increase maintenance costs by a factor of 3, assuming a base of 1 for natural gas, and by a factor of 1.5 for distillate fueling. Similarly, maintenance costs will be three times higher for the same number of fired hours if the unit is started, i.e. cycled, once every fired hour, instead of starting once very 1000 .fired hours. Peaking at 110 percent of rating will increase maintenance costs by a factor of 3 relative to base-load operation at rated capacity, for the same number of fired hours. The control system on combined-cycle units is largely automatic so, after a start is initiated by an operator, the unit accelerates, synchronizes and loads with automatic monitoring and adjustment of unit conditions in accordance with present programs. The number of operators required in a combined-cycle plant therefore is lower than in a steam plant.
Developed Country Combined Cycle Installations The following key topics provide examples of developed country combinedcycle installations. Electricity Supply Board of Ireland Oil-to-Gas Conversion The electricity Supply Board of Ireland converted two old oil-fired steam plants to gas-fired combined cycle units in the late 1970s. Originally, there units were used for baseloaded operation, but recently change to intermediate load. Refer To: World Bank IEN Working Paper #35: "Prospects for Gas-Fueled Combined-Cycle Power Generation in the Developing Countries", May 1991. Midland Nuclear Plant Conversion, U.S.A. Twelve Asea Brown Boveri 85 MW gas turbines and heat recovery boilers were installed to supply two 350 MW steam units originally installed for the Midland nuclear plant. This combined-cycle cogeneration plant will supply 1380 MW to Consumer Power Co. and process steam plus 60 MW of power to Dow Chemical Co. Refer To: World Bank IEN Working Paper #35: "Prospects for Gas-Fueled Combined-Cycle Power Generation in the Developing Countries", May 1991. LNG-Fired Combined-Cycle by Tokyo Electric The world's largest regasified LNG-fueled combined-cycle plant is in operation near Tokyo in Japan. Fourteen 165 MW single-shaft combined-cycle units serve as mixed base-load and mid-range generation on the 41,000 MW Tokyo Electric Power Co. system. The plant capacity is 2,310 MW at 15C ambient decreasing to 2,000 MW at 32C. A unique feature is the low NOx emission level of 10 ppm due to the use of selective catalytic reduction equipment.
Refer To: World Bank, IEN Working Paper #35: "Prospects for Gas-Fueled Combined-Cycle Power Generation in the Developing Countries", May 1991.
Developing Country Combined Cycle Installations The following list provides examples of Combined Cycle projects in developing countries. These examples are discussed in greater detail in the associated Key Topics. 5 x 300 MW in India 3 x 300 MW Gas Turbines in Malaysia 2 x 300 MW in Pakistan 5 Combined-Cycle plants in Mexico 300 MW in Egypt 772 MW in Thailand Combined-Cycle in Bangladesh
The dollar per kilowatt capacity costs vary from $592/kW for a new 1,080 MW combined-cycle plant in Egypt to $875/kW for a steam addition to convert four gas turbines at Multan in Pakistan to a combined-cycle plant. Although the operating performance of combined-cycle units in North America is reported to be satisfactory with availability factors of about 85 percent, the developing country experience is less favorable, and in some countries the performance has been poor.
GE Energy
The world demands a reliable supply of clean, dependable power. Always on the cutting edge of gas
turbine technology, GE offers a wide array of technological options to meet the most challenging
energy requirements. Using an integrated approach that includes parts, service, repair and project
management, we deliver results that contribute to our customers success. And our reputation for
Heat Rate Btu/kWh kJ/kWh 5,690 5,690 5,880 5,950 6,000 6,000 6,202 6,276
MS6001FA
CC CC SC SC CC SC CC SC CC SC CC SC
117.7 MW 118.1 MW 75.9 MW 75.9 MW 262.6 MW 171.7 MW 390.8 MW 255.6 MW 193.2 MW 126.1 MW 130.2 MW 85.1 MW
50 Hz 60 Hz 50 Hz 60 Hz 60 Hz 60 Hz 50 Hz 50 Hz 50 Hz 50 Hz 60 Hz 60 Hz
6,240 6,250 9,760 9,795 6,090 9,360 6,020 9,250 6,570 10,100 6,800 10,430
6,582 6,593 10,295 10,332 6,424 9,873 6,350 9,757 6,930 10,653 7,173 11,002
MS7001FA
MS9001FA
10
MS9001E
11
MS7001EA
12
MS6001B
CC CC SC
50 Hz 60 Hz 50/60 Hz
13
MS6001C
CC CC SC SC
14
H System
MS9001H/MS7001H COMBINED CYCLE PERFORMANCE RATINGS
Net Plant Heat Rate Output (MW) (Btu/kWh) (kJ/kWh) Net Plant Efficiency 60.0% GT Number & Type 1 x MS9001H
H SYSTEM
GEs H Systemthe worlds most advanced combined cycle system and the first capable of breaking
the 60% efficiency barrierintegrates the gas turbine, steam turbine, generator and heat recovery steam
50 Hz
S109H 520 5,690
generator into a seamless system, optimizing each components performance. Undoubtedly the leading
60 Hz
S107H 400 5,690
6,000
technology for both 50 and 60 Hz applications, the H delivers higher efficiency and output to reduce the
6,000
60.0%
1 x MS7001H
Open loop air-cooled gas turbines have a significant temperature drop across the first stage nozzles, which
reduces firing temperature and thermal efficiency. The closed-loop steam cooling system allows the turbine
to fire at a higher temperature for increased performance. It is this closed-loop steam cooling that enables
Baglan Bay Power Station is the launch site for GEs H System.
