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Gas Combined Cycle
Gas Turbine Design
In gas turbine design the firing temperature, compression ratio, mass flow, and centrifugal stresses are the factors limiting both unit size and efficiency. For example, each 55°C (100°F) increase in firing temperature gives a 10 - 13 percent output increase and a 2 - 4 percent efficiency increase. The most critical areas in the gas turbine determining the engine efficiency and life are the hot gas path, i.e., the combustion chambers and the turbine first stage stationary nozzles and rotating buckets. The components in these areas represent only 2 percent of the total cost of the gas turbine, yet they are the controlling factor in limiting gas turbine output and efficiency. The development process takes time, however, because each change of material may require years of laboratory and field tests to ensure its suitability in terms of creep strength, yield limit, fatigue strength, oxidation resistance, corrosion resistance, thermal cycling effects, etc. Manufacturers use various combustor arrangements: General Electric has several combustors mounted in a ring around the turbine; Asea Brown Boveri sometimes has a single combustor above the turbine; Siemens has two combustors, one on each side of the turbine. Gas turbines can be fueled with natural gas, diesel oil (distillate), and even residual or crude oil if appropriate customized fuel treatment facilities are installed and properly operated.
Turbine nozzles and buckets are cast from nickel super alloys and are coated under vacuum with special metals (platinum-chromium-aluminide) to resist the hot corrosion that occurs ! the high temperatures encountered in the first stage of the turbine, particularly if contaminants such as sodium, vanadium and potassium are present. Only a few parts per million of these contaminants can cause hot corrosion of uncoated components at the high firing temperature encountered. With proper coating of nozzles and buckets and treatment of fuels to minimize the contaminants, manufacturers claim the hot-gas-path components should last 30,000 to 40,000 hours of operation before replacement, particularly the hot-gas-path parts, that give rise to the relatively high maintenance cost for gas turbines (typical O&M annual costs of 4 percent of the capital cost).
The continuing improvements in firing temperatures and compression ratios has permitted manufacturers to increase the operating performance on the same basic gas turbine frame or housing. For example, General Electric introduced its Frame 7 series in 1970 with a rating of 45 MW, a firing temperature of 900°C (1650 °F) and an air flow of 0.8 million kgs (1.8 million lbs) per hour. Through many changes and upgrades the latest Model F of the same Frame 7 series has a rating of 147 MW, a firing temperature of 1260°C (2300°F) and an air flow of 1.5 million kgs (3.3 million lbs) per hour. One of the major advances made was to air cool nozzles and buckets using bleed air from the compressor to increase the firing temperature while limiting the metal temperatures of the nozzles and buckets to withstand hot corrosion and creep. This limiting of the
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 28°C (50°F) 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.
Aeroderivitive Versus Industrial Gas Turbines
The advanced gas turbine designs available today are largely due to the huge sums that have been spent over the last 50 years to develop effective jet engines for military applications, including their adaptation as gas turbine propulsion systems for naval vessels. The commercial aviation, electric power and to a lesser extent, the sea and land transportation industries, have benefited accordingly. Given the aircraft designer's need for engine minimum weight, maximum thrust, high reliability, long life and compactness, it follows that the cutting-edge gas turbine developments in materials, metallurgy and thermodynamic designs have occurred in the aircraft engine designs, with subsequent transfer to land and sea gas turbine applications. However, there are weight and size limitations to aircraft engine designs, whereas the stationary power gas turbine designers are seeking ever larger unit sizes and higher efficiency.
To emphasize this difference in approach, today the largest aeroderivative power gas turbine is probably General Electric's 40 MW LM6000 engine with a 40 percent simple-cycle efficiency and a weight of only 6 tons. This engine is adapted from the CF6-80C2 engine that is used on the CF6 military transport aircraft. By comparison, General Electric's largest industrial gas turbine, the Frame 9 Model F has an output of about 200 MW, an open-cycle efficiency of 34 percent, but is huge compared to the LM6000 and weights 400 tons. The aeroderivative is a light weight, close clearance, high efficiency power gas turbine suited to smaller systems. The industrial or frame type gas turbine tends to be a larger, more rugged, slightly less efficient power source, better suited to base-load operation, particularly if arranged in a combined-cycle block on large
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 1985-1989 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 Sizes/Costs
Gas turbines of about 150 MW size are already in operation manufactured by at least four separate groups-General Electric and its licensees, Asea Brown Boveri, Siemens, and Westinghouse/Mitsubishi. These groups are also developing, testing and/or marketing gas turbine sizes of about 200 MW. Combined-cycle units are made up of one or more such gas turbines, each with a waste heat steam generator arranged to supply steam to a single steam turbine, thus formatting a combined-cycle unit or block. Typical combined-cycle block sizes offered by three major manufacturers (Asea Brown Boveri, General Electric and Siemens) are roughly in the range of 50 MW to 500 MW and costs are about $600/kW.
Combined Cycle Efficiencies
Combined-cycle efficiencies are already over 50 percent and research aimed at 1370°C (2500°F) turbine inlet temperature may make 60 percent efficiency possible by the turn of the century, according to some gas turbine manufacturers.
Low-Grade Fuel for Turbines
Gas turbines burn mainly natural gas and light oil. Crude oil, residual, and some distillates contain corrosive components and as such require fuel treatment equipment. In addition, ash deposits from these fuels result in gas turbine deratings of up to 15 percent They may still be economically attractive fuels however, particularly in combined-cycle plants.
Sodium and potassium are removed from residual, crude and heavy distillates by a water washing procedure. A simpler and less expensive purification system will do the same job for light crude and light distillates. A magnesium additive system may also be needed to reduce the corrosive effects if vanadium is present.
Fuels requiring such treatment must have a separate fuel-treatment plant and a system of accurate fuel monitoring to assure reliable, low-maintenance operation of gas turbines.
Alternative Combined Cycle Designs
Gas dampers are often provided so the gas turbine exhaust can bypass the heat recovery boiler allowing the gas turbine to operate if the steam unit is down for maintenance. In earlier designs supplementary oil or gas firing was also included to permit steam unit operation with the gas turbine down. This is not normally provided on recent combined-cycle designs, because it adds to the capital cost, complicates the control system, and reduced efficiency.
Sometimes as many as four gas turbines with individual boilers may be associated with a single steam turbine. The gas turbine, steam turbine, and generator may be arranged as a single-shaft design, or a multishaft arrangement may be used with each gas turbine driving a generator and exhausting into its heat recovery boiler with all boilers supplying a separate steam turbine and generator.
Combined-Cycle Shaft Arrangements
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 hot-gas-path inspections and for major overhauls, which usually involve hot-gas-path 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 combined-cycle 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 15°C ambient decreasing to 2,000 MW at 32°C. 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.
GAS
TURB
INE
AND
CO
MBI
NED
CYC
LE P
ROD
UCT
S
GE
Ener
gy
The
Pow
er o
f Tec
hnol
ogy,
Exp
erie
nce
and
Inno
vatio
n
The
wor
ld d
eman
ds a
rel
iabl
e su
pply
of c
lean
, dep
enda
ble
pow
er. A
lway
s on
the
cut
ting
edge
of g
as
turb
ine
tech
nolo
gy, G
E of
fers
a w
ide
arra
y of
tec
hnol
ogic
al o
ptio
ns t
o m
eet
the
mos
t ch
alle
ngin
g
ener
gy r
equi
rem
ents
. Usi
ng a
n in
tegr
ated
app
roac
h th
at in
clud
es p
arts
, ser
vice
, rep
air
and
proj
ect
man
agem
ent,
we
deliv
er r
esul
ts t
hat
cont
ribu
te t
o ou
r cu
stom
ers’
suc
cess
. And
our
rep
utat
ion
for
exce
llenc
e ca
n be
see
n in
eve
ryth
ing
we
do.
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9,79
510
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2 2 6 6 8 8 10 11 12 13 14 16
GE
ENER
GY
GA
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RBIN
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CO
MB
INED
CYC
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CC52
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5,69
06,
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Btu/
kWh
kJ/k
Wh
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5,69
06,
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CC41
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9,31
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MS9
001H
MS7
001H
MS9
001F
B
MS7
001F
B
MS7
001F
A
MS9
001F
A
MS9
001E
MS7
001E
A
MS6
001C
MS6
001B
Hea
vy D
uty
Smal
l Hea
vy-D
uty
and
Aero
deriv
ativ
e G
as T
urbi
ne
Prod
ucts
Ove
rvie
w
IGCC
(Int
egra
ted
Gas
ifica
tion
Com
bine
d C
ycle
) Ove
rvie
w
NO
TE: A
ll ra
tings
are
net
pla
nt b
ased
on
ISO
con
ditio
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nd n
atur
al g
as fu
el.
All C
C r
atin
gs s
how
n ab
ove
are
base
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a 1
GT/
1 ST
con
figur
atio
n.
8
Out
put
Hea
t Rat
e
Wor
ld’s
Mos
t Adv
ance
d C
ombi
ned
Cyc
le G
as T
urbi
ne T
echn
olog
y
GE’
s H
Sys
tem
™—
the
wor
ld’s
mos
t adv
ance
d co
mbi
ned
cycl
e sy
stem
and
the
first
cap
able
of b
reak
ing
the
60%
eff
icie
ncy
barr
ier—
inte
grat
es th
e ga
s tu
rbin
e, s
team
turb
ine,
gen
erat
or a
nd h
eat r
ecov
ery
stea
m
gene
rato
r in
to a
sea
mle
ss s
yste
m, o
ptim
izin
g ea
ch c
ompo
nent
’s p
erfo
rman
ce. U
ndou
bted
ly th
e le
adin
g
tech
nolo
gy fo
r bo
th 5
0 an
d 60
Hz
appl
icat
ions
, the
H d
eliv
ers
high
er e
ffic
ienc
y an
d ou
tput
to r
educ
e th
e
cost
of e
lect
ricity
of t
his
gas-
fired
pow
er g
ener
atio
n sy
stem
.
Clo
sed-
Loop
Ste
am C
oolin
g
Ope
n lo
op a
ir-co
oled
gas
turb
ines
hav
e a
sign
ifica
nt te
mpe
ratu
re d
rop
acro
ss th
e fir
st s
tage
noz
zles
, whi
ch
redu
ces
firin
g te
mpe
ratu
re a
nd th
erm
al e
ffic
ienc
y. T
he c
lose
d-lo
op s
team
coo
ling
syst
em a
llow
s th
e tu
rbin
e
to fi
re a
t a
high
er te
mpe
ratu
re fo
r in
crea
sed
perf
orm
ance
. It i
s th
is c
lose
d-lo
op s
team
coo
ling
that
ena
bles
the
H S
yste
m™
to a
chie
ve 6
0% fu
el e
ffic
ienc
y ca
pabi
lity
whi
le m
aint
aini
ng a
dher
ence
to th
e st
ricte
st lo
w N
Ox
stan
dard
s an
d re
duci
ng C
O2
emis
sion
s. A
dditi
onal
ly, c
lose
d-lo
op c
oolin
g al
so m
inim
izes
par
asiti
c ex
trac
tion
of c
ompr
esso
r di
scha
rge
air,
ther
eby
allo
win
g m
ore
air
to fl
ow to
the
com
bust
or fo
r fu
el p
rem
ixin
g, th
ereb
y
enab
ling
low
er e
mis
sion
s.
H S
yste
m™
2 H SYSTEM™
An
MS9
001H
is s
een
durin
g
asse
mbl
y in
the
fact
ory.
Bag
lan
Bay
Pow
er S
tatio
n is
the
laun
ch s
ite fo
r G
E’s
H S
yste
m™
.
RDC27903-13-03
PSP30462-05
520
5,69
0 6,
000
60.0
%
1 x
MS9
001H
MS9
001H
/MS7
001H
CO
MBI
NED
CYC
LE P
ERFO
RMAN
CE
RATI
NG
S
Net
Pla
ntO
utpu
t (M
W)
S109
H
50 Hz 60 Hz
(Btu
/kW
h)H
eat R
ate
(kJ/
kWh)
Net
Pla
ntEf
ficie
ncy
GT
Num
ber
& T
ype
400
5,69
0 6,
000
60.0
%
1 x
MS7
001H
S107
H
Sing
le C
ryst
al M
ater
ials
The
use
of th
ese
adva
nced
mat
eria
ls a
nd T
herm
al B
arrie
r C
oatin
gs e
nsur
es th
at c
ompo
nent
s w
ill s
tand
up to
hig
h fir
ing
tem
pera
ture
s w
hile
mee
ting
mai
nten
ance
inte
rval
s.
Dry
Low
NO
xC
ombu
stor
s
Build
ing
on G
E’s
desi
gn e
xper
ienc
e, th
e H
Sys
tem
™em
ploy
s a
can-
annu
lar
lean
pre
-mix
DLN
-2.5
Dry
Low
NO
x(D
LN) C
ombu
stor
Sys
tem
. Fou
rtee
n co
mbu
stio
n ch
ambe
rs a
re u
sed
on th
e 9H
, and
12 c
ombu
stio
n ch
ambe
rs a
re u
sed
on th
e 7H
. GE
DLN
com
bust
ion
syst
ems
have
dem
onst
rate
d
the
abili
ty to
ach
ieve
low
NO
xle
vels
in s
ever
al m
illio
n ho
urs
of fi
eld
serv
ice
arou
nd th
e w
orld
.
