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GT 11 N 2 115 MW
500 600
kJ/kg kg / s
400
500
300
400
PS
mA
200 40
38 300 35
36 28
34 21
32 14
η pR
30 th 7
11N 11 N 2 13 E 2 8C 24/ 26 11 N 11 N 2 13 E2 8C 24 / 26
Specific power (PS ) and thermal efficiency (ηth ) 5 Inlet-air mass flow (m · ) and compressor pressure 6
A
of GTs from ABB (red) and other vendors ratio (pR ) of GTs from ABB (red) and other vendors
(blue, green, white) – all data reduced to 3,600 rev/min (blue, green, white) – all data reduced to 3,600 rev/min
tors employ approximately the same ation for AVA Göttingen through the 2nd been given to reducing the secondary
technology as these. and 3rd generations (NACA profiles) to losses in the peripheral zone and the tip
Development of the compressor profile the 4th and 5th generations with multiple clearance losses as well as to the rela-
has advanced steadily over the past circular arcs and controlled diffusion. tionship between the radial blade clear-
60 years, progressing from the 1st gener- An increasing amount of attention has ance and the surge margin. Additional
ABB burner technologies for natural gas and light oil (no 2) 7
A-A
1 2 G
a
s
4
SA-EV
72 burners for GT13E2 A A
30 burners for GT24
NOx in vppm
>15-25 3
6
5
SBK Dry low-NOx EV-silo
1 burner 36-54 burners 19-54 burners 7
NOx in vppm* NOx in vppm NOx in vppm SEV 2
25-42 40-60 <15-25 24 burners for GT24 EV burner
MPa 8
CMSX-4
+50 °C
CMSX-4
Materials and protective +100 °C 6
DS CM247LC
DS CM247LC
coatings 100
The continued development of the tur- 4
Type GT13E2 gas turbine being assembled in the Mannheim works of ABB 11
stages by direction-solidified blades. Gas turbine design bines (with ratings exceeding 30 MW) is
Single-crystal, nickel alloy blades Over the past 60 years ABB has built based on proven technology and char-
(CMSX2 and CMSX4) represent the latest more than 1,200 gas turbines with a total acterized by simplicity and ease of main-
development step in this area 1 . rating exceeding 50,000 MW. Know-how tenance. A welded shaft and two bear-
An enormous improvement has been based on decades of experience, good ings plus a simple control concept are
made in the long-time creep resistance operational characteristics, a simple the fundamental characteristics of these
and cyclic load capability as well as in the design, technological innovation and a turbines. The design of the smaller gas
turbine inlet temperature, as 10 shows. focus on customers’ requirements, turbines, on the other hand, is tradition-
Long-term experience with blades of this underpin the ABB concept for gas tur- ally based on aero-engine designs. Fun-
type is available from the aero-engine bines and combined cycle power plants. damentally, the design of ABB gas tur-
sector. In the industrial gas turbine field, A report on the design features of the bines has remained unchanged since the
only limited operational experience is many different gas turbine types built by 1960s, although it has been continuously
available with modern DS and SC blades; ABB over six decades appeared in [13, improved through further development in
the repair options, in particular, have to 14]. Between 1947 and 1960 BBC built the years since.
be determined on the basis of oper- dual-shaft gas turbines featuring an inter- 11 shows a GT13E2 during assembly.
ational experience. mediate cooler, air preheater and dual The GT13E2, which was derived from the
The development of coatings for pro- heat supply (with reheat). The advan- GT13E1, has an annular combustor in-
tection against high-temperature cor- tages of a single shaft were soon recog- stead of a silo combustor to keep costs
rosion and oxidation, and also of the so- nized and this design was consequently down and facilitate ease of maintenance
called thermal barrier coatings, has introduced. In spite of the wide range of as well as improve the hot-gas supply.
allowed the cooling air flow rate to be designs based on this concept, the main The design of its combustor is based on
reduced in spite of the higher hot-gas components have remained the same. the annular combustor of the GT8.