the H System to achieve 60% fuel efficiency capability while maintaining adherence to the strictest low NOx
standards and reducing CO2 emissions. Additionally, closed-loop cooling also minimizes parasitic extraction
of compressor discharge air, thereby allowing more air to flow to the combustor for fuel premixing, thereby
RDC27903-13-03
PSP30462-05
3
H SYSTEM
The use of these advanced materials and Thermal Barrier Coatings ensures that components will stand
Building on GEs design experience, the H System employs a can-annular lean pre-mix DLN-2.5
Dry Low NOx (DLN) Combustor System. Fourteen combustion chambers are used on the 9H, and
12 combustion chambers are used on the 7H. GE DLN combustion systems have demonstrated
RDC27916-09-09
the ability to achieve low NOx levels in several million hours of field service around the world.
The H System offers approximately 40% improvement in power density per installed megawatt
compared to other combined cycle systems, once again helping to reduce the overall cost of
producing electricity.
Thoroughly Tested
PSP30246-10
The design, development and validation of the H System has been conducted under a regimen of extensive
Worlds first H turbine is transported through Wales to Baglan Bay Power Station.
component, sub-system and full unit testing. Broad commercial introduction has been controlled to follow
launch units demonstration. This thorough testing approach provides the introduction of cutting edge tech-
F Class
F CLASS
With over ten million hours of operation, our F class turbines have established GE as the clear industry
leader for successful fired hours in advanced technology gas turbines. Representing the worlds largest,
most experienced fleet of highly efficient gas turbines, designed for maximum reliability and efficiency
with low life cycle costs, our F class turbines are favored by both power generators and industrial
Introduced in 1987, GEs F class gas turbines resulted from a multi-year development program using
technology advanced by GEs aircraft engine team and GE Global Research. GE continually advances
this technology by incrementally improving the F class product to attain ever higher combined cycle
PSP30027-06
Dry Low NOx combustor systems allow GEs F Class turbines to meet todays strict environmental emissions requirements.
RDC27305-02a
Our F class gas turbines, including the 6F (either 50 or 60 Hz), the 7F (60 Hz) and the 9F (50 Hz), offer
5
F CLASS
flexibility in cycle configuration, fuel selection and site adaptation. All F class gas turbines include an
18-stage axial compressor and a three-stage turbine, and they feature a cold-end drive and axial exhaust,
which is beneficial for combined cycle arrangements where net efficiencies over 58% can be achieved.
F/FA/FB EXPERIENCE
14000
11,844 11,594 10,327 9,061
12000
10000
8000
6000
4000
2000
0 95 96 97 98 99 00 01 02 03 04 05
YEAR
Half of all 6FA installations are located in Europe. This CHP plant is owned by Porvoo,
PSP30114
Finland.
PSP30210-01
The FB is the latest evolutionary step in GEs proven F series. Taking F technology to a new level of output
and efficiency, weve applied our cutting-edge technology, including the materials developed for the
H System, and the experience gained in over ten million advanced gas turbine fired hours. The result is a
large combined cycle system designed to provide high performance and low electrical cost.
This MS9001FB is seen on half shell during assembly.
Improved output and efficiency means better fuel economy and reduced cost of producing electricity. With
todays competitive markets and unpredictable fuel prices, thisnow more than everis the key to success.
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PSP30510-01
In developing the FB, we followed a specific course that significantly improved the key driver of efficiency
MS7001FB/MS9001FB COMBINED CYCLE PERFORMANCE RATINGS
Heat Rate Net Plant Output (MW) (Btu/kWh) (kJ/kWh) S109FB S209FB S107FB S207FB 562.5 280.3 5,950 5,940 825.4 5,884 412.9 5,880 6,202 6,206 6,276 6,266
firing temperature. The FB firing temperature was increased more than 100 degrees Fahrenheit over GEs FA
technology, resulting in combined cycle efficiency rating improvements of better than one percentage
point. Output improvements of more than 5% were also achieved. These improvements equate to more MW
60 Hz 50 Hz
The use of advanced turbine materials, such as Single Crystal First Stage Buckets, ensures that components
can stand up to the higher firing temperatures of the FB without an increase in maintenance intervals.
Providing the basis of process rigor, Six Sigma methodologies were used to assure a highly reliable robust
design optimized for lowest cost of electricity. Indeed, in developing the FB, we were able to maintain many
of the proven features of the worlds most successful advanced technology turbine, the F/FA.
An MS7001FB is seen in test cell.