Smal
l Foo
tprin
t/H
igh
Pow
er D
ensi
ty
The
H S
yste
m™
offe
rs a
ppro
xim
atel
y 40
% im
prov
emen
t in
pow
er d
ensi
ty p
er in
stal
led
meg
awat
t
com
pare
d to
oth
er c
ombi
ned
cycl
e sy
stem
s, o
nce
agai
n he
lpin
g to
red
uce
the
over
all c
ost
of
prod
ucin
g el
ectr
icity
.
Thor
ough
ly T
este
d
The
desi
gn, d
evel
opm
ent a
nd v
alid
atio
n of
the
H S
yste
m™
has
been
con
duct
ed u
nder
a re
gim
en o
f ext
ensi
ve
com
pone
nt, s
ub-s
yste
m a
nd fu
ll un
it te
stin
g. B
road
com
mer
cial
intr
oduc
tion
has
been
con
trol
led
to fo
llow
laun
ch u
nits
dem
onst
ratio
n. T
his
thor
ough
test
ing
appr
oach
pro
vide
s th
e in
trod
uctio
n of
cut
ting
edge
tech
-
nolo
gy w
ith h
igh
cust
omer
con
fiden
ce.
3 H SYSTEM ™
Wor
ld’s
firs
t H
tur
bine
is t
rans
port
ed
thro
ugh
Wal
es t
o B
agla
n B
ay P
ower
Sta
tion.
PSP30246-10
RDC27916-09-09
A 9
H g
as t
urbi
ne is
read
ied
for
test
ing.
Wor
ld’s
Mos
t Exp
erie
nced
Adv
ance
d Te
chno
logy
Gas
Tur
bine
s
With
ove
r te
n m
illio
n ho
urs
of o
pera
tion,
our
F c
lass
turb
ines
hav
e es
tabl
ishe
d G
E as
the
clea
r in
dust
ry
lead
er fo
r su
cces
sful
fire
d ho
urs
in a
dvan
ced
tech
nolo
gy g
as tu
rbin
es. R
epre
sent
ing
the
wor
ld’s
larg
est,
mos
t exp
erie
nced
flee
t of h
ighl
y ef
ficie
nt g
as tu
rbin
es, d
esig
ned
for
max
imum
rel
iabi
lity
and
effic
ienc
y
with
low
life
cyc
le c
osts
, our
F c
lass
turb
ines
are
favo
red
by b
oth
pow
er g
ener
ator
s an
d in
dust
rial
coge
nera
tors
req
uirin
g la
rge
bloc
ks o
f rel
iabl
e po
wer
.
Intr
oduc
ed in
198
7, G
E’s
F cl
ass
gas
turb
ines
res
ulte
d fr
om a
mul
ti-ye
ar d
evel
opm
ent p
rogr
am u
sing
tech
nolo
gy a
dvan
ced
by G
E’s
airc
raft
eng
ine
team
and
GE
Glo
bal R
esea
rch.
GE
cont
inua
lly a
dvan
ces
this
tech
nolo
gy b
y in
crem
enta
lly im
prov
ing
the
F cl
ass
prod
uct t
o at
tain
eve
r hi
gher
com
bine
d cy
cle
effic
ienc
ies,
whi
le m
aint
aini
ng r
elia
bilit
y an
d av
aila
bilit
y.
F C
lass
4 F CLASS
Dry
Low
NO
xco
mbu
stor
sys
tem
s al
low
GE’
s F
Cla
ss t
urbi
nes
to m
eet
toda
y’s
stric
t
envi
ronm
enta
l em
issi
ons
requ
irem
ents
.
RDC27305-02a
An
MS9
001F
A g
as t
urbi
ne
ship
s fr
om t
he p
lant
.
PSP30027-06
5 F CL ASS
Our
F c
lass
gas
turb
ines
, inc
ludi
ng th
e 6F
(eith
er 5
0 or
60
Hz)
, the
7F
(60
Hz)
and
the
9F (5
0 H
z), o
ffer
flexi
bilit
y in
cyc
le c
onfig
urat
ion,
fuel
sel
ectio
n an
d si
te a
dapt
atio
n. A
ll F
clas
s ga
s tu
rbin
es in
clud
e an
18-s
tage
axi
al c
ompr
esso
r an
d a
thre
e-st
age
turb
ine,
and
they
feat
ure
a co
ld-e
nd d
rive
and
axia
l exh
aust
,
whi
ch is
ben
efic
ial f
or c
ombi
ned
cycl
e ar
rang
emen
ts w
here
net
eff
icie
ncie
s ov
er 5
8% c
an b
e ac
hiev
ed.
F/FA
/FB
EXPE
RIEN
CE
0
2000
4000
6000
8000
1000
0
1200
0
1400
0 ’95
’96
’97
’98
’99
’00
’01
’02
’03
’04
’05
FIRED HOURS IN THOUSANDS
YEAR
11,8
4411
,594
10,3
27
9,06
1
7,79
46,
859
5,79
04,
899
4,18
63,
575
2,98
9
Hal
f of a
ll 6F
A in
stal
latio
ns a
re lo
cate
d in
Euro
pe. T
his
CH
P pl
ant
is o
wne
d by
Por
voo,
Finl
and.
PSP30114
PSP30210-01
Wor
ld’s
Mos
t Adv
ance
d Ai
r-C
oole
d G
as T
urbi
ne
The
FB is
the
late
st e
volu
tiona
ry s
tep
in G
E’s
prov
en F
ser
ies.
Tak
ing
F te
chno
logy
to a
new
leve
l of o
utpu
t
and
effic
ienc
y, w
e’ve
app
lied
our
cutt
ing-
edge
tech
nolo
gy, i
nclu
ding
the
mat
eria
ls d
evel
oped
for
the
H S
yste
m™
, and
the
expe
rienc
e ga
ined
in o
ver
ten
mill
ion
adva
nced
gas
turb
ine
fired
hou
rs. T
he r
esul
t is
a
larg
e co
mbi
ned
cycl
e sy
stem
des
igne
d to
pro
vide
hig
h pe
rfor
man
ce a
nd lo
w e
lect
rical
cos
t.
Impr
oved
out
put a
nd e
ffic
ienc
y m
eans
bet
ter
fuel
eco
nom
y an
d re
duce
d co
st o
f pro
duci
ng e
lect
ricity
. With
toda
y’s
com
petit
ive
mar
kets
and
unp
redi
ctab
le fu
el p
rices
, thi
s—no
w m
ore
than
eve
r—is
the
key
to s
ucce
ss.
MS7
001F
B a
nd M
S900
1FB
6 MS7001FB and MS9001FB
This
MS7
001F
B is
sho
wn
in
the
fact
ory.
This
MS9
001F
B is
see
n on
hal
f she
ll
durin
g as
sem
bly.
PSP30251-39PSP30510-01
Hun
ters
tow
n, P
A 7
FB la
unch
site
.
PSP30371-02
7 MS7001FB and MS9001FB
In d
evel
opin
g th
e FB
, we
follo
wed
a s
peci
fic c
ours
e th
at s
igni
fican
tly im
prov
ed th
e ke
y dr
iver
of e
ffic
ienc
y—
firin
g te
mpe
ratu
re. T
he F
B fir
ing
tem
pera
ture
was
incr
ease
d m
ore
than
100
deg
rees
Fah
renh
eit o
ver
GE’
s FA
tech
nolo
gy, r
esul
ting
in c
ombi
ned
cycl
e ef
ficie
ncy
ratin
g im
prov
emen
ts o
f bet
ter
than
one
per
cent
age
poin
t. O
utpu
t im
prov
emen
ts o
f mor
e th
an 5
% w
ere
also
ach
ieve
d. T
hese
impr
ovem
ents
equ
ate
to m
ore
MW
per
MBt
u of
nat
ural
gas
bur
ned.
The
use
of a
dvan
ced
turb
ine
mat
eria
ls, s
uch
as S
ingl
e C
ryst
al F
irst S
tage
Buc
kets
, ens
ures
that
com
pone
nts
can
stan
d up
to th
e hi
gher
firin
g te
mpe
ratu
res
of th
e FB
with
out a
n in
crea
se in
mai
nten
ance
inte
rval
s.
Prov
idin
g th
e ba
sis
of p
roce
ss r
igor
, Six
Sig
ma
met
hodo
logi
es w
ere
used
to a
ssur
e a
high
ly r
elia
ble
robu
st
desi
gn o
ptim
ized
for
low
est c
ost o
f ele
ctric
ity. I
ndee
d, in
dev
elop
ing
the
FB, w
e w
ere
able
to m
aint
ain
man
y
of th
e pr
oven
feat
ures
of t
he w
orld
’s m
ost s
ucce
ssfu
l adv
ance
d te
chno
logy
turb
ine,
the
F/FA
.
An
MS7
001F
B is
seen
in t
est
cell.
PSP30266-02
PSP30299
412.
9 5,
880
6,20
2 58
.0%
1
x M
S900
1FB
Net
Pla
ntO
utpu
t (M
W)
S109
FB
50 Hz
(Btu
/kW
h)H
eat R
ate
(kJ/
kWh)
Net
Pla
ntEf
ficie
ncy
GT
Num
ber
& T
ype
60 Hz
825.
4 5,
884
6,20
6 58
.0%
2
x M
S900
1FB
S209
FB
280.
3 5,
950
6,27
6 57
.3%
1
x M
S700
1FB
S107
FB
562.
5 5,
940
6,26
6 57
.5%
2
x M
S700
1FB
S207
FB
MS7
001F
B/M
S900
1FB
COM
BIN
ED C
YCLE
PER
FORM
ANC
E RA
TIN
GS
8 MS6001FA, MS7001FA and MS9001FA
MS6
001F
A, M
S700
1FA
and
MS9
001F
A
Prov
en P
erfo
rman
ce in
a M
id-S
ize
Pack
age
The
high
ly e
ffic
ient
gea
r-dr
iven
6FA
gas
turb
ine
is a
mid
-siz
e ve
rsio
n of
the
wel
l-pro
ven
7FA
and
9FA
. Its
outp
ut r
ange
, hig
h ex
haus
t ene
rgy,
full
pack
agin
g an
d ro
bust
des
ign
idea
lly s
uit a
pplic
atio
ns r
angi
ng fr
om
coge
nera
tion
and
dist
rict h
eatin
g to
pur
e po
wer
gen
erat
ion
in c
ombi
ned
cycl
e an
d In
tegr
ated
Gas
ifica
tion
Com
bine
d Cy
cle
(IGCC
).
To m
eet
the
need
for
mid
-siz
e po
wer
blo
cks
with
hig
h pe
rfor
man
ce in
com
bine
d he
at a
nd p
ower
appl
icat
ions
, the
hig
h-sp
eed
6FA
pro
duce
s 75
.9 M
W o
f sim
ple
cycl
e po
wer
at
35%
eff
icie
ncy
and
117
MW
of c
ombi
ned
cycl
e po
wer
at
54.7
% n
et e
ffic
ienc
y. In
IGC
C o
pera
tion,
gro
ss p
lant
eff
icie
ncie
s
can
reac
h up
to
46%
.
A c
lass
ic e
xam
ple
of G
E’s
evol
utio
nary
des
igns
, the
6FA
is a
2/3
sca
le o
f the
7FA
. Its
aer
odyn
amic
ally
scal
ed 1
8-st
age
axia
l des
ign
redu
ces
com
bust
ion
cham
bers
from
14
to 6
. A c
old-
end
driv
e al
low
s ex
haus
t
gase
s to
be
dire
cted
axi
ally
into
the
HRS
G. W
ith o
ver
860,
000
oper
atin
g ho
urs
and
61 u
nits
inst
alle
d or
on
orde
r, th
e 6F
A p
rovi
des
maj
or fu
el s
avin
gs o
ver
earli
er m
id-r
ange
uni
ts in
bas
e-lo
ad o
pera
tion.
Ada
ptab
le
to s
ingl
e or
mul
ti-sh
aft
conf
igur
atio
ns, i
t bu
rns
a va
riety
of f
ossi
l fue
ls, w
hich
can
be
switc
hed
afte
r st
art-
up
with
out
sacr
ifici
ng p
erfo
rman
ce. O
n na
tura
l gas
the
ava
ilabl
e D
ry L
ow N
Ox
(DLN
) sys
tem
can
ach
ieve
NO
x
emis
sion
s of
15
ppm
.
Indu
stry
Sta
ndar
d fo
r 60
Hz
Pow
er in
All
Dut
y C
ycle
s
The
wid
e ra
nge
of p
ower
gen
erat
ion
appl
icat
ions
for
the
7FA
gas
turb
ine
incl
udes
com
bine
d cy
cle,
cog
ener
a-
tion,
sim
ple
cycl
e pe
akin
g an
d IG
CC in
bot
h cy
cle
and
base
load
ope
ratio
n w
ith a
wid
e ra
nge
of fu
els.
Its
high
relia
bilit
y—co
nsis
tent
ly 9
8% o
r be
tter
—pr
ovid
es c
usto
mer
s m
ore
days
of o
pera
tion
per
year
whi
le m
inim
izin
g
over
all l
ife c
ycle
cos
t.
RDC27834-34
117.