temperature. The design of today’s large ABB gas tur- Otherwise, the GT13E1 and GT13E2 are
identical. The mass flows and the turbine bration and freedom from maintenance. radial fixing of the turbine rotor blades,
inlet temperature of the GT13E2 have The critical parts of the rotor are the first which are also secured axially. In the tur-
been increased slightly. The turbine inlet and the last turbine discs as well as the bine zone, the shaft is fitted with heat
temperature could be raised without in- first and last discs of the compressor. shields to protect it from the high thermal
creasing the peak temperature due to the The first compressor disc and the last loading caused by the hot gas. These
uniform temperature profile of the annular turbine disc have to be able to withstand shields are cooled by the compressor air,
combustor. high centrifugal forces; the last compres- which is also used to cool the front rotor
One of the most important com- sor disc and the first turbine disc, on the blades. The shaft lies in two bearings,
ponents of the gas turbine is the shaft. other hand, are subjected to high tem- access to which is easily gained without
This is subjected to massive centrifugal peratures. Field experience with the having to open the machine. The axial
forces at high temperatures. The rotor- welded rotor shows it to be very robust position of the rotor is fixed by a thrust
cooling, which protects the rotor from the with respect to both low cycle fatigue bearing in the inlet casing.
hot gas, and the slow, controlled warm- and reliability. Other manufacturers build rotors with
up during cold starting (to keep the ther- For gas turbines in the 30-MW class discs held together by pretensioned
mal stresses low) are important rotor and above, the usual practice at ABB is bolts. Mutual slipping of the discs is pre-
design criteria. Other suppliers use differ- to build up the shafts by welding forged vented either by Hirth-type serrations or
ent designs for their rotors, based on discs together. Tests are carried out on by the friction between the faces of the
their traditional design and production the discs and the welded shaft to verify discs.
concepts. The comparison of the rotor the mechanical properties and to identify Modern high-temperature gas turbines
designs of other vendors in [15] shows possible faults. The compressor rotor increasingly are being employed with
the main operational benefits of the blades are fixed in circumferential slots. waste heat recovery boilers in combined
welded construction, namely lower vi- So-called ‘fir-tree’ roots are used for the cycle plants. Since the generator drive is
located on the cold side of the compres- with EV burners. The sequential com- The design of the compact high-
sor, the entire turbine torque is trans- bustion system is based on 45 years pressure annular combustor is similar to
mitted via the compressor to the gener- of operating experience with a total of that of the proven GT13E2. Both the
ator. When the torque is transmitted by 27 units. 1978 saw the first single-shaft inner and outer casings consist of simple,
friction via the discs, this has caused dif- machine to be based on this concept convection-cooled segments. The ends
ficulties in the past. However, years of built for the air-storage plant in Huntdorf, of the 30 EV burners, which are fixed to
experience and further development Germany. the hood, are located in the front sege-
work in this area have led to the bolted The inlet casing of the GT24/26 is of ment. The fuel distribution systems for
shaft also acquiring a reputation for being compact design and features an opti- the natural gas and oil are integrated in
robust in operation. mized inlet flow. Also, the bearings and the hood.
the monitoring sensors can be removed The low-pressure SEV combustor is
without having to dismantle the casing. of compact, annular design with seg-
Design features of the GT24/26 The compressor has 22 stages (pressure ments which are cooled, as in the case of
The GT24 (60 Hz) and the GT26 (50 Hz) ratio 30 : 1) with three rows of adjustable the high-pressure combustor, by con-
both belong to the same gas turbine guide vanes, resulting in relatively low vection. The diffusors in front of the
family. 12 shows a cutaway drawing of stage loads and very good part-load be- 24 fuel injection lances are effusion-
the GT24 and 13 a view of the same type haviour 14 . 15 shows the main com- cooled.
during assembly. Almost all of the com- ponents of the middle section: the final The 3-D twisted turbine blades 15
ponents of the GT26 are scaled-up compressor stage, the sequential com- are designed for use with a shroud joint.
(1.2 : 1) versions of the GT24 com- bustion system with high-pressure tur- The rotor blades have axial fir-tree roots.
ponents. ABB employs tried and tested bine stage in the center, and the 4-stage Appropriate cooling of the high-pressure
solutions here too: a welded shaft with low-pressure turbine on the exhaust-gas stage blades and of three stages of the
two bearings and an annular combustor side. low-pressure turbine ensure that the
supports. 70
40 50 60 70 80 90 % 100
L
such as start-up, load reduction and fre- Red GT24/26 gas turbines combined cycle plants KA24/26
quency support. The new requirements Blue ‘F’ class gas turbines from other vendors
are due to the operating range being Green ‘G’ class gas turbines from other vendors
lation of the operating conditions. While Among the key technologies attracting [10] A. Aigner et al: Second generation
the protection measures serve oper- interest are the combustion process and low-emission combustors for ABB gas
ational reliability, they also generally im- the combustor design, primarily as a re- turbines: tests under full engine con-
pair the availability of the installation. The sult of the growing importance being ditions. Gas Turbine and Aeroengine
availability therefore has to be secured by given to fuel flexibility. Congress and Exposition, Brussels,
introducing redundancy where neces- Sequential combustion, the high Belgium, June 11–14 1990, Paper no
sary, by adopting automatic test pro- pressure ratio of the GT24/26 and the 90-GT-308.