PSP30299
PSP30266-02
The highly efficient gear-driven 6FA gas turbine is a mid-size version of the well-proven 7FA and 9FA. Its
output range, high exhaust energy, full packaging and robust design ideally suit applications ranging from
cogeneration and district heating to pure power generation in combined cycle and Integrated Gasification
M S 6 0 0 1 FA , M S 7 0 0 1 FA a n d M S 9 0 0 1 FA
To meet the need for mid-size power blocks with high performance in combined heat and power
MS6001FA COMBINED CYCLE PERFORMANCE RATINGS
Heat Rate Net Plant Output (MW) (Btu/kWh) (kJ/kWh) S106FA S206FA S106FA S206FA 117.7 237.9 118.1 237.5 6,240 6,170 6,250 6,210 6,582 6,508 6,593 6,550 Net Plant Efficiency 54.7% 55.3% 54.6% 54.9% GT Number & Type 1 x MS6001FA 2 x MS6001FA 1 x MS6001FA 2 x MS6001FA
applications, the high-speed 6FA produces 75.9 MW of simple cycle power at 35% efficiency and
117 MW of combined cycle power at 54.7% net efficiency. In IGCC operation, gross plant efficiencies
A classic example of GEs evolutionary designs, the 6FA is a 2/3 scale of the 7FA. Its aerodynamically
scaled 18-stage axial design reduces combustion chambers from 14 to 6. A cold-end drive allows exhaust
gases to be directed axially into the HRSG. With over 860,000 operating hours and 61 units installed or on
order, the 6FA provides major fuel savings over earlier mid-range units in base-load operation. Adaptable
to single or multi-shaft configurations, it burns a variety of fossil fuels, which can be switched after start-up
without sacrificing performance. On natural gas the available Dry Low NOx (DLN) system can achieve NOx
KEPCOs Seoinchon Plant, one of the worlds largest combined cycle plants, has operated for more than 40,000 hours in daily start/stop cyclic duty.
emissions of 15 ppm.
The wide range of power generation applications for the 7FA gas turbine includes combined cycle, cogenera-
tion, simple cycle peaking and IGCC in both cycle and base load operation with a wide range of fuels. Its high
RDC27834-34
reliabilityconsistently 98% or betterprovides customers more days of operation per year while minimizing
As an industry leader in reducing emissions, the 7FAs DLN-2.6 combustor (proven in hundreds of thousands
of operating hours) produces less than 9 ppm NOx and COminimizing the need for exhaust cleanup sys-
With 100s of units in operation, GE continually makes incremental design enhancements to improve output,
efficiency, reliability and availabilityfor new units and upgrades to existing units. GE adds customer value
M S 6 0 0 1 FA , M S 7 0 0 1 FA a n d M S 9 0 0 1 FA
with power augmentation equipment that provides additional gas turbine performance in summer peak
MS7001FA COMBINED CYCLE PERFORMANCE RATINGS
Net Plant Heat Rate Output (MW) (Btu/kWh) (kJ/kWh) Net Plant Efficiency 262.6 S207FA 529.9 6,090 6,040 6,424 6,371 56.0% 56.5% GT Number & Type 1 x MS7001FA 2 x MS7001FA
Power producers around the world require reliable power generationwhich makes the 9FA the 50 Hz gas
turbine of choice for large combined cycle applications. As an aerodynamic scale of the highly successful
MS9001FA SIMPLE CYCLE PERFORMANCE RATINGS
50 Hz Power Generation Output Heat Rate Pressure Ratio Mass Flow Turbine Speed Exhaust Temperature Model Designation (lb/sec) (kg/sec) (rpm) (F) (C) (MW) (Btu/kWh) (kJ/kWh) 255.6 9,250 9,757 17.0:1 1,413 641 3,000 1,116 602 PG9351FA
7FA gas turbine, the 9FA provides key advantages that include a fuel-flexible combustion system and higher
output performance.
The 9FA gas turbine is configured with the robust DLN-2.0+. Ideally suited for diverse fuels, this combustor
is the industry leader in pollution prevention for 50 Hz combined cycle applications with greater than 56%
The 9FA can be configured to meet site and power requirements. For re-powering applications with space
limitations, it can be configured in a single-shaft combined cycle arrangement with the generator and steam
turbine. For large combined cycle or cogeneration plants where flexible operation and maximum perform-
ance is the prime consideration, it can be arranged in a multi-shaft configuration where one or two gas
turbines are combined with a single steam turbine to produce power blocks of 390 or 786 MW.
50 Hz
S109FA S209FA
60 Hz
S107FA
390.8 786.9
6,020 5,980
6,350 6,308
56.7% 57.1%
1 x MS9001FA 2 x MS9001FA
MS9001E
MS9001E SIMPLE CYCLE PERFORMANCE RATINGS
50 Hz Power Generation Output (MW) (Btu/kWh) (kJ/kWh) Heat Rate Pressure Ratio Mass Flow Turbine Speed Exhaust Temperature Model Designation (lb/sec) (kg/sec) (rpm) (F) (C) 126.1 10,100 10,653 12.6:1 922 418 3,000 1,009 543 PG9171E
10
Fuel-Flexible 50 Hz Performer
MS9001E
The MS9001E gas turbine is GEs 50 Hz workhorse. With more than 390 units, it has accumulated over
14 million fired hours of utility and industrial service, many in arduous climates ranging from desert heat
and tropical humidity to arctic cold. Originally introduced in 1978 at 105 MW, the 9E has incorporated
numerous component improvements. The latest model boasts an output of 126 MW and is capable of
Whether for simple cycle or combined cycle application, base load or peaking duty, 9E packages are
comprehensively engineered with integrated systems that include controls, auxiliaries, ducts and silencing.
They are designed for reliable operation and minimal maintenance at a competitively low installed cost.