7 6,
240
6,58
2 54
.7%
1
x M
S600
1FA
MS6
00
1FA
CO
MB
INED
CYC
LE P
ERFO
RM
AN
CE
RAT
ING
S
MS6
00
1FA
SIM
PLE
CYC
LE P
ERFO
RM
AN
CE
RAT
ING
S
Net
Pla
ntO
utpu
t (M
W)
S106
FA
50 Hz
(Btu
/kW
h)H
eat R
ate
(kJ/
kWh)
Net
Pla
ntEf
ficie
ncy
GT
Num
ber
& T
ype
60 Hz
237.
9 6,
170
6,50
8 55
.3%
2
x M
S600
1FA
S206
FA
118.
1 6,
250
6,59
3 54
.6%
1
x M
S600
1FA
S106
FA
237.
5 6,
210
6,55
0 54
.9%
2
x M
S600
1FA
S206
FA
(MW
) 75
.9
75.9
50 H
z Po
wer
G
ener
atio
n
Out
put
60 H
z Po
wer
G
ener
atio
n
(Btu
/kW
h)
9,76
0 9.
795
(kJ/
kWh)
10
,295
10
,332
H
eat R
ate
15
.6:1
15
.7:1
Pres
sure
Rat
io
(lb/s
ec)
447
449
(kg/
sec)
20
3 20
4M
ass
Flow
(rpm
) 5,
231
5,25
4Tu
rbin
e Sp
eed
(ºF)
1,
117
1,11
8(º
C)
603
603
Exha
ust T
empe
ratu
re
PG
6111
FA
PG61
11FA
Mod
el D
esig
natio
n
KEPC
O’s
Seo
inch
on P
lant
, one
of t
he w
orld
’s la
rges
t co
mbi
ned
cycl
e pl
ants
, has
ope
rate
d
for
mor
e th
an 4
0,00
0 ho
urs
in
daily
sta
rt/s
top
cycl
ic d
uty.
9As
an
indu
stry
lead
er in
red
ucin
g em
issi
ons,
the
7FA’
s D
LN-2
.6 c
ombu
stor
(pro
ven
in h
undr
eds
of th
ousa
nds
of o
pera
ting
hour
s) p
rodu
ces
less
than
9 p
pm N
Ox
and
CO—
min
imiz
ing
the
need
for
exha
ust c
lean
up s
ys-
tem
s an
d sa
ving
mill
ions
for
our
cust
omer
s.
With
100
s of
uni
ts in
ope
ratio
n, G
E co
ntin
ually
mak
es in
crem
enta
l des
ign
enha
ncem
ents
to im
prov
e ou
tput
,
effic
ienc
y, r
elia
bilit
y an
d av
aila
bilit
y—fo
r ne
w u
nits
and
upg
rade
s to
exi
stin
g un
its. G
E ad
ds c
usto
mer
val
ue
with
pow
er a
ugm
enta
tion
equi
pmen
t tha
t pro
vide
s ad
ditio
nal g
as tu
rbin
e pe
rfor
man
ce in
sum
mer
pea
k
dem
and
perio
ds—
incl
udin
g in
let c
oolin
g, s
team
inje
ctio
n, a
nd p
eak
firin
g.
Prov
en E
xcel
lenc
e in
Rel
iabl
e 50
Hz
Com
bine
d C
ycle
Per
form
ance
Pow
er p
rodu
cers
aro
und
the
wor
ld r
equi
re r
elia
ble
pow
er g
ener
atio
n—w
hich
mak
es th
e 9F
A th
e 50
Hz
gas
turb
ine
of c
hoic
e fo
r la
rge
com
bine
d cy
cle
appl
icat
ions
. As
an a
erod
ynam
ic s
cale
of t
he h
ighl
y su
cces
sful
7FA
gas
turb
ine,
the
9FA
prov
ides
key
adv
anta
ges
that
incl
ude
a fu
el-f
lexi
ble
com
bust
ion
syst
em a
nd h
ighe
r
outp
ut p
erfo
rman
ce.
The
9FA
gas
turb
ine
is c
onfig
ured
with
the
robu
st D
LN-2
.0+.
Idea
lly s
uite
d fo
r di
vers
e fu
els,
this
com
bust
or
is th
e in
dust
ry le
ader
in p
ollu
tion
prev
entio
n fo
r 50
Hz
com
bine
d cy
cle
appl
icat
ions
with
gre
ater
than
56%
effic
ienc
y, a
chie
ving
less
than
25
ppm
NO
x.
The
9FA
can
be c
onfig
ured
to m
eet s
ite a
nd p
ower
req
uire
men
ts. F
or r
e-po
wer
ing
appl
icat
ions
with
spa
ce
limita
tions
, it c
an b
e co
nfig
ured
in a
sin
gle-
shaf
t com
bine
d cy
cle
arra
ngem
ent w
ith th
e ge
nera
tor
and
stea
m
turb
ine.
For
larg
e co
mbi
ned
cycl
e or
cog
ener
atio
n pl
ants
whe
re fl
exib
le o
pera
tion
and
max
imum
per
form
-
ance
is th
e pr
ime
cons
ider
atio
n, it
can
be
arra
nged
in a
mul
ti-sh
aft c
onfig
urat
ion
whe
re o
ne o
r tw
o ga
s
turb
ines
are
com
bine
d w
ith a
sin
gle
stea
m tu
rbin
e to
pro
duce
pow
er b
lock
s of
390
or
786
MW
.
MS6001FA , MS7001FA and MS9001FA
262.
6 6,
090
6,42
4 56
.0%
1
x M
S700
1FA
MS7
00
1FA
CO
MB
INED
CYC
LE P
ERFO
RM
AN
CE
RAT
ING
S
MS7
00
1FA
SIM
PLE
CYC
LE P
ERFO
RM
AN
CE
RAT
ING
S
Net
Pla
ntO
utpu
t (M
W)
S107
FA
60 Hz
(Btu
/kW
h)H
eat R
ate
(kJ/
kWh)
Net
Pla
ntEf
ficie
ncy
GT
Num
ber
& T
ype
529.
9 6,
040
6,37
1 56
.5%
2
x M
S700
1FA
S207
FA
(MW
) 17
1.7
60 H
z Po
wer
Gen
erat
ion
Out
put
(Btu
/kW
h)
9,36
0(k
J/kW
h)
9,87
3 H
eat R
ate
16
.0:1
Pres
sure
Rat
io
(lb/s
ec)
981
(kg/
sec)
44
5M
ass
Flow
(rpm
) 3,
600
Turb
ine
Spee
d
(ºF)
1,
114
(ºC
) 60
1Ex
haus
t Tem
pera
ture
PG
7241
FAM
odel
Des
igna
tion
390.
8 6,
020
6,35
0 56
.7%
1
x M
S900
1FA
MS9
001F
A CO
MBI
NED
CYC
LE P
ERFO
RMAN
CE
RATI
NG
S
MS9
001F
A SI
MPL
E C
YCLE
PER
FORM
ANC
E RA
TIN
GS
Net
Pla
ntO
utpu
t (M
W)
S109
FA50 Hz
(Btu
/kW
h)H
eat R
ate
(kJ/
kWh)
Net
Pla
ntEf
ficie
ncy
GT
Num
ber
& T
ype
786.
9 5,
980
6,30
8 57
.1%
2
x M
S900
1FA
S209
FA
(MW
) 25
5.6
50 H
z Po
wer
Gen
erat
ion
Out
put
(Btu
/kW
h)
9,25
0(k
J/kW
h)
9,75
7 H
eat R
ate
17
.0:1
Pres
sure
Rat
io
(lb/s
ec)
1,41
3(k
g/se
c)
641
Mas
s Fl
ow
(rpm
) 3,
000
Turb
ine
Spee
d
(ºF)
1,
116
(ºC
) 60
2Ex
haus
t Tem
pera
ture
PG
9351
FAM
odel
Des
igna
tion
Fuel
-Fle
xibl
e 50
Hz
Perf
orm
er
The
MS9
001E
gas
turb
ine
is G
E’s
50 H
z w
orkh
orse
. With
mor
e th
an 3
90 u
nits
, it h
as a
ccum
ulat
ed o
ver
14 m
illio
n fir
ed h
ours
of u
tility
and
indu
stria
l ser
vice
, man
y in
ard
uous
clim
ates
ran
ging
from
des
ert h
eat
and
trop
ical
hum
idity
to a
rctic
col
d. O
rigin
ally
intr
oduc
ed in
197
8 at
105
MW
, the
9E
has
inco
rpor
ated
num
erou
s co
mpo
nent
impr
ovem
ents
. The
late
st m
odel
boa
sts
an o
utpu
t of 1
26 M
W a
nd is
cap
able
of
achi
evin
g m
ore
than
52%
eff
icie
ncy
in c
ombi
ned
cycl
e.
Whe
ther
for
sim
ple
cycl
e or
com
bine
d cy
cle
appl
icat
ion,
bas
e lo
ad o
r pe
akin
g du
ty, 9
E pa
ckag
es a
re
com
preh
ensi
vely
eng
inee
red
with
inte
grat
ed s
yste
ms
that
incl
ude
cont
rols
, aux
iliar
ies,
duc
ts a
nd s
ilenc
ing.
They
are
des
igne
d fo
r re
liabl
e op
erat
ion
and
min
imal
mai
nten
ance
at a
com
petit
ivel
y lo
w in
stal
led
cost
.
Like
GE’
s ot
her
E-cl
ass
tech
nolo
gy u
nits
, the
Dry
Low
NO
xco
mbu
stio
n sy
stem
is a
vaila
ble
on 9
E, w
hich
can
achi
eve
NO
xem
issi
ons
unde
r 15
ppm
whe
n bu
rnin
g na
tura
l gas
.
With
its
flexi
ble
fuel
han
dlin
g ca
pabi
litie
s, th
e 9E
acc
omm
odat
es a
wid
e ra
nge
of fu
els,
incl
udin
g na
tura
l
gas,
ligh
t and
hea
vy d
istil
late
oil,
nap
htha
, cru
de o
il an
d re
sidu
al o
il. D
esig
ned
for
dual
-fue
l ope
ratio
n,
it is
abl
e to
sw
itch
from
one
fuel
to a
noth
er w
hile
run
ning
und
er lo
ad. I
t is
also
abl
e to
bur
n a
varie
ty o
f
syng
ases
pro
duce
d fr
om o
il or
coa
l with
out t
urbi
ne m
odifi
catio
n. T
his
flexi
bilit
y, a
long
with
its
exte
nsiv
e
expe
rienc
e an
d re
liabi
lity
reco
rd, m
akes
the
9E w
ell s
uite
d fo
r IG
CC p
roje
cts.
In s
impl
e cy
cle,
the
MS9
001E
is a
rel
iabl
e, lo
w fi
rst-
cost
mac
hine
for
peak
ing
serv
ice,
whi
le it
s hi
gh
com
bine
d cy
cle
effic
ienc
y gi
ves
exce
llent
fuel
sav
ings
in b
ase
load
ope
ratio
ns. I
ts c
ompa
ct d
esig
n
prov
ides
flex
ibili
ty in
pla
nt la
yout
as
wel
l as
the
easy
add
ition
of i
ncre
men
ts o
f pow
er w
hen
a ph
ased
capa
city
exp
ansi
on is
req
uire
d.
MS9
001E
10
MS9001E
The
MS9
001E
gas
tur
bine
is d
esig
ned
to a
ttai
n hi
gh
avai
labi
lity
leve
ls a
nd lo
w
mai
nten
ance
cos
ts, r
esul
ting
in e
xtre
mel
y lo
w t
otal
cos
t
of o
wne
rshi
p.
RDC26213-12
193.
2 6,
570
6,93
0 52
.0%
1
x M
S900
1E
MS9
001E
CO
MBI
NED
CYC
LE P
ERFO
RMAN
CE
RATI
NG
S
MS9
001E
SIM
PLE
CYC
LE P
ERFO
RMAN
CE
RATI
NG
S
Net
Pla
ntO
utpu
t (M
W)
S109
E
50 Hz
(Btu
/kW
h)H
eat R
ate
(kJ/
kWh)
Net
Pla
ntEf
ficie
ncy
GT
Num
ber
& T
ype
391.
4 6,
480
6,83
5 52
.7%
2
x M
S900
1ES2
09E
(MW
) 12
6.1
50 H
z Po
wer
Gen
erat
ion
Out
put
(Btu
/kW
h)
10,1
00(k
J/kW
h)
10,6
53
Hea
t Rat
e
12
.6:1
Pres
sure
Rat
io
(lb/s
ec)
922
(kg/
sec)
41
8M
ass
Flow
(rpm
) 3,
000
Turb
ine
Spee
d
(ºF)
1,
009
(ºC
) 54
3Ex
haus
t Tem
pera
ture
PG
9171
EM
odel
Des
igna
tion
11 MS7001E A
Tim
e-Te
sted
Per
form
er fo
r 60
Hz
Appl
icat
ions
With
mor
e th
an 7
50 u
nits
in s
ervi
ce, t
he 7
E/EA
flee
t has
acc
umul
ated
tens
of m
illio
ns o
f hou
rs o
f ser
vice
and
is w
ell r
ecog
nize
d fo
r hi
gh r
elia
bilit
y an
d av
aila
bilit
y.