cedures, and by the use of reliable, rug- low and medium BTU burners in the [11] F. Joos et al: The SEV combustor:
ged components. The most important GT11N2 and GT13E2, are future- an innovative concept leading to single
functions of the protection system are oriented gas turbine technologies that digit NOx emission levels. PowerGen ’95
protective load shedding (load reduced show that ABB is on the right path. Asia, Sept 27-29, Singapore.
to zero in 2 minutes) and the gas turbine [12] K. Döbbeling et al: Low NOx pre-
trip. The latter should be avoided when- mixed combustion of MBTU fuels using
ever possible due to the high stress it References the ABB double-cone burner (EV burner).
imposes on the machine. [1] A. Meyer: The combustion gas tur- International Gas Turbine and Aeroengine
bine: its history, development and pros- Congress and Exposition, The Hague,
pects. Brown Boveri Rev 26 (1939) 6, Netherlands, June 13–16, 1994.
Future prospects 127–140. [13] W. Endres: 40 years of Brown
Reflecting the current positive market [2] A. Stodola: Load tests of a combus- Boveri gas turbines. Brown Boveri Rev
trend, gas turbine development is pro- tion gas-turbine built by Brown, Boveri & 66 (1979) 2, 61–67.
gressing at a fast pace [4, 5, 16, 17]. An Company. Brown Boveri Rev 27 (1940) 4, [14] W. Endres: Gas turbine types 9, 11
increase in the unit rating and thermal 79–83. and 13, development and performance.
efficiency in parallel with acceptable [3] D. Mukherjee: Experience with un- Brown Boveri Rev 64 (1977) 1, 5–11.
emission levels and a rugged design will conventional gas turbine fuels. ABB [15] W. Endres: Rotor design for large
continue to be the main focal points. Review 9/95, 29–37. industrial gas turbines. International Gas
Sequential combustion and further devel- [4] R. Farmer: Steam-cooled 501G rated Turbine and Aeroengine Congress and
opment of the core technologies will 230 MW with 2600 ˚F rotor inlet tempera- Exposition, Cologne, Germany, June 1–4,
enable ABB to achieve, in the near future, ture. Gas Turbine World, Nov/Dec 1994, 1992.
the goal of 60 percent thermal efficiency 22–27. [16] J. C. Corman: Gas turbine power
without compromising power plant avail- [5] J. C. Corman, T. C. Paul: Power sys- generation – status and environmental
ability. tems for the 21st century. ‘H’, Gas Tur- considerations. ASME 95-CTP-29.
All GT manufacturers are committed bine Combined Cycles, GER-3935. [17] H. Matsuzaki et al: Development of
to further development of the key tech- [6] Siemens unveils 240 MW V94.3 gas advanced gas turbines. ASME IGTI Con-
nologies. Steam cooling of the gas tur- turbine. Modern Power Systems – Staff ference, Birmingham, 1996.
bines in a closed loop which is integrated Report. March 1995.
in the combined-cycle process, as pat- [7] H. Dörr: Die neue Generation der
ented by ABB already in 1982, has to leistungsstarken Gasturbinen für den
be introduced with care. Problems invol- Einsatz in GuD/Kombi-Kraftwerken in
ving deposits and blockage of the small Einwellenanordnung. BWK, vol 48 (1996)
cooling holes, start-up with cooling air, 1/2, 47–51.
then changeover to steam, load change, [8] F. Farkas: The development of a
shutdown, etc, have to be solved for multi-stage, heavy-duty transonic com-
large-scale commercially viable instal- pressor for industrial gas turbines. ASME
lations. Synergies can without doubt be 86-GT-91.
found in certain areas (eg, materials, pro- [9] T. Sattelmayer et al: Second gener- Author’s address
tective coatings and CFD) and full benefit ation low-emission combustors for ABB Dr. Dilip K. Mukherjee
should be taken of this potential through gas turbines: burner development and ABB Power Generation
joint development work in international tests at atmospheric pressure. Turbine P.O. box
committees that include the gas turbine and Aeroengine Congress and Exposi- CH-5401 Baden
manufacturers. This should also have tion, Brussels, Belgium, June 11–14 Switzerland
cost benefits for the manufacturers. 1990, Paper no 90-GT-162. Telefax: +41 56 205 28 88