MS9001E COMBINED CYCLE PERFORMANCE RATINGS
Heat Rate Net Plant Output (MW) (Btu/kWh) (kJ/kWh) Net Plant Efficiency GT Number & Type
Like GEs other E-class technology units, the Dry Low NOx combustion system is available on 9E, which can
50 Hz
S109E S209E
193.2 391.4
6,570 6,480
6,930 6,835
52.0% 52.7%
1 x MS9001E 2 x MS9001E
With its flexible fuel handling capabilities, the 9E accommodates a wide range of fuels, including natural
gas, light and heavy distillate oil, naphtha, crude oil and residual oil. Designed for dual-fuel operation,
it is able to switch from one fuel to another while running under load. It is also able to burn a variety of
syngases produced from oil or coal without turbine modification. This flexibility, along with its extensive
The MS9001E gas turbine is designed to attain high availability levels and low maintenance costs, resulting in extremely low total cost of ownership.
experience and reliability record, makes the 9E well suited for IGCC projects.
In simple cycle, the MS9001E is a reliable, low first-cost machine for peaking service, while its high
combined cycle efficiency gives excellent fuel savings in base load operations. Its compact design
provides flexibility in plant layout as well as the easy addition of increments of power when a phased
MS7001EA
MS7001EA SIMPLE CYCLE PERFORMANCE RATINGS
60 Hz Power Generation Output (MW) (Btu/kWh) (kJ/kWh) 85.1 10,430 11,002 12.7:1 (lb/sec) (kg/sec) (rpm) (F) (C) 648 294 3,600 997 536 PG7121EA (lb/sec) (kg/sec) (rpm) (F) (C) Heat Rate Pressure Ratio Mass Flow Turbine Speed Exhaust Temperature Model Designation Mechanical Drive (hp) (Btu/shp-hr) 115,630 7,720 11.9:1 659 299 3,600 999 537 M7121EA
11
MS7001EA
With more than 750 units in service, the 7E/EA fleet has accumulated tens of millions of hours of service
With strong efficiency performance in simple and combined cycle applications, this 85 MW machine is
used in a wide variety of power generation, industrial and cogeneration applications. It is uncomplicated
and versatile; its medium-size design lends itself to flexibility in plant layout and fast, low-cost additions
of incremental power.
With state-of-the-art fuel handling equipment, advanced bucket cooling, thermal barrier coatings and
MS7001EA COMBINED CYCLE PERFORMANCE RATINGS
Net Plant Heat Rate Output (MW) (Btu/kWh) (kJ/kWh) Net Plant Efficiency GT Number & Type
a multiple-fuel combustion system, the 7EA can accommodate a full range of fuels. It is designed for dual-
fuel operation, able to switch from one fuel to another while the turbine is running under load or during
shutdown. 7E/EA units have accumulated millions of hours of operation using crude and residual oils.
60 Hz
6,800 6,700
7,173 7,067
50.2% 50.9%
1 x MS7001EA 2 x MS7001EA
In addition to power generation, the 7EA is also well suited for mechanical drive applications.
GT20821
MS6001B
MS6001B SIMPLE CYCLE PERFORMANCE RATINGS
50/60 Hz Power Generation Mechanical Drive Output Heat Rate (Btu/kWh) (kJ/kWh) Pressure Ratio Mass Flow Turbine Speed Exhaust Temperature Model Designation (lb/sec) (kg/sec) (rpm) (F) (C) (MW) 42.1 10,642 11,226 12.2:1 311 141 5,163 1,018 548 PG6581B (lb/sec) (kg/sec) (rpm) (F) (C) (hp) 58,380 (Btu/shp-hr) 7,650 12.0:1 309 140 5,111 1,011 544 M6581B
12
MS6001B
The MS6001B is a performance proven 40 MW class gas turbine, designed for reliable 50/60 Hz power
generation and 50,000 hp class mechanical drive service. With availability well documented at 97.1% and
reliability at 99.3%, it is the popular choice for efficient, low installed cost power generation or prime movers
in mid-range service.
With over 980 units in service, the versatile and widely used 6B gas turbine has accumulated over
45 million operating hours in a broad range of applications: simple cycle, heat recovery, combined cycle,
and mechanical drive. It can be installed fast for quick near-term capacity.
The rugged and reliable 6B can handle multiple start-ups required for peak load. It can accommodate a
variety of fuels and is well suited to IGCC. In combined cycle operation the 6B is a solid performer at nearly
50% efficiency. It is also a flexible choice for cogeneration applications capable of producing a thermal
50 Hz
S206B S406B S106B
Like all GE heavy-duty gas turbines, the 6B has earned a solid reputation for high reliability and environ60 Hz
mental compatibility. With a Dry Low NOx combustion system, the 6B is capable of achieving less than
S206B S406B
130.7 261.3
6,850 6,850
7,225 7,225
49.8% 49.8%
2 x MS6001B 4 x MS6001B
With its excellent fuel efficiency, low cost per horsepower and high horsepower per square foot, the MS6001B
MS6001C
MS6001C SIMPLE CYCLE PERFORMANCE RATINGS
50 Hz Output (MW) (Btu/kWh) (kJ/kWh) Heat Rate Pressure Ratio Mass Flow Turbine Speed Exhaust Temperature Model Designation (lb/sec) (kg/sec) (rpm) (F) (C) 45.4 9,315 9,830 19.6:1 270 122 7,100 1,078 581 60 Hz 45.3 9,340 9,855 19.6:1 270 122 7,100 1,078 581 PG6591C
13
MS6001C
The 6C meets the need for low-cost electricity production in heat recovery operations for both 50 and 60 Hz
including industrial cogeneration, district heating, and mid-sized combined-cycle power plants.