With
str
ong
effic
ienc
y pe
rfor
man
ce in
sim
ple
and
com
bine
d cy
cle
appl
icat
ions
, thi
s 85
MW
mac
hine
is
used
in a
wid
e va
riety
of p
ower
gen
erat
ion,
indu
stria
l and
cog
ener
atio
n ap
plic
atio
ns. I
t is
unco
mpl
icat
ed
and
vers
atile
; its
med
ium
-siz
e de
sign
lend
s its
elf t
o fle
xibi
lity
in p
lant
layo
ut a
nd fa
st, l
ow-c
ost a
dditi
ons
of in
crem
enta
l pow
er.
With
sta
te-o
f-th
e-ar
t fue
l han
dlin
g eq
uipm
ent,
adv
ance
d bu
cket
coo
ling,
ther
mal
bar
rier
coat
ings
and
a m
ultip
le-f
uel c
ombu
stio
n sy
stem
, the
7EA
can
acc
omm
odat
e a
full
rang
e of
fuel
s. It
is d
esig
ned
for
dual
-
fuel
ope
ratio
n, a
ble
to s
witc
h fr
om o
ne fu
el to
ano
ther
whi
le th
e tu
rbin
e is
run
ning
und
er lo
ad o
r du
ring
shut
dow
n. 7
E/EA
uni
ts h
ave
accu
mul
ated
mill
ions
of h
ours
of o
pera
tion
usin
g cr
ude
and
resi
dual
oils
.
In a
dditi
on to
pow
er g
ener
atio
n, th
e 7E
A is
als
o w
ell s
uite
d fo
r m
echa
nica
l driv
e ap
plic
atio
ns.
MS7
001E
A
An
MS7
001E
A is
sho
wn
on h
alf s
hell
durin
g as
sem
bly.
GT20821
130.
2 6,
800
7,17
3 50
.2%
1
x M
S700
1EA
MS7
001E
A CO
MBI
NED
CYC
LE P
ERFO
RMAN
CE
RATI
NG
S
MS7
001E
A SI
MPL
E C
YCLE
PER
FORM
ANC
E RA
TIN
GS
Net
Pla
ntO
utpu
t (M
W)
S107
EA
60 Hz
(Btu
/kW
h)H
eat R
ate
(kJ/
kWh)
Net
Pla
ntEf
ficie
ncy
GT
Num
ber
& T
ype
263.
6 6,
700
7,06
7 50
.9%
2
x M
S700
1EA
S207
EA
(MW
) 85
.1
(hp)
11
5,63
0
60 H
z Po
wer
Gen
erat
ion
Out
put
Mec
hani
cal D
rive
(Btu
/kW
h)
10,4
30
(Btu
/shp
-hr)
7,72
0(k
J/kW
h)
11,0
02
Hea
t Rat
e
12
.7:1
11.9
:1Pr
essu
re R
atio
(lb/s
ec)
648
(lb/s
ec)
659
(kg/
sec)
29
4 (k
g/se
c)
299
Mas
s Fl
ow
(rpm
) 3,
600
(rpm
) 3,
600
Turb
ine
Spee
d
(ºF)
99
7 (º
F)
999
(ºC
) 53
6 (º
C)
537
Exha
ust T
empe
ratu
re
PG
7121
EA
M
7121
EAM
odel
Des
igna
tion
Relia
ble
and
Rugg
ed 5
0/60
Hz
Pow
er
The
MS6
001B
is a
per
form
ance
pro
ven
40 M
W c
lass
gas
turb
ine,
des
igne
d fo
r re
liabl
e 50
/60
Hz
pow
er
gene
ratio
n an
d 50
,000
hp
clas
s m
echa
nica
l driv
e se
rvic
e. W
ith a
vaila
bilit
y w
ell d
ocum
ente
d at
97.
1% a
nd
relia
bilit
y at
99.
3%, i
t is
the
popu
lar
choi
ce fo
r ef
ficie
nt, l
ow in
stal
led
cost
pow
er g
ener
atio
n or
prim
e m
over
s
in m
id-r
ange
ser
vice
.
With
ove
r 98
0 un
its in
ser
vice
, the
ver
satil
e an
d w
idel
y us
ed 6
B ga
s tu
rbin
e ha
s ac
cum
ulat
ed o
ver
45 m
illio
n op
erat
ing
hour
s in
a b
road
ran
ge o
f app
licat
ions
: sim
ple
cycl
e, h
eat r
ecov
ery,
com
bine
d cy
cle,
and
mec
hani
cal d
rive.
It c
an b
e in
stal
led
fast
for
quic
k ne
ar-t
erm
cap
acity
.
The
rugg
ed a
nd r
elia
ble
6B c
an h
andl
e m
ultip
le s
tart
-ups
req
uire
d fo
r pe
ak lo
ad. I
t can
acc
omm
odat
e a
varie
ty o
f fue
ls a
nd is
wel
l sui
ted
to IG
CC. I
n co
mbi
ned
cycl
e op
erat
ion
the
6B is
a s
olid
per
form
er a
t nea
rly
50%
eff
icie
ncy.
It is
als
o a
flexi
ble
choi
ce fo
r co
gene
ratio
n ap
plic
atio
ns c
apab
le o
f pro
duci
ng a
ther
mal
outp
ut r
angi
ng fr
om 2
0 to
400
mill
ion
Btu/
hr.
Like
all
GE
heav
y-du
ty g
as tu
rbin
es, t
he 6
B ha
s ea
rned
a s
olid
rep
utat
ion
for
high
rel
iabi
lity
and
envi
ron-
men
tal c
ompa
tibili
ty. W
ith a
Dry
Low
NO
xco
mbu
stio
n sy
stem
, the
6B
is c
apab
le o
f ach
ievi
ng le
ss th
an
15 p
pm N
Ox
on n
atur
al g
as.
With
its
exce
llent
fuel
effi
cien
cy, l
ow c
ost p
er h
orse
pow
er a
nd h
igh
hors
epow
er p
er s
quar
e fo
ot, t
he M
S600
1B
is a
n ex
celle
nt fi
t for
sel
ectiv
e m
echa
nica
l app
licat
ions
.
MS6
001B
12
MS6001B
An
MS6
001B
rot
or is
seen
on
half
shel
l.
RDC24656-03
64.
3 6,
950
7,34
1 49
.0%
1
x M
S600
1B
MS6
00
1B
CO
MB
INED
CYC
LE P
ERFO
RM
AN
CE
RAT
ING
S
MS6
00
1B
SIM
PLE
CYC
LE P
ERFO
RM
AN
CE
RAT
ING
S
Net
Pla
ntO
utpu
t (M
W)
S106
B
50 Hz
(Btu
/kW
h)H
eat R
ate
(kJ/
kWh)
Net
Pla
ntEf
ficie
ncy
GT
Num
ber
& T
ype
60 Hz
130
.7
6,85
0 7,
225
49.8
%
2 x
MS6
001B
S206
B
261
.3
6,85
0 7,
225
49.8
%
4 x
MS6
001B
S406
B
64
.3
6,96
0 7,
341
49.0
%
1 x
MS6
001B
S106
B
130.
7 6,
850
7,22
5 49
.8%
2
x M
S600
1BS2
06B
261
.3
6,85
0 7,
225
49.8
%
4 x
MS6
001B
S406
B
50/6
0 H
z Po
wer
Gen
erat
ion
Out
put
Mec
hani
cal D
rive
Hea
t Rat
e
12
.2:1
12.0
:1Pr
essu
re R
atio
Mas
s Fl
ow
Turb
ine
Spee
d
Exha
ust T
empe
ratu
re
PG
6581
B
M65
81B
Mod
el D
esig
natio
n
(MW
) 42
.1
(hp)
58
,380
(lb/s
ec)
311
(lb/
sec)
30
9(k
g/se
c)
141
(kg/
sec)
14
0
(rpm
) 5,
163
(rpm
) 5,
111
(ºF)
1,
018
(ºF)
1,
011
(ºC
) 54
8 (º
C)
544
(Btu
/kW
h)
10,6
42
(Btu
/shp
-hr)
7,65
0(k
J/kW
h)
11,2
26
MS6
001C
Hig
h Ef
ficie
ncy
45 M
W C
lass
Gas
Tur
bine
The
6C m
eets
the
need
for
low
-cos
t ele
ctric
ity p
rodu
ctio
n in
hea
t rec
over
y op
erat
ions
for
both
50
and
60 H
z—
incl
udin
g in
dust
rial c
ogen
erat
ion,
dis
tric
t hea
ting,
and
mid
-siz
ed c
ombi
ned-
cycl
e po
wer
pla
nts.
Cons
iste
nt w
ith G
E’s
evol
utio
nary
des
ign
philo
soph
y, th
e 6C
inco
rpor
ates
tech
nolo
gies
that
hav
e be
en v
alid
ated
in s
ervi
ce w
orld
wid
e. T
his
evol
utio
nary
app
roac
h en
sure
s us
ers
of th
e 6C
that
they
are
rec
eivi
ng a
dvan
ced
but
wel
l-pr
oven
tec
hnol
ogy.
The
Fra
me
6C b
uild
s on
the
exp
erie
nce
and
perf
orm
ance
of G
E’s
Fram
e 6B
tech
nolo
gy, p
rove
n in
mor
e th
an 4
5 m
illio
n ho
urs
of s
ervi
ce, a
nd a
lso
inco
rpor
ates
key
fea
ture
s of
GE’
s
adva
nced
F te
chno
logy
.
The
turb
ine
incl
udes
com
pone
nts
that
pro
vide
hig
h re
liabi
lity
and
mai
ntai
nabi
lity,
suc
h as
a 1
2-st
age
com
pres
sor
with
few
er p
arts
and
rem
ovab
le b
lade
s an
d va
nes.
NO
xem
issi
ons
are
limite
d to
15
ppm
dry
whe
n op
erat
ing
on n
atur
al g
as, a
nd 4
2 pp
m w
hen
burn
ing
light
dis
tilla
te w
ith w
ater
inje
ctio
n.
Impr
oved
ope
rabi
lity
feat
ures
incl
ude
less
tha
n 50
%
turn
dow
n w
hile
mai
ntai
ning
em
issi
ons
guar
ante
es, f
ast
and
relia
ble
star
ts in
13
min
utes
, and
thr
ee s
tage
s of
com
pres
sor
guid
e va
nes
for
high
eff
icie
ncy
at p
art l
oad.
The
6C a
lso
feat
ures
an
F-cl
ass
mod
ular
arr
ange
men
t
and
a M
ark
VI S
peed
tron
ic c
ontr
ol s
yste
m.
13 MS6001C
67.
2
6,28
1
6,6
27
54.3
%
1 x
MS6
001C
MS6
001C
CO
MBI
NED
CYC
LE P
ERFO
RMAN
CE
RATI
NG
S
MS6
001C
SIM
PLE
CYC
LE P
ERFO
RMAN
CE
RATI
NG
S
Net
Pla
ntO
utpu
t (M
W)
S106
C
50 Hz
(Btu
/kW
h)H
eat R
ate
(kJ/
kWh)
Net
Pla
ntEf
ficie
ncy
60 Hz
136.
1
6,20
3
6,
544
55.0
%
2 x
MS6
001C
S206
C
67.
2
6,28
1
6,
627
54.3
%
1 x
MS6
001C
S106
C
136.
1
6,20
3
6,
544
55.0
%
2 x
MS6
001C
S206
C
(MW
) 45
.445
.3
50 H
z
Out
put
60 H
z
(Btu
/kW
h)
9,31
5(k
J/kW
h)
9,83
0 9,
340
9,85
5H
eat R
ate
19
.6:1
19.6
:1Pr
essu
re R
atio
(lb/s
ec)
270
(kg/
sec)
12
227
012
2M
ass
Flow
(rpm
) 7,
100
7,10
0Tu
rbin
e Sp
eed
(ºF)
1,
078
(ºC
) 58
11,
078
581
Exha
ust T
empe
ratu
re
PG65
91C
Mod
el D
esig
natio
n
GT
Num
ber
& T
ype
PSP30646-02
Ake
nerji
Kem
alpa
sa-I
zmir
Turk
ey
206C
Com
bine
d-C
ycle
—C
OD
sin
ce N
ovem
ber
2005
Rigo
rous
fiel
d va
lidat
ion
test
s co
nduc
ted
at th
e Ke
mal
pasa
6C
laun
ch
site
con
firm
ed t
he o
utst
andi
ng o
pera
bilit
y of
the
tur
bine
—hi
gh
effic
ienc
y an
d lo
w e
mis
sion
s.
A Br
oad
Port
folio
of P
acka
ged
Pow
er P
lant
s
GE
prov
ides
a b
road
ran
ge o
f pow
er p
acka
ges
from
5 M
W to
nea
rly 5
0 M
W fo
r si
mpl
e cy
cle,
com
bine
d
cycl
e or
cog
ener
atio
n ap
plic
atio
ns in
the
utili
ty, p
rivat
e an
d m
obile
pow
er in
dust
ries.
Mar
ine
appl
icat
ions
for
thes
e m
achi
nes
rang
e fr
om c
omm
erci
al fa
st fe
rrie
s an
d cr
uise
shi
ps to
mili
tary
pat
rol b
oats
, frig
ates
,
dest
roye
rs a
nd a
ircra
ft c
arrie
rs.
Oil
& G
as
GE
is a
wor
ld le
ader
in h
igh-
tech
nolo
gy tu
rbin
e pr
oduc
ts a
nd s
ervi
ces
for
the
oil &
gas
indu
stry
.