Consistent with GEs evolutionary design philosophy, the 6C incorporates technologies that have been validated
in service worldwide. This evolutionary approach ensures users of the 6C that they are receiving advanced
but well-proven technology. The Frame 6C builds on the experience and performance of GEs Frame 6B
technology, proven in more than 45 million hours of service, and also incorporates key features of GEs
advanced F technology.
The turbine includes components that provide high reliability and maintainability, such as a 12-stage compressor
with fewer parts and removable blades and vanes. NOx emissions are limited to 15 ppm dry when operating
on natural gas, and 42 ppm when burning light distillate with water injection.
Akenerji Kemalpasa-Izmir Turkey 206C Combined-CycleCOD since November 2005 Rigorous field validation tests conducted at the Kemalpasa 6C launch site confirmed the outstanding operability of the turbinehigh efficiency and low emissions.
PSP30646-02
60 Hz 50 Hz
14
GE provides a broad range of power packages from 5 MW to nearly 50 MW for simple cycle, combined
cycle or cogeneration applications in the utility, private and mobile power industries. Marine applications
for these machines range from commercial fast ferries and cruise ships to military patrol boats, frigates,
GE is a world leader in high-technology turbine products and services for the oil & gas industry.
RDC26874-04
We offer full turnkey systems and aftermarket solutions for production, LNG, transportation, storage,
S M A L L H E AV Y - D U T Y a n d A E R O D E R I VAT I V E G A S T U R B I N E S
GE5
Generator Drive*
GE10
MS5001
GE5
GE10
Mechanical Drive**
MS5002C
MS5002E
*ISO conditions natural gas electrical generator terminals **ISO conditions natural gas shaft output
15
Pressure Ratio 40:1 40:1 31.5:1 29.2:1 30.9:1 29.3:1 28.5:1 23:1 23:1 19.4:1 18.0:1 16.0:1 20.2:1 40:1 40:1 31.3:1 3,600 299 136 819 437 3,600 456 207 782 417 3,600 458 207.6 780 416 7,900 104 47 915 491 3,000 142 64 894 479 3,000 154 70 1001 538 3,000 168 76 927 497
GE Energys Oil & Gas products are installed in major upstream, midstream, downstream and distribution applications around the world.
Turbine Speed (rpm) 3,000 3,000 3,627 3,627 3,627 3,627 3,627 3,600 3,600 201 91 977 525 202 92 976 524 279 272 127 123 838 853 448 456 292 132 834 446 284 129 817 436 456 302 207 137 783 813 417 434 458 208 782 416
LMS100PA 98,359 50,041 42,890 46,903 41,711 40,400 32,916 32,689 26,463 22,346 17,674 13,748 98,816 98,196 50,080 43,471 46,824 42,336 40,200 33,394 33,165 27,763 23,292 17,606 13,769 Output (hp) 59,355 45,740 45,417 31,164 24,146 19,105 8,896 7,872 7,986 10,283 10,315 10,158 9,148 9,391 9,369 8,833 8,915 8,725 8,621 7,873 8,925
98,894
7,979
LM6000PC
LM6000PD Sprint
LM2500RC
50 Hz Power Gen
LM2500RD
LM2500PH
LM2000PE
S M A L L H E AV Y - D U T Y a n d A E R O D E R I VAT I V E G A S T U R B I N E S
LM2000PS
LM1600PE
LMS100PA
LMS100PB
LM6000PC Sprint*
LM6000PC
LM6000PD Sprint
LM6000PD
452
LM2500RC
60 Hz Power Gen
LM2500RD
LM2500PH
LM2500PE
LM2000PS
LM1600PE
LM6000PC
LM2500RD
LM2500PE
LM2000PE
*Sprint 2002 deck is used with water injection to 25 ppmvd for power enhancement. NOTE: Performance based on 59F amb. Temp., 60% RH, sea level, no inlet/exhaust losses on gas fuel with no NOx media unless otherwise specified
Mechanical Drive
LM1600PE
PSP30305
LM2500RC
IGCC
GE GAS TURBINES FOR IGCC APPLICATIONS
Gas Turbines Model GE10 6B 7EA 9E 6FA 7FA 9FA 7FB 90 MW (50/60 Hz) 197 MW (60 Hz) 286 MW (50 Hz) 232 MW (60 Hz) 90 MW (60 Hz) 150 MW (50 Hz) 42 MW (50/60 Hz) 10 MW (50/60 Hz) GE10 106B 107EA 109E 106FA 107FA 109FA 207FB Syngas Power Rating Model IGCC Syngas CC Output Power 14 MW (50/60 Hz) 63 MW (50/60 Hz) 130 MW (60 Hz) 210 MW (50 Hz) 130 MW (50/60 Hz) 280 MW (60 Hz) 420 MW (50 Hz) 750 MW (60 Hz)
16
I G CC
Integrated Gasification Combined Cycle (IGCC) technology is increasingly important in the world energy
market, where low cost opportunity feedstocks such as coal, heavy oils and pet coke are the fuels of choice.
And IGCC technology produces low cost electricity while meeting strict environmental regulations.
The IGCC gasification process cleans heavy fuels and converts them into high value fuel for gas turbines.
Pioneered by GE almost 30 years ago, IGCC technology can satisfy output requirements from 10 MW to
more than 1.5 GW and can be applied in almost any new or re-powering project where solid and heavy
Optimal Performance
For each gasifier type and fuel, there are vast numbers of technical possibilities. Integrated Gasification
Combined Cycle (IGCC) systems can be optimized for each type of fuel as well as site and environmental
requirements. Using knowledge gained from successfully operating many IGCC units, GE has optimized
system configurations for all major gasifier types and all GE IGCC gas turbine models.
PSP30120
Experience
This 550 MW IGCC is located at the Saras oil refinery in Sardinia. The three GE 109E singleshaft combined cycle units have accumulated over 12,000 hours of syngas operation.
GE engages experts from throughout the gasification industry at both operating and research levels to
develop the most economical and reliable approaches to IGCC technology. Using the same combined cycle
technology for IGCC that we use for conventional systems, GE offers extensive experience and high levels
Cover Photo: PSP30502-03, Inside Cover Photos: RDC27191-05-05, PSP30502-01. Designed by GE Energy Creative Services.
of reliability.
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GER-3935B
GE Power Systems
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The unique feature of an H technology, combined-cycle system is the integrated heat transfer system, which combines both the steam plant reheat process and gas turbine bucket and nozzle cooling. This feature allows the power generator to operate at a higher firing temperature, which in turn produces dramatic improvements in fuel-efficiency. The end result is generation of electricity at the lowest, most competitive price possible. Also, despite the higher firing temperature of the H System, combustion temperature is kept at levels that minimize emission production. GE has more than two million fired hours of experience in operating advanced technology gas turbines, more than three times the fired hours of competitors units combined. The H System design incorporates lessons learned from this experience with knowledge gleaned from operating GE aircraft engines. In addition, the 9H gas turbine is the first ever designed using Design for Six Sigma methodology, which maximizes reliability and availability throughout the entire design process. Both the 7H and 9H gas turbines will achieve the reliability levels of our F-class technology machines. GE has tested its H System gas turbine more thoroughly than any system previously introduced into commercial service. The H System gas turbine has undergone extensive design validation and component testing. Full-speed, noload testing (FSNL) of the 9H was achieved in May 1998 and pre-shipment testing was completed in November 1999. This H System will also undergo approximately a half-year of extensive demonstration and characterization testing at the launch site. Testing of the 7H began in December 1999, and full-speed, no-load testing was completed in February 2000. The 7H gas turbine will also be subjected to extensive demonstration and characterization testing at the launch site. 1
Conceptual Design
The GE H System is a combined-cycle plant. The hot gases from the gas turbine exhaust proceed to a downstream boiler or heat recovery steam generator (HRSG). The resulting steam is passed through a steam turbine and the steam turbine output then augments that from the gas turbine. The output and efficiency of the steam turbines bottoming cycle is a function of the gas turbine exhaust temperature. For a given firing temperature class, 2600F / 1430C for the H System, the gas turbine exhaust temperature is largely determined by the work required to drive the compressor, that is, in turn, affected by the compressor pressure ratio. The H Systems pressure ratio of 23:1 was selected to optimize the combined-cycle performance, while at the same time allowing for an uncooled last-stage gas turbine bucket, consistent with past GEPS practice. The 23:1 compressor-pressure ratio, in turn, determined that using four turbine stages would provide the optimum performance and cost solution. This is a major change from the earlier F class gas turbines, which used a 15:1 compressor-pressure ratio and three turbine
Figure 1. Combustion and firing temperatures Combustion temperature must be as low as possible to establish low NOx emissions, while the firing temperature must be as high as possible for optimum cycle efficiency. The goal is to adequately cool the stage 1 nozzle, while minimizing the decrease in combustion product temperature as it passes through the stage 1 nozzle. This is achieved with closed-loop steam cooling.
AIR IN
AIR IN
STEAM IN
OUT
IN
STEAM OUT
NOZZLE DT = 280F/155C
NOZZLE DT = 80F/44C
Figure 2. Impact of stage 1 nozzle cooling method of compressor discharge air, thereby allowing more to flow to the head-end of the combustor for fuel premixing. In conventional gas turbines, compressor air is also used to cool rotational and stationary components downstream of the stage 1 nozzle in the turbine section. This air is traditional labeled as chargeable air, because it reduces cycle performance. In H System gas turbines, this chargeable air is replaced with steam, which
GE is moving forward concurrently with development of the 9H and 7H. However, in response to specific customer commitments, the 9H was
2400 (1316) 2600 (1430) 953 (433) 15 263 56.0 9 1230 (558) 23 400 60 9
Table 2. H Technology performance characteristics (60 Hz) tices within the industry, but has been driven by customer input to GE. The specified output of the H technology products is 400 MW at 60 Hz and 480 MW at 50 Hz in a single-shaft, combined-cycle system. The 9H has been introduced at 25 ppm NOx, based on global market needs and economics. GE Power Systems GER-3935B (10/00)
introduced first. The 7H program is following closely, about 12 months behind the 9H. The 7H development has made progress as part of the Advanced Turbine Systems program of the U.S. Department of Energy and its encouragement and support is gratefully acknowledged.