We
offe
r fu
ll tu
rnke
y sy
stem
s an
d af
term
arke
t sol
utio
ns fo
r pr
oduc
tion,
LN
G, t
rans
port
atio
n, s
tora
ge,
refin
erie
s, p
etro
chem
ical
and
dis
trib
utio
n sy
stem
s.
Smal
l Hea
vy-D
uty
and
Aero
deriv
ativ
e G
as T
urbi
nes
14
SMALL HEAVY-DUTY and AERODERIVATIVE GAS TURBINES
The
pow
erfu
l LM
6000
is o
ne o
f the
mos
t
fuel
-eff
icie
nt s
impl
e cy
cle
gas
turb
ines
in
the
wor
ld.
RDC26874-04
SMAL
L H
EAVY
-DU
TY G
AS T
URB
INES Out
put
Pres
sure
Turb
ine
Spee
dEx
haus
t Tem
p.Ex
haus
t Flo
w
MechanicalDrive**
GeneratorDrive*
G
E5
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11
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574
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84
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81
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00
104.
7 47
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900
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S500
1 26
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12
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12
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10
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094
276.
1 12
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901
483
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E5
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080
—
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00
44.2
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55
6
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123.
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7
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S500
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43,6
90
8,65
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10
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670
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7 14
1.4
948
509
*ISO
con
ditio
ns –
nat
ural
gas
– e
lect
rical
gen
erat
or te
rmin
als
**IS
O c
ondi
tions
– n
atur
al g
as –
sha
ft o
utpu
t
(kW
)Ra
tio(rp
m)
(lb/s
ec)
(kg/
sec)
(ºF)
(ºC
)H
eat R
ate
(Btu
/kW
h)
Out
put
Pres
sure
Turb
ine
Spee
dEx
haus
t Tem
p.Ex
haus
t Flo
w(s
hp)
Ratio
(rpm
)(lb
/sec
)(k
g/se
c)(º
F)(º
C)
Hea
t Rat
e(B
tu/s
hp-h
)
(kJ/
kWh)
15 SMALL HE AVY-DUT Y and AER ODERIVATIVE GAS TURBINES
GE
Ener
gy’s
Oil
& G
as p
rodu
cts
are
inst
alle
d in
maj
or u
pstr
eam
,
mid
stre
am, d
owns
trea
m
and
dist
ribut
ion
appl
icat
ions
arou
nd t
he w
orld
.
PSP30305
GT06543
AERO
DER
IVAT
IVE
GAS
TU
RBIN
ES
60 Hz Power Gen Mechanical Drive50 Hz Power Gen
LM
6000
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prin
t 46
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8,
235
8,68
6 30
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600
290
132
837
447
LM
6000
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42,3
36
8,30
8 8,
763
29.3
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3,60
0 27
8 12
6 84
6 45
2
LM
6000
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iqui
d fu
el)
40,2
00
8,41
5 8,
876
28.1
:1
3,60
0 26
8 12
2 85
7 45
8
LM
2500
RC
33,3
94
8,75
3 9,
235
23:1
3,
600
201.
9 91
.6
976
524
LM
2500
RD
33,1
65
8,77
4 9,
257
23:1
3,
600
201
91
977
525
LM
2500
PE
23,2
92
9,31
5 9,
825
19.1
:1
3,60
0 15
3 69
99
2 53
3
LM
1600
PE
13,7
69
9,73
5 10
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20
.2:1
7,
900
104
47
894
479
LM
2500
PH
27,7
63
8,39
1 8,
850
19.4
:1
3,60
0 16
7 76
92
2 49
4
LM
2000
PS
17,6
06
9,58
7 10
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15
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3,
600
139
63
886
474
LM
6000
PC
43,4
71
8,11
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557
29.1
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0 28
2 12
8 82
4 44
0
LM
S100
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98,1
96
7,58
2 7,
872
40:1
3,
600
456
207
782
417
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7,56
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3,
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6 78
0 41
6
LM
6000
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prin
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8,43
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0 29
9 13
6 81
9 43
7
LM
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98,8
94
7,56
3 7,
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40:1
3,
000
458
208
782
416
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98,3
59
7,56
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873
40:1
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456
207
783
417
LM
6000
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prin
t*
50,0
41
8,46
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925
31.5
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2 13
7 81
3 43
4
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6000
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42,8
90
8,17
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621
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7 28
4 12
9 81
7 43
6
LM
6000
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prin
t 46
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272
8,72
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132
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iqui
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00
8,45
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7 27
2 12
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6
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6000
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41,7
11
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7 27
9 12
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8
LM
2500
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32,9
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369
23:1
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600
202
92
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524
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89
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391
23:1
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600
201
91
977
525
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2500
PH
26,4
63
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148
19.4
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0 16
8 76
92
7 49
7
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2000
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22,3
46
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000
154
70
1001
53
8
LM
1600
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13,7
48
9,74
9 10
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20
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900
104
47
915
491
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6000
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55
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29
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600
282
127.
9 82
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0
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40
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17
6,45
0 —
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91.1
98
1 52
7
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2500
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64
6,78
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600
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69.0
97
6 52
4
LM
2000
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600
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885
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900
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3 47
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491
*Spr
int 2
002
deck
is u
sed
with
wat
er in
ject
ion
to 2
5 pp
mvd
for p
ower
enh
ance
men
t.
NO
TE: P
erfo
rman
ce b
ased
on
59ºF
am
b. T
emp.
, 60%
RH
, sea
leve
l, no
inle
t/ex
haus
t los
ses
onga
sfu
elw
ithno
NO
xm
edia
unle
ssot
herw
ise
spec
ified
Out
put
Pres
sure
Turb
ine
Spee
dEx
haus
t Tem
p.Ex
haus
t Flo
w(h
p)Ra
tio(rp
m)
(lb/s
ec)
(kg/
sec)
(ºF)
(ºC
)H
eat R
ate
(Btu
/shp
-h)
Out
put
Pres
sure
Turb
ine
Spee
dEx
haus
t Tem
p.Ex
haus
t Flo
w(k
W)
Ratio
(rpm
)(lb
/sec
)(k
g/se
c)(º
F)(º
C)
Hea
t Rat
e(B
tu/k
Wh)
(kJ/
kWh)
LM
2000
PS
17,6
74
9,77
9 10
,315
16
.0:1
3,
000
142
64
894
479
The
Nex
t Gen
erat
ion
Pow
er P
lant
Mak
ing
Envi
ronm
enta
l Com
plia
nce
Affo
rdab
le
Inte
grat
ed G
asifi
catio
n C
ombi
ned
Cyc
le (I
GCC
) tec
hnol
ogy
is in
crea
sing
ly im
port
ant i
n th
e w
orld
ene
rgy
mar
ket,
whe
re lo
w c
ost o
ppor
tuni
ty fe
edst
ocks
suc
h as
coa
l, he
avy
oils
and
pet
cok
e ar
e th
e fu
els
of c
hoic
e.
And
IGCC
tech
nolo
gy p
rodu
ces
low
cos
t ele
ctric
ity w
hile
mee
ting
stric
t env
ironm
enta
l reg
ulat
ions
.
The
IGCC
gas
ifica
tion
proc
ess
“cle
ans”
hea
vy fu
els
and
conv
erts
them
into
hig
h va
lue
fuel
for
gas
turb
ines
.
Pion
eere
d by
GE
alm
ost 3
0 ye
ars
ago,
IGCC
tech
nolo
gy c
an s
atis
fy o
utpu
t req
uire
men
ts fr
om 1
0 M
W to
mor
e th
an 1
.5 G
W a
nd c
an b
e ap
plie
d in
alm
ost a
ny n
ew o
r re
-pow
erin
g pr
ojec
t whe
re s
olid
and
hea
vy
fuel
s ar
e av
aila
ble.
Opt
imal
Per
form
ance
For
each
gas
ifier
type
and
fuel
, the
re a
re v
ast n
umbe
rs o
f tec
hnic
al p
ossi
bilit
ies.
Inte
grat
ed G
asifi
catio
n
Com
bine
d C
ycle
(IG
CC) s
yste
ms
can
be o
ptim
ized
for
each
type
of f
uel a
s w
ell a
s si
te a
nd e
nviro
nmen
tal
requ
irem
ents
. Usi
ng k
now
ledg
e ga
ined
from
suc
cess
fully
ope
ratin
g m
any
IGCC
uni
ts, G
E ha
s op
timiz
ed
syst
em c
onfig
urat
ions
for
all m
ajor
gas
ifier
type
s an
d al
l GE
IGCC
gas
turb
ine
mod
els.
Expe
rienc
e
GE
enga
ges
expe
rts
from
thro
ugho
ut th
e ga
sific
atio
n in
dust
ry a
t bot
h op
erat
ing
and
rese
arch
leve
ls to
deve
lop
the
mos
t eco
nom
ical
and
rel
iabl
e ap
proa
ches
to IG
CC te
chno
logy
. Usi
ng th
e sa
me
com
bine
d cy
cle
tech
nolo
gy fo
r IG
CC th
at w
e us
e fo
r co
nven
tiona
l sys
tem
s, G
E of
fers
ext
ensi
ve e
xper
ienc
e an
d hi
gh le
vels
of r
elia
bilit
y.
IGCC
16
IGCC
This
550
MW
IGC
C is
loca
ted
at t
he S
aras
oil
refin
ery
in S
ardi
nia.
The
thr
ee G
E 10
9E s
ingl
e-
shaf
t co
mbi
ned
cycl
e un
its h
ave
accu
mul
ated
over
12,
000
hour
s of
syn
gas
oper
atio
n.
PSP30120
Mod
el
Syng
as P
ower
Rat
ing
Mod
el
Syng
as C
C O
utpu
t Pow
er
Gas
Tur
bine
sIG
CC
GE1
0 10
MW
(50/
60 H
z)
GE1
0 14
MW
(50/
60 H
z)
6B
42 M
W (5
0/60
Hz)
10
6B
63 M
W (5
0/60
Hz)
7EA
90 M
W (6
0 H
z)
107E
A 13
0 M
W (6
0 H
z)
9E
150
MW
(50
Hz)
10
9E
210
MW
(50
Hz)
6FA
90 M
W (5
0/60
Hz)
10
6FA
130
MW
(50/
60 H
z)
7FA
197
MW
(60
Hz)
10
7FA
280
MW
(60
Hz)
9FA
286
MW
(50
Hz)
10
9FA
420
MW
(50
Hz)
7FB
232
MW
(60
Hz)
20
7FB
750
MW
(60
Hz)
GE
GAS
TU
RBIN
ES F
OR
IGCC
APP
LIC
ATIO
NS
Cover Photo: PSP30502-03, Inside Cover Photos: RDC27191-05-05, PSP30502-01. Designed by GE Energy — Creative Services.
GE
Valu
e
GE
is a
lead
ing
glob
al s
uppl
ier
of p
ower
gen
erat
ion
tech
nolo
gy, e
nerg
y se
rvic
es a
nd m
anag
emen
t
syst
ems,
with
an
inst
alle
d ba
se o
f pow
er g
ener
atio
n eq
uipm
ent i
n m
ore
than
120
cou
ntrie
s. G
E En
ergy
prov
ides
inno
vativ
e, te
chno
logy
-bas
ed p
rodu
cts
and
serv
ice
solu
tions
acr
oss
the
full
spec
trum
of t
he
ener
gy in
dust
ry.
Indu
strie
s Se
rved
:
■C
omm
erci
al a
nd in
dust
rial p
ower
gen
erat
ion
■D
istr
ibut
ed p
ower
■En
ergy
man
agem
ent
■O
il &
Gas
■Pe
troc
hem
ical
■G
as c
ompr
essi
on
■C
omm
erci
al m
arin
e po
wer
■En
ergy
ren
tals
Our
peo
ple,
pro
duct
s an
d se
rvic
es p
rovi
de e
nhan
ced
perf
orm
ance
, com
petit
ive
life-
cycl
e co
sts
and
cont
inuo
us te
chno
logi
cal i
nnov
atio
n w
ith u
nmat
ched
exp
erie
nce.
Our
Cus
tom
er-C
entr
ic a
ppro
ach,
com
bine
d w
ith S
ix S
igm
a qu
ality
met
hodo
logy
, ass
ures
that
cus
tom
er n
eeds
are
def
ined
up
fron
t and
that
per
form
ance
aga
inst
cus
tom
er e
xpec
tatio
ns is
mea
sure
d an
d m
anag
ed e
very
ste
p of
the
way
.
17
GE
Valu
e
GE
is a
lead
ing
glob
al s
uppl
ier
of p
ower
gen
erat
ion
tech
nolo
gy, e
nerg
y se
rvic
es a
nd m
anag
emen
t
syst
ems,
with
an
inst
alle
d ba
se o
f pow
er g
ener
atio
n eq
uipm
ent i
n m
ore
than
120
cou
ntrie
s.
GE
Ener
gy p
rovi
des
inno
vativ
e, te
chno
logy
-bas
ed p
rodu
cts
and
serv
ice
solu
tions
acr
oss
the
full
spec
trum
of t
he e
nerg
y in
dust
ry.