ed by a new, third-generation, full-authority digital system, the Mark VI controller. This control system was designed with and is supplied by GE Industrial Systems (GEIS), which is yet another GE business working closely with GEPS. The control system for the H System manages steam flows between the HRSG, steam turbine and gas turbine. It also schedules distribution of cooling steam to the gas turbine. A diagnostic capability is built into the control system, which also stores critical data in an electronic historian for easy retrieval and troubleshooting. The development of the Mark VI and integrated control system has been deliberately scheduled ahead of the H gas turbine to reduce the gas turbine risk. With the help of GE CR&D, the Mark VI followed a separate and rigorous NPI risk abatement procedure, which included proof of concept tests and shake down tests of a full combined-cycle plant at GE Aircraft Engines in Lynn, Massachusetts. The Systems and controls teams have state-ofthe-art computer simulations at their disposal to facilitate full engineering of control and fallback strategies. Digital simulations also serve as a training tool for new operators. Simulation capability was used in real time during the 9H Full-Speed No-Load (FSNL)-1 test in May 1998. This facilitated revision of the accelerating torque demand curves for the gas turbine and re-setting of the starter motor current and gas turbine combustor fuel schedule. The end result was an automated, one-button, softstart for the gas turbine, which was used by the TEPCO team to initiate the May 30, 1998 customer witness test. The balance of this paper will focus on the gas turbine and its associated development program.
Log Printer
Operator Station
Operator Station
Engineering Workstation
Historian
Redundant Unit Data Highway HMI/ Server Steam Turbine & Bypass Control Gas Turbine & Cooling Steam Control
Static Starter
HMI/ Server
Alarm Printer
All New Microprocessor Design Triple Modular Redundant Remotable I/O Capability for I/O Expansion Redundant Control and Plant Data Highways Peer-to-Peer Communications Time Synchronized Unit Controls Time Coherent System Data Integrated System Diagnostics Independent OS and OT Protection
Combustor Overview
The H System can-annular combustion system is a lean pre-mix DLN-2.5 H System, similar to the GE DLN combustion systems in FA-class service today. Fourteen combustion chambers are used on the 9H, and twelve combustion chambers are used on the 7H. DLN combustion systems have demonstrated the ability to achieve low NOx levels in field service and are capable of meeting the firing temperature requirements of the GE H System gas turbine while obtaining single-digit (ppm) NOx and CO emissions.
Turbine Overview
The case for steam cooling was presented earlier under Conceptual Design. The GE H System gas turbines first two stages use closed-loop steam cooling, the third stage uses air cooling, while the fourth and last stage is uncooled. Closed-loop cooling eliminates the film cooling on the gas path side of the airfoil, and increases the temperature gradients through the airfoil walls. This method of cooling results in higher thermal stresses on the airfoil materials, and has led GEPS to use single-crystal super-alloys for the first stage, in conjunction with thin ceramic thermal barrier coatings (Figure 7). This is a combination that GEAE has employed in its jet engines for 20 years. GEPS reached into the extensive GEAE design, analysis, testing and production database and worked closely with GEAE, its supplier base, and CR&D to translate this experience into a reliable and effective feature of the H System gas turbine design. GE follows a rigorous system of design practices which the company has developed through hav-
Compressor Overview
The H compressor provides a 23:1 pressure ratio with 1510 lb/s (685 kg/s) and 1230 lb/s (558 kg/s) airflow for the 9H and 7H gas turbines, respectively. These units are derived from the high-pressure compressor GE Aircraft Engines (GEAE) used in the CF6-80C2 aircraft engine and the LM6000 aeroderivative gas turbine. For use in the H gas turbines, the CF6-80C2 compressor has been scaled up (2.6:1 for the MS7001H and 3.1:1 for the MS9001H) with four stages added to achieve the desired combination of airflow and pressure ratio. The CF6 compressor design has accumulated over 20 million hours of running experience, providing a solid design foundation for the H System gas turbine. In addition to the variable inlet guide vane (IGV), used on prior GE gas turbines to modulate airflow, the H compressors have variable stator vanes (VSV) at the front of the compressor. They are used, in conjunction with the IGV,
Figure 7. H Stage 1 nozzle and bucket single crystal ing a wide range of experiences with gas turbines in the last 20 years. For instance, GEAEs experience base of over 4000 parts indicates that thermal barrier coating on many airfoils is subject to loss early in operation, and that maximization of coating thickness is limited by deposits from environmental elements, evidenced by coating spallation when thickness limits are exceeded. Through laboratory analyses and experience-based data and knowledge, GE has created an airfoil that has shown, during field tests, that it maintains performance over a specific minimum cyclic life coatings, even with localized loss of coatings, as has been noted during field service.