Our
peo
ple,
pro
duct
s an
d se
rvic
es p
rovi
de e
nhan
ced
perf
orm
ance
, com
petit
ive
life
cycl
e co
sts
and
cont
inuo
us te
chno
logi
cal i
nnov
atio
n w
ith u
nmat
ched
exp
erie
nce.
Our
Cus
tom
er-C
entr
ic
appr
oach
, com
bine
d w
ith S
ix S
igm
a qu
ality
met
hodo
logy
, ass
ures
that
cus
tom
er n
eeds
are
defin
ed u
p fr
ont a
nd th
at p
erfo
rman
ce a
gain
st c
usto
mer
exp
ecta
tions
is m
easu
red
and
man
aged
eve
ry s
tep
of th
e w
ay.
Indu
stri
es S
erve
d:■
Com
mer
cial
and
indu
stria
l po
wer
gen
erat
ion
■D
istr
ibut
ed p
ower
■En
ergy
man
agem
ent
■O
il &
Gas
■Pe
troc
hem
ical
■G
as c
ompr
essi
on
■C
omm
erci
al m
arin
e po
wer
■En
ergy
ren
tals
GE
Ener
gy
4200
Wild
woo
d Pa
rkw
ayAt
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GE Power Systems
Power Systems forthe 21st Century –“H” Gas TurbineCombined-Cycles
R.K. MattaG.D. MercerR.S. TuthillGE Power SystemsSchenectady, NY
GER-3935B
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Contents
Abstract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Background and Rationale for the H System™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Conceptual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
The Case for Steam Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3H Technology, Combined-Cycle System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4H Product Family and Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
System Strategy and Integration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5H Gas Turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Compressor Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Combustor Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Turbine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Gas Turbine Validation: Testing to Reduce Risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Compressor Design Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Combustor Design Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Fuel Injection Design Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Turbine Design Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Gas Turbine Factory Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Validation Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power Systems for the 21st Century – “H” Gas Turbine Combined-Cycles
GE Power Systems ■ GER-3935B ■ (10/00) i
Power Systems for the 21st Century – “H” Gas Turbine Combined-Cycles
GE Power Systems ■ GER-3935B ■ (10/00) ii
AbstractThis paper provides an overview of GE’s HSystem™ technology and describes the intensivedevelopment work necessary to bring this revo-lutionary technology to commercial reality. Inaddition to describing the magnitude of per-formance improvement possible through use ofH System™ technology, this paper discusses thetechnological milestones during the develop-ment of the first 9H (50 Hz) and 7H (60 Hz)gas turbines.
To illustrate the methodical product develop-ment strategy used by GE, this paper discussesseveral technologies which are essential to theintroduction of the H System™. Also includedherein are analyses of the series of comprehen-sive tests of materials, components and subsys-tems which necessarily preceded full-scale fieldtesting of the H System™. This paper validatesone of the basic premises on which GE startedthe H System™ development program:Exhaustive and elaborate testing programs min-imize risk at every step of this process, andincrease the probability of success when the HSystem™ is introduced into commercial service.
In 1995, GE, the world leader in gas turbinetechnology for over half a century, introducedits new generation of gas turbines. This HSystem™ technology is the first gas turbine everto achieve the milestone of 60% fuel efficiency.Because fuel represents the largest individualexpense of running a power plant, an efficiencyincrease of even a single percentage point cansubstantially reduce operating costs over the lifeof a typical gas-fired, combined-cycle plant inthe 400 to 500 megawatt range.
The H System™ is not simply a state-of-the-art gasturbine. It is an advanced, integrated, com-bined-cycle system every component of which isoptimized for the highest level of performance.
The unique feature of an H technology, com-bined-cycle system is the integrated heat trans-fer system, which combines both the steamplant reheat process and gas turbine bucket andnozzle cooling. This feature allows the powergenerator to operate at a higher firing temper-ature, which in turn produces dramaticimprovements in fuel-efficiency. The end resultis generation of electricity at the lowest, mostcompetitive price possible. Also, despite thehigher firing temperature of the H System™,combustion temperature is kept at levels thatminimize emission production.
GE has more than two million fired hours ofexperience in operating advanced technologygas turbines, more than three times the firedhours of competitors’ units combined. The HSystem™ design incorporates lessons learnedfrom this experience with knowledge gleanedfrom operating GE aircraft engines. In addi-tion, the 9H gas turbine is the first everdesigned using “Design for Six Sigma” method-ology, which maximizes reliability and availabil-ity throughout the entire design process. Boththe 7H and 9H gas turbines will achieve the reli-ability levels of our F-class technology machines.
GE has tested its H System™ gas turbine morethoroughly than any system previously intro-duced into commercial service. The H System™gas turbine has undergone extensive design val-idation and component testing. Full-speed, no-load testing (FSNL) of the 9H was achieved inMay 1998 and pre-shipment testing was com-pleted in November 1999. This H System™ willalso undergo approximately a half-year ofextensive demonstration and characterizationtesting at the launch site.
Testing of the 7H began in December 1999, andfull-speed, no-load testing was completed inFebruary 2000. The 7H gas turbine will also besubjected to extensive demonstration and char-acterization testing at the launch site.
Power Systems for the 21st Century – “H” Gas Turbine Combined-Cycles
GE Power Systems ■ GER-3935B ■ (10/00) 1
Background and Rationale for the H System™The use of gas turbines for power generationhas been steadily increasing in popularity formore than five decades. Gas turbine cycles areinherently capable of higher power density,higher fuel efficiency, and lower emissions thanthe competing platforms. Gas turbine perform-ance is driven by the firing temperature, whichis directly related to specific output, andinversely related to fuel consumption per kW ofoutput. This means that increases in firing tem-perature provide higher fuel efficiency (lowerfuel consumption per kW of output) and, at thesame time, higher specific output (more kWper pound of air passing through the turbine).
The use of aircraft engine materials and coolingtechnology has allowed firing temperature forGE’s industrial gas turbines to increase steadily.However, higher temperatures in the combus-tor also increase NOx production. In the“Conceptual Design” section of this paper, wedescribe how the GE H System™ solved the NOxproblem, and is able to raise firing temperatureby 200°F / 110°C over the current “F” class ofgas turbines and hold the NOx emission levelsat the initial “F” class levels.
The General Electric Company is made up of anumber of different businesses. The companyhas thrived and grown due, in part, to the rapidtransfer of improved technology and businesspractices among these businesses. The primarytechnology transfer channel is the GECorporate Research & Development (CR&D)Center located in Schenectady, NY. The HSystem™ new product introduction (NPI) teamis also located in Schenectady, facilitating theefficient transfer of technology from CR&D tothe NPI team. Formal technology councils,including, for instance, the Thermal Barrier
Coatings Council, High Temperature MaterialsCouncil, and the Dry Low NOx (DLN)Combustion Council, also promote synergyamong the businesses, fostering developmentof advanced technology.
GE Power Systems (GEPS) and GE AircraftEngines (GEAE) share many common links,including testing facilities for DLN, compressorcomponents, and steam turbine components.In a move which could only have occurred with-in GE, with its unique in-house resources, over200 engineers were transferred from GEAE andCR&D to GEPS, to support the development ofthe H System™. These transfers became the coreof the H System™’s “Design and Systems” teams.H System™ technology is shared in its entiretybetween GEPS and GEAE, including test dataand analytical codes.
In contrast to the free exchange of core techni-cal personnel between GEPS and GEAE, severalof GE’s competitors have been forced to pur-chase limited aircraft engine technology fromoutside companies. This approach results in theacquisition of a specific design with limiteddetail and flexibility, but with no understandingof the underlying core technology.
In contrast, the transfer from GE AircraftEngines to GEPS includes, but is not limited to,the following technologies, which are describedlater in the paper:
■ Compressor aerodynamics, mechanicaldesign and scale model rig testing
■ Full-scale combustor testing atoperating pressures and temperatures
■ Turbine aerodynamics, heat transfer,and nozzle cascade testing
■ Transfer of materials and coating data
■ Processing for turbine blade andwheel superalloys
Power Systems for the 21st Century – “H” Gas Turbine Combined-Cycles
GE Power Systems ■ GER-3935B ■ (10/00) 2
■ Gas turbine instrumentationapplication and monitoring.
Technology contributed by CR&D includes:
■ Development of heat transfer andfluid flow codes
■ Process development for thermalbarrier coatings
■ Materials characterization and data
■ Numerous special purpose componentand subsystem tests
■ Design and introduction of non-destructive evaluation techniques.
Conceptual DesignThe GE H System™ is a combined-cycle plant.The hot gases from the gas turbine exhaust pro-ceed to a downstream boiler or heat recoverysteam generator (HRSG). The resulting steamis passed through a steam turbine and the steamturbine output then augments that from the gasturbine. The output and efficiency of the steamturbine’s “bottoming cycle” is a function of thegas turbine exhaust temperature.
For a given firing temperature class, 2600°F /1430°C for the H System™, the gas turbineexhaust temperature is largely determined bythe work required to drive the compressor, thatis, in turn, affected by the “compressor pressureratio”. The H System™’s pressure ratio of 23:1was selected to optimize the combined-cycleperformance, while at the same time allowingfor 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 stageswould provide the optimum performance andcost solution. This is a major change from theearlier “F” class gas turbines, which used a 15:1compressor-pressure ratio and three turbine
stages. With the H System™’s higher pressureratio, the use of only three turbine stages wouldhave increased the loading on each stage to apoint where unacceptable reduction in stageefficiencies would result. By using four stages,the H turbine is able to specify optimum workloading for each stage and achieve high turbineefficiency.
The Case for Steam Cooling The GE H System™ gas turbine uses closed-loopsteam cooling of the turbine. This unique cool-ing system allows the turbine to fire at a highertemperature for increased performance, yetwithout increased combustion temperatures ortheir resulting increased emissions levels. It isthis closed-loop steam cooling that enabled thecombined-cycle GE H System™ to achieve 60%fuel efficiency while maintaining adherence tothe strictest, low NOx standards (Figure 1).
Combustion temperature must be as low as pos-sible to establish low NOx emissions, while thefiring temperature must be as high as possiblefor optimum cycle efficiency. The goal is to ade-quately cool the stage 1 nozzle, while minimiz-ing the decrease in combustion product tem-perature as it passes through the stage 1 nozzle.This is achieved with closed-loop steam cooling.
Power Systems for the 21st Century – “H” Gas Turbine Combined-Cycles
GE Power Systems ■ GER-3935B ■ (10/00) 3
Figure 1. Combustion and firing temperatures
In conventional gas turbines, with designs pre-dating the H System™, the stage 1 nozzle iscooled with compressor discharge air. This cool-ing process causes a temperature drop acrossthe stage 1 nozzle of up to 280°F/155°C. In HSystem™ gas turbines, cooling the stage 1 noz-zle with a closed-loop steam coolant reduces thetemperature drop across that nozzle to less than80°F/44°C (Figure 2). This results in a firingtemperature class of 2600°F/1430°C, or200°F/110°C higher than in preceding systems,yet with no increase in combustion tempera-ture. An additional benefit of the H System™ isthat while the steam cools the nozzle, it picks upheat for use in the steam turbine, transferringwhat was traditionally waste heat into usableoutput. The third advantage of closed-loopcooling is that it minimizes parasitic extraction
of compressor discharge air, thereby allowingmore to flow to the head-end of the combustorfor fuel premixing.
In conventional gas turbines, compressor air isalso used to cool rotational and stationary com-ponents downstream of the stage 1 nozzle in theturbine section. This air is traditional labeled as“chargeable air”, because it reduces cycle per-formance. In H System™ gas turbines, this“chargeable air” is replaced with steam, which
enhances cycle performance by up to 2 pointsin efficiency, and significantly increases the gasturbine output, since all the compressor air canbe channeled through the turbine flowpath todo useful work. A second advantage of replac-ing “chargeable air” with steam accrues to the HSystem™’s cycle through recovery of the heatremoved from the gas turbine in the bottomingcycle.
H Technology, Combined-Cycle System The H technology, combined-cycle system con-sists of a gas turbine, a three-pressure-levelHRSG and a reheat steam turbine.
The features of the combined-cycle system,which include the coolant steam flow from thesteam cycle to the gas turbine, are shown inFigure 3. The high-pressure steam from theHRSG is expanded through the steam turbine'shigh-pressure section. The exhaust steam fromthis turbine section is then split. One part isreturned to the HRSG for reheating; the otheris combined with intermediate-pressure (IP)steam and used for cooling in the gas turbine.
Steam is used to cool the stationary and rota-tional parts of the gas turbine. In turn, the heattransferred from the gas turbine increases thesteam temperature to approximately reheattemperature. The gas turbine cooling steam isreturned to the steam cycle, where it is mixedwith the reheated steam from the HRSG andintroduced to the IP steam turbine section.Further details about the H combined-cycle sys-tem and its operation can be found in GER3936A, “Advanced Technology Combined-Cycles” and will not be repeated in this paper.
H Product Family and Performance The H technology, with its higher pressure ratioand higher firing temperature design, willestablish a new family of gas turbine products.The 9H and 7H combined-cycle specifications
Power Systems for the 21st Century – “H” Gas Turbine Combined-Cycles
GE Power Systems ■ GER-3935B ■ (10/00) 4
Advanced Open LoopAir-Cooled Nozzle
H SystemTM
Closed-Loop Cooled Nozzle
NOZZLE DT = 280F/155C NOZZLE DT = 80F/44C
STEAM IN OUT IN STEAM OUTAIR IN AIR IN
Figure 2. Impact of stage 1 nozzle cooling method
are compared in Tables 1 and 2 with the similar“F” technology family members.