23:1 Compressor Compressor Rig Tests Full pressure combustion tests Single crystal material Robust TBC coatings Steam Cooling Systems Nozzle cascade test Mark VI Control System
Inlet/Exhaust/Structures Through-Bolt Rotor Cold end drive PS & AE materials DLN combustion Proven analytical tools Proven production sources
Commercial Operation
GE Proprietary
H Event JAE 9
Figure 8. GE validation process data were specified. Plans to abate risk and facilitate design were arranged, funded, and executed. The second development phase covered product conceptual and preliminary designs, and included the introduction of knowledge gained through experience, materials data, and analytical codes from GEPS and GEAE. The H System development program is currently in its third and final phase, technology readiness demonstration. This phase includes execution of detailed design and product validation through component and gas turbine testing. A high degree of confidence has been gained through component and subsystem testing and validation of analysis codes. Completion of the development program results in full-scale gas turbine testing at our factory test stand in Greenville, SC, followed by combined-cycle power plant testing at the Baglan Energy Park launch site, in the United Kingdom.
Combustion Liner
Transition Piece
Figure 11. Combustion system cross-section impingement holes for liner aft cooling. The liner cooling is of the turbolator type so that all available air can be allocated to the reaction zone to reduce NOx. Advanced 2-Cool composite wall convective cooling is utilized at the aft end of the liner. An effusion-cooled cap is utilized at the forward end of the combustion chamber.
Diffusion Gas Holes Uninterrupted Flowpath Diffusion Air Passage Inlet Flow Conditioner
Figure 12. Fuel injector system cross-section GE Power Systems GER-3935B (10/00)
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Figure 13. Combustion mode staging scheme three combustion modes: diffusion, piloted premix, and full premix mode. These modes are supported by the presence of four fuel circuits: outer nozzle premixed fuel (P4), center nozzle premixed fuel (P1), burner quaternary premixed fuel (BQ), and diffusion fuel (D4). The gas turbine is started on D4, accelerated to FullSpeed No-Load (FSNL), and loaded further. At approximately 20-35% gas turbine load, two premixed fuel streams P1, and P4, are activated in the transfer into piloted premix. After loading the gas turbine to approximately 40-50% load, transfer to full premix mode is made and all D4 fuel flow is terminated while BQ fuel flow is activated. This very simplified staging strategy has major advantages for smooth unit operability and robustness. GE Power Systems GER-3935B (10/00)
Figure 15. Comparable combustion dynamics data ignition testing was performed on the fuel injector premixing passages. In all cases the fuel injectors exhibited well in excess of 30 ft/s flameholding margin after the hydrogen torch 11
.dvmpp -2
Program Goal Program Goal Program Margined Goal Progam Margined Goal
Figure 17. Materials validation testing in steam Thermal barrier coating (TBC) is used on the flowpath surfaces of the steam-cooled turbine airfoils. Life validation has been performed using both field trials (Figure 18) and laboratory analysis. The latter involved a test that duplicates thermal-mechanical conditions, which the TBC will experience on the H System airfoils. Long-term durability of the steam-cooled components is dependent on avoidance of internal deposit buildup, which is, in turn, dependent on steam purity. This is accomplished through system design and filtration of the gas turbine cooling steam. Long-term validation testing,
Figure 16. Full-scale stage 1 nozzle heat transfer test validates design and analysis predictions GE Power Systems GER-3935B (10/00)
obtained. A second test series, with actual 9H production nozzles, is scheduled to start in the 4th quarter of 2000).
Figure 19. Nozzle cascade test facility The rotor steam delivery system delivers steam for cooling stage 1 and 2 turbine buckets. This steam delivery system relies on spoolies to deliver steam to the buckets without detrimental leakage, which would lead to performance loss and adverse thermal gradients within the rotor structure. The basic concept for power system steam sealing is derived from many years of successful application of spoolies in the GE CF6 and CFM56 aircraft engine families. In the conceptual design phase, material selection was made only after considering the effects of steam present in this application. Coatings to improve durability of the spoolie were also tested. These basic coupon tests and operational experience provided valuable information to the designers. In the preliminary design phase, parametric analysis was performed to optimize spoolie configuration. Component testing began for both air and steam systems. The spoolie was instrumented to validate the analysis. Again, the combination of analysis and validation tests provided confirmation that the design(s) under consideration were based on the right concept. 13
Figure 20. Rotating rig installed in test stand GE Power Systems GER-3935B (10/00)
Figure 21. 9H gas turbine in half shell prior to first FSNL test 14
Figure 22. 9H gas turbine in test stand for pre-shipment test This second 9H test series took seven fired starts and verified that the gas turbine was ready to ship to the field for the final validation step. Many firsts were accomplished. The pre-shipment test confirmed that the rotating air/steam cooling system performed as modeled and designed. In particular, leakage, which is critical to the cooling and life of the turbine airfoils and the achievement of well-balanced and predictable rotor behaviors, was well under allowable limits. Compressor and turbine blade aeromechanics data were obtained at rates of up to 108% of the design speed, clearing the unit to run at design and over-speed conditions. Rotor dynamics
Validation Summary
GE is utilizing extensive design data and validation test programs to ensure that a reliable H System power plant is delivered to the customer. A successful baseline compressor test program has validated the H System compressor design approach. As a result of the 9H and 15
Conclusion
The rigorous design and technology validation of the H System is an illustration of the GE NPI process in its entirety. It began with a well-reasoned concept that endured a rigorous review
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List of Tables
Table 1. Table 2. H Technology performance characteristics (50 Hz) H Technology performance characteristics (60 Hz)
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