The 9H and 7H are not scaled geometrically toone another. This is a departure from past prac-
tices within the industry, but has been driven bycustomer input to GE. The specified output ofthe H technology products is 400 MW at 60 Hzand 480 MW at 50 Hz in a single-shaft, com-bined-cycle system. The 9H has been intro-duced at 25 ppm NOx, based on global marketneeds and economics.
One extremely attractive feature of the H tech-nology, combined-cycle power plants is the highspecific output. This permits compact plantdesigns with a reduced “footprint” when com-pared with conventional designs, and conse-quently, the potential for reduced plant capitalcosts (Figure 4). In a 60 Hz configuration, the Htechnology’s compact design results in a 54%increase in output over the FA plants with anincrease of just 10% in plant size.
GE is moving forward concurrently with devel-opment of the 9H and 7H. However, in responseto specific customer commitments, the 9H was
introduced first. The 7H program is followingclosely, about 12 months behind the 9H.
The 7H development has made progress as partof the Advanced Turbine Systems program of theU.S. Department of Energy and its encourage-ment and support is gratefully acknowledged.
System Strategy and IntegrationWhile component and subsystem validation isnecessary and is the focus of most NPI pro-
Power Systems for the 21st Century – “H” Gas Turbine Combined-Cycles
GE Power Systems ■ GER-3935B ■ (10/00) 5
Figure 3. H Combined-cycle and steam description
9FA 9H
Firing Temperature Class, F (C) 2400 (1316) 2600 (1430)
Air Flow, lb/sec (kg/sec) 1376 (625) 1510 (685)
Pressure Ratio 15 23
Combined Cycle Net Output, MW 391 480
Net Efficiency, % 56.7 60
NOx (ppmvd at 15% O2) 25 25
Table 1. H Technology performance characteris-tics (50 Hz)
7FA 7H
Firing Temperature Class, F (C) 2400 (1316) 2600 (1430)
Air Flow, lb/sec (kg/sec) 953 (433) 1230 (558)
Pressure Ratio 15 23
Combined Cycle Net Output, MW 263 400
Net Efficiency, % 56.0 60
NOx (ppmvd at 15% O2) 9 9
Table 2. H Technology performance characteris-tics (60 Hz)
Figure 4. 7H and 7FA footprint comparison
grams, other factors must also be considered increating a successful product. The gas turbinemust operate as a system, combining the com-pressor, combustor and turbine at design point(baseload), at part load turndown conditions,and at no load. The power plant and all powerisland components must also operate at steadystate and under transient conditions, from start-up, to purge, to full speed.
Unlike traditional combined-cycle units, the HSystem™ gas turbine, steam turbine and HRSGare linked into one, interdependent system.Clearly, the reasoning behind these GE HSystem™ components runs contrary to the tradi-tional approach, which designs and specifieseach component as a stand-alone entity. In theH System™, the performance of the gas turbine,combined-cycle and balance of plant has beenmodeled, both steady state and transient; andanalyzed in detail, as one large, integrated sys-tem, from its inception.
The GE H System™ concept incorporates anintegrated control system (ICS) to act as theglue, which ties all the subsystems together(Figure 5).
Systems and controls teams, working closelywith one another as well as with customers, haveformulated improved hardware, software, andcontrol concepts. This integration was facilitat-
ed by a new, third-generation, full-authority dig-ital system, the Mark VI controller. This controlsystem was designed with and is supplied by GEIndustrial Systems (GEIS), which is yet anotherGE business working closely with GEPS.
The control system for the H System™ managessteam flows between the HRSG, steam turbineand gas turbine. It also schedules distribution ofcooling steam to the gas turbine. A diagnosticcapability is built into the control system, whichalso stores critical data in an electronic histori-an for easy retrieval and troubleshooting.
The development of the Mark VI and integrat-ed control system has been deliberately sched-uled ahead of the H gas turbine to reduce thegas turbine risk. With the help of GE CR&D, theMark VI followed a separate and rigorous NPIrisk abatement procedure, which includedproof of concept tests and shake down tests of afull combined-cycle plant at GE AircraftEngines in Lynn, Massachusetts.
The Systems and controls teams have state-of-the-art computer simulations at their disposal tofacilitate full engineering of control and fall-back strategies. Digital simulations also serve asa training tool for new operators.
Simulation capability was used in real time dur-ing the 9H Full-Speed No-Load (FSNL)-1 test inMay 1998. This facilitated revision of the accel-erating torque demand curves for the gas tur-bine and re-setting of the starter motor currentand gas turbine combustor fuel schedule. Theend result was an automated, one-button, soft-start for the gas turbine, which was used by theTEPCO team to initiate the May 30, 1998 cus-tomer witness test.
The balance of this paper will focus on the gasturbine and its associated development pro-gram.
GE Power Systems ■ GER-3935B ■ (10/00) 6
Power Systems for the 21st Century – “H” Gas Turbine Combined-Cycles
Redundant Unit Data Highway
HRSG/MA
Generator
Steam Turbine
Gas TurbineBOP
Equipment
GeneratorExcitation
&Protection
StaticStarter
SteamTurbine
&BypassControl
GasTurbine &CoolingSteamControl
HRSG &Steam CycleMechanicalAuxiliaries
Unit AuxiliaryControl
HMI/Server
HMI/Server
AlarmPrinter
ColorDisplayPrinter
LogPrinter
OperatorStation
Historian
Remote Dispatch
Fault Tolerant Plant Data Highway
Control Room
OperatorStation
EngineeringWorkstation
•All New Microprocessor Design•Triple Modular Redundant•Remotable I/O•Capability for I/O Expansion•Redundant Control and PlantData Highways
•Peer-to-Peer Communications•Time Synchronized Unit Controls•Time Coherent System Data•Integrated System Diagnostics•Independent OS and OTProtection
Figure 5. Mark VI – ICS design integrated with HSystems™ design
H Gas TurbineThe heart of the GE H System™ is the gas tur-bine. The challenges, design details, and valida-tion program results follow. We start with a briefoverview of the 9H and 7H gas turbine compo-nents (Figure 6).
Compressor OverviewThe H compressor provides a 23:1 pressureratio with 1510 lb/s (685 kg/s) and 1230 lb/s(558 kg/s) airflow for the 9H and 7H gas tur-bines, respectively. These units are derived fromthe high-pressure compressor GE AircraftEngines (GEAE) used in the CF6-80C2 aircraftengine and the LM6000 aeroderivative gas tur-bine. For use in the H gas turbines, theCF6-80C2 compressor has been scaled up (2.6:1for the MS7001H and 3.1:1 for the MS9001H)with four stages added to achieve the desiredcombination of airflow and pressure ratio. TheCF6 compressor design has accumulated over20 million hours of running experience, pro-viding a solid design foundation for the HSystem™ gas turbine.
In addition to the variable inlet guide vane(IGV), used on prior GE gas turbines to modu-late airflow, the H compressors have variablestator vanes (VSV) at the front of the compres-sor. They are used, in conjunction with the IGV,
to control compressor airflow during turn-down, as well as to optimize operation for varia-tions in ambient temperature.
Combustor Overview The H System™ can-annular combustion systemis a lean pre-mix DLN-2.5 H System™, similar tothe GE DLN combustion systems in FA-classservice today. Fourteen combustion chambersare used on the 9H, and twelve combustionchambers are used on the 7H. DLN combustionsystems have demonstrated the ability toachieve low NOx levels in field service and arecapable of meeting the firing temperaturerequirements of the GE H System™ gas turbinewhile obtaining single-digit (ppm) NOx and COemissions.
Turbine Overview The case for steam cooling was presented earli-er under Conceptual Design. The GE H System™gas turbine’s first two stages use closed-loopsteam cooling, the third stage uses air cooling,while the fourth and last stage is uncooled.
Closed-loop cooling eliminates the film coolingon the gas path side of the airfoil, and increasesthe temperature gradients through the airfoilwalls. This method of cooling results in higherthermal stresses on the airfoil materials, and hasled GEPS to use single-crystal super-alloys forthe first stage, in conjunction with thin ceramicthermal barrier coatings (Figure 7). This is acombination that GEAE has employed in its jetengines for 20 years. GEPS reached into theextensive GEAE design, analysis, testing andproduction database and worked closely withGEAE, its supplier base, and CR&D to translatethis experience into a reliable and effective fea-ture of the H System™ gas turbine design.
GE follows a rigorous system of design practiceswhich the company has developed through hav-
Power Systems for the 21st Century – “H” Gas Turbine Combined-Cycles
GE Power Systems ■ GER-3935B ■ (10/00) 7
Figure 6. Cross-section H gas turbine
ing a wide range of experiences with gas tur-bines in the last 20 years. For instance, GEAE’sexperience base of over 4000 parts indicatesthat thermal barrier coating on many airfoils issubject to loss early in operation, and that max-imization of coating thickness is limited bydeposits from environmental elements, evi-denced by coating spallation when thicknesslimits are exceeded. Through laboratory analy-ses and experience-based data and knowledge,GE has created an airfoil that has shown, duringfield tests, that it maintains performance over aspecific minimum cyclic life coatings, even withlocalized loss of coatings, as has been noted dur-ing field service.
Gas Turbine Validation: Testing toReduce RiskAlthough GEPS officially introduced the HSystem™ concept and two product lines, the 9Hand 7H gas turbines, to the industry in 1995, HSystem™ technology has been under develop-ment since 1992. The development has been ajoint effort among GEPS, GEAE, and CR&D,with encouragement and support from the U.S.Department of Energy, and has followed GE’scomprehensive design and technology valida-tion plan that will, when complete, havespanned 10 years from concept to power plantcommissioning.
The systematic design and technology-valida-tion approach described in this paper hasproved to be the aerospace and aircraft indus-try’s most reliable practice for introduction ofcomplex, cutting-edge technology products.The approach is costly and time consuming, butis designed to deliver a robust product into thefield for initial introduction. At its peak, theeffort to develop and validate the H System™required the employment of over 600 peopleand had annual expenses of over $100 million.
Other suppliers perceive that design and con-struction of a full-scale prototype may be afaster development-and-design approach.However, it is difficult, if not impossible, for aprototype to explore the full operating processin a controlled fashion. For example, prototypetesting limits the opportunity to evaluate alter-native compressor stator gangs and to explorecause-and-effect among components whenproblems are encountered. The prototypeapproach also yields a much greater probabilityof failure during the initial field introduction ofa product than does the comprehensive designapproach, coupled with “Six Sigma” disciplinesand the technology validation plan used by GE(Figure 8).
The first phase in the H System™ developmentprocess was a thorough assessment of productoptions, corresponding design concepts, andsystem requirements. Also crucial in the firstphase was careful selection of materials, com-ponents and subsystems. These were sorted intocategories of existing capabilities or requiredtechnology advancements. All resources andtechnological capabilities of GEAE and CR&Dwere made available to the Power Systems’ H-technology team.
For each component and subsystem, risk wasassessed and abatement analyses, testing, and
Power Systems for the 21st Century – “H” Gas Turbine Combined-Cycles
GE Power Systems ■ GER-3935B ■ (10/00) 8
Figure 7. H Stage 1 nozzle and bucket – singlecrystal
data were specified. Plans to abate risk and facil-itate design were arranged, funded, and exe-cuted.
The second development phase covered prod-uct conceptual and preliminary designs, andincluded the introduction of knowledge gainedthrough experience, materials data, and analyt-ical codes from GEPS and GEAE.
The H System™ development program is cur-rently in its third and final phase, technologyreadiness demonstration. This phase includesexecution of detailed design and product vali-dation through component and gas turbinetesting. A high degree of confidence has beengained through component and subsystem test-ing and validation of analysis codes.Completion of the development programresults in full-scale gas turbine testing at our fac-tory test stand in Greenville, SC, followed bycombined-cycle power plant testing at theBaglan Energy Park launch site, in the UnitedKingdom.
Compressor Design StatusModifications and proof-of-design are madethrough a rigorous design process that includesGEAE and GEPS experience-based analyticaltools, component tests, compressor rig tests andinstrumented product tests. The aerodynamic
design process uses pitchline design and off-design performance evaluation, axisymmetricstreamline curvature calculations with empiri-cism for secondary flows and mixing, two-dimensional inviscid blade-to-blade analysis andthree dimensional viscous CFD blade row analy-sis. The aerodynamic design is iterated in con-cert with the aeromechanical design of the indi-vidual blade stages, optimizing on GEAE andGEPS experience-supported limits on bladeloading, stage efficiency, surge margin, stresslimits, etc.
The program has completed the third and finalcompressor rig test at GEAE’s Lynn, MA testfacility.
Tests are run with CF6 full-scale hardware,which amounts to a one-third scale test for the9H and 7H gas turbines. Each rig test is expen-sive, approximately $20M, but provides valida-tion and flexibility, significantly surpassing anyother test options. The 7H rig test had over 800sensors and accumulated over 150 hours tocharacterize the compressor’s aerodynamic andaeromechanical operations (Figure 9). Key testelements include optimum ganging of the vari-able guide vanes and stators; performance map-ping to quantify airflow, efficiency, and stallmargins; stage pressure and temperature splits;start-up, acceleration, and turndown character-
Power Systems for the 21st Century – “H” Gas Turbine Combined-Cycles
GE Power Systems ■ GER-3935B ■ (10/00) 9
H Event JAE9GE Proprietaryg
FSNL FactoryFSNL FactoryTestsTests
•• 23:1 Compressor23:1 Compressor•• Compressor Rig TestsCompressor Rig Tests•• Full pressureFull pressure combustion tests combustion tests•• Single crystal materialSingle crystal material•• Robust TBC coatingsRobust TBC coatings•• Steam Cooling SystemsSteam Cooling Systems•• Nozzle cascade testNozzle cascade test•• Mark VI Control SystemMark VI Control System
Commercial Commercial OperationOperation
FSFL FieldFSFL FieldTestTest
Design, AnalysisDesign, Analysis&&
Component TestsComponent Tests
Proven Best PracticesProven Best Practicesfrom from
Experience BaseExperience Base
Advanced TechnologiesAdvanced TechnologiesNeededNeeded
•• Inlet/Exhaust/StructuresInlet/Exhaust/Structures•• Through-Bolt RotorThrough-Bolt Rotor•• Cold end driveCold end drive•• PS & AE materialsPS & AE materials•• DLN combustionDLN combustion•• Proven analytical toolsProven analytical tools•• Proven productionProven production
sourcessources
Figure 8. GE validation process
Figure 9. 7H compressor test rig
istics; and identification of flutter and vibratorycharacteristics of the airfoils (aeromechanics).
The three-test series has accomplished the fol-lowing:
■ Proof of concept, with four stagesadded to increase pressure ratio, andinitial power generation operability –completed August 1995.
■ 9H compressor design validation andmaps including tri-passage diffuserperformance and rotor cooling proof-of-concept – completed August 1997.
■ 7H compressor design validation –completed August 1999, (Figure 10)
Combustor Design Status Figure 11 shows a cross-section of the combus-tion system. The technical approach features atri-passage radial prediffuser which optimizesthe airflow pressure distribution around thecombustion chambers, a GTD222 transitionpiece with an advanced integral aft framemounting arrangement, and impingementsleeve cooling of the transition piece. The tran-sition piece seals are the advanced cloth varietyfor minimum leakage and maximum wearresistance. The flow sleeve incorporates
impingement holes for liner aft cooling. Theliner cooling is of the turbolator type so that allavailable air can be allocated to the reactionzone to reduce NOx. Advanced 2-Cool™ com-posite wall convective cooling is utilized at theaft end of the liner. An effusion-cooled cap isutilized at the forward end of the combustionchamber.
Fuel Injector Design Status The H System™ fuel injector is shown in Figure12 and is based on the swozzle concept. Theterm swozzle is derived by joining the words“swirler” and “nozzle.” The premixing passageof the swozzle utilizes swirl vanes to impart rota-tion to the admitted airflow, and each of theseswirl vanes also contains passages for injectingfuel into the premixer airflow. Thus, the pre-mixer is very aerodynamic and highly resistant
Power Systems for the 21st Century – “H” Gas Turbine Combined-Cycles
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Figure 10. Compressor map
Swozzle Based Fuel Nozzle
Flowsleeve
Cap Assembly
Impingement Sleeve
Transition Piece
Combustion Liner
Figure 11. Combustion system cross-section
Inlet Flow Conditioner
Diffusion Swirler
Diffusion Gas Holes
Swirler Vanes
Premix Fuel Passages
UninterruptedFlowpath
Diffusion Air Passage
Figure 12. Fuel injector system cross-section
to flashback and flameholding. Downstream ofthe swozzle vanes, the outer wall of the premix-er is integral to the fuel injector to provideadded flameholding resistance. Finally, for dif-fusion flame starting and low load operation, aswirl cup is provided in the center of each fuelinjector.
The H System™ combustor uses a simplifiedcombustion mode staging scheme to achievelow emissions over the premixed load rangewhile providing flexible and robust operation atother gas turbine loads. Figure 13 shows aschematic diagram of the staging scheme. Themost significant attribute is that there are only
three combustion modes: diffusion, piloted pre-mix, and full premix mode. These modes aresupported by the presence of four fuel circuits:outer nozzle premixed fuel (P4), center nozzlepremixed fuel (P1), burner quaternary pre-mixed fuel (BQ), and diffusion fuel (D4). Thegas turbine is started on D4, accelerated to Full-Speed No-Load (FSNL), and loaded further. Atapproximately 20-35% gas turbine load, twopremixed fuel streams P1, and P4, are activatedin the transfer into piloted premix. After load-ing the gas turbine to approximately 40-50%load, transfer to full premix mode is made andall D4 fuel flow is terminated while BQ fuel flowis activated. This very simplified staging strategyhas major advantages for smooth unit operabil-ity and robustness.
The H System™ combustor was developed in anextensive test series to ensure low emissions,quiet combustion dynamics, ample flashback/flameholding resistance, and rigorouslyassessed component lifing supported by a com-plete set of thermal data. In excess of thirtytests were run at the GEAE combustion testfacility, in Evendale, OH, with full pressure,temperature, and airflow. Figure 14 shows typi-cal NOx baseload emissions as a function ofcombustor exit temperature, and Figure 15shows the comparable combustion dynamicsdata. The H components have significant mar-gin in each case. In addition, hydrogen torch
ignition testing was performed on the fuelinjector premixing passages. In all cases thefuel injectors exhibited well in excess of 30 ft/sflameholding margin after the hydrogen torch
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PREMIXED MODE TURNDOWN(BASE LOAD VGV SIMULATION )
T3.95C -- degrees F
ISO NOx @ 15% O
2 -- ppmvd.
Program Goal
Progam Margined Goal
Figure 14. NOx baseload emissions as a function ofcombustor exit temperature
Figure 13. Combustion mode staging scheme
PREMIXED MODE TURNDOWN( BASE LOAD VGV SIMULATION )
T3.95C -- degrees F
Combustion Dynamics, Peak to Peak -- psida.
Overall Level
Highest Discrete Peak
Discrete Peak Guideline Upper Limit
Figure 15. Comparable combustion dynamics data
PREMIXED MODE TURNDOWN(BASELOAD VGV SIMULATION)
T3.95c – degrees F
PREMIXED MODE TURNDOWN(BASELOAD VGV SIMULATION)
T3.95c – degrees F
Overall Level
Highest Discrete Peak
Program Margined Goal
Program Goal
ISO
NO
x@
15%
O2
– pp
mvd
.C
ombu
stio
n D
ynam
ics,
Pea
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Pea
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Discrete Peak Guideline Upper Limit
was de-activated. In addition, lifing studies haveshown expected combustion system componentlives with short term Z-scores between 5.5 and7.5 relative to the combustion inspection inter-vals on a thermal cycles to crack initiation basis.Thus, there is a 99.9% certainty that compo-nent lifing goals will be met.
Turbine Design StatusThe turbine operates with high gas path tem-peratures, providing the work extraction todrive the compressor and generator. Two of thefactors critical to reliable, long life are the tur-bine airfoil's heat transfer and material capabil-ities. When closed circuit steam cooling is used,as on the H turbine, the key factors do notchange. However, the impact of steam on theairfoil's heat transfer and material capabilitiesmust also be considered.
For many years, the U.S. Department of Energy(DOE) Advanced Turbine System has providedcooperative support for GE’s development ofthe H System™ turbine heat transfer materialscapability and steam effects. Results have fullydefined and validated the factors vital to suc-cessful turbine operation. A number of differ-ent heat transfer tests have been performed tofully characterize the heat transfer characteris-tics of the steam-cooled components. Figure 16
shows results for stage 1 nozzle internal coolingheat transfer. An extensive array of materialtests has been performed to validate the mate-rial characteristics in a steam environment.Testing has included samples of base materialand joints and the testing has addressed the fol-lowing mechanisms: cyclic oxidation, fatiguecrack propagation, creep, low-cycle fatigue andnotched low-cycle fatigue (Figure 17).
Thermal barrier coating (TBC) is used on theflowpath surfaces of the steam-cooled turbineairfoils. Life validation has been performedusing both field trials (Figure 18) and laboratoryanalysis. The latter involved a test that dupli-cates thermal-mechanical conditions, which theTBC will experience on the H System™ airfoils.
Long-term durability of the steam-cooled com-ponents is dependent on avoidance of internaldeposit buildup, which is, in turn, dependenton steam purity. This is accomplished throughsystem design and filtration of the gas turbinecooling steam. Long-term validation testing,
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Figure 16. Full-scale stage 1 nozzle heat transfertest validates design and analysis pre-dictions
Figure 17. Materials validation testing in steam
Figure 18. Thermal barrier coating durability
currently underway at an existing power plant,has defined particle size distribution and vali-dated long-term steam filtration. As further val-idation, specimens duplicating nozzle coolingpassages have initiated long-term exposuretests. A separate rotational rig is being used forbucket validation.
The H turbine airfoils have been designedusing design data and validation test results forheat transfer, material capability and steamcooling effects. The durability of ceramic ther-mal barrier coatings has been demonstrated bythree different component tests performed byCR&D:
■ Furnace cycle test
■ Jet engine thermal shock tests
■ Electron beam thermal gradienttesting
The electron beam thermal gradient test wasdeveloped specifically for GEPS to accuratelysimulate the very high heat transfers and gradi-ents representative of the H System™ gas tur-bine. Heat transfers and gradients representa-tive of the H System™ gas turbine have also beenproven by field testing of the enhanced coatingsin E- and F-class gas turbines.
The stage 1 nozzle, which is the H System™component subjected to the highest operatingtemperatures and gradients, has been validatedby another intensive component test. A nozzlecascade facility was designed and erected atGEAE (Figure 19). It features a turbine segmentcarrying two closed-loop steam-cooled nozzlesdownstream from a full-scale H System™ com-bustor and transition piece. This testing facilityaccurately provides the actual gas turbine oper-ating environment. Two prototype nozzles com-plete with pre-spalled TBC were tested in April1998. Data was obtained validating the aerody-namic design and heat transfer codes.Accelerated endurance test data was also
obtained. A second test series, with actual 9Hproduction nozzles, is scheduled to start in the4th quarter of 2000).
The rotor steam delivery system delivers steamfor cooling stage 1 and 2 turbine buckets. Thissteam delivery system relies on “spoolies” todeliver steam to the buckets without detrimen-tal leakage, which would lead to performanceloss and adverse thermal gradients within therotor structure. The basic concept for powersystem steam sealing is derived from many yearsof successful application of spoolies in the GECF6 and CFM56 aircraft engine families.
In the conceptual design phase, material selec-tion was made only after considering the effectsof steam present in this application. Coatings toimprove durability of the spoolie were also test-ed. These basic coupon tests and operationalexperience provided valuable information tothe designers.
In the preliminary design phase, parametricanalysis was performed to optimize spoolie con-figuration. Component testing began for bothair and steam systems. The spoolie was instru-mented to validate the analysis. Again, the com-bination of analysis and validation tests provid-ed confirmation that the design(s) under con-sideration were based on the right concept.
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Figure 19. Nozzle cascade test facility
Over 50 component tests have been conductedon these spoolies, evaluating coatings, lateralloads, fits, axial motion, angular motion, tem-perature and surface finish.
The detailed design phase focused on optimiza-tion of the physical features of the subsystem,spoolie-coating seat. In addition, refined analy-sis was performed to allow for plasticity lifecyclecalculations in the region of the highest stress-es. This analysis was again validated with aspoolie cyclic life test, which demonstratedeffective sealing at machine operating condi-tions with a life over of 20,000 cycles.
Spoolies were also used on the H System™ FSNLgas turbine tests. During the 9H FSNL-2 testing,compressor discharge air flowed through thecircuit. This is typical of any no-load operation.Assembly and disassembly tooling and processeswere developed. The spoolies were subjected toa similar environment with complete mechani-cal G loading. Post-testing condition of the sealswas correlated to the observation made on thecomponent tests. This provided another oppor-tunity for validation.
A rotating steam delivery rig (Figure 20) hasbeen designed and manufactured to conductcyclic endurance testing of the delivery systemunder any load environment. The rotating rigwill subject components to the same centrifugal
forces and thermal gradients that occur duringactual operation of the turbine. This system test-ing will provide accelerated lifecycle testing.
Leakage checks will be completed periodicallyto monitor sealing effectiveness. Test rig instru-mentation will insure that the machine matchesthe operating environment. The rig has beeninstalled in the test cell, and testing shouldresume in April 2000.
Gas Turbine Factory TestsThe first six years of the GE H System™ valida-tion program focused on sub-component andcomponent tests. Finally, in May 1998, the pro-gram moved on to the next stage, that of full-scale gas turbine testing at the Greenville, SouthCarolina factory (Figure 21). The 9H gas turbineachieved first fire and full speed and, then, overa space of five fired tests, accomplished the fullset of objectives. These objectives included con-firmation of rotor dynamics: vibration levelsand onset of different modes; compressor air-foil aero-mechanics; compressor performance,including confirmation of airflow and efficien-cy scale-up effects vs. the CF6 scale rig tests;measurement of compressor and turbine rotorclearances; and demonstration of the gas tur-bine with the Mark VI control system.
The testing also provided data on key systems:
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Figure 20. Rotating rig installed in test standFigure 21. 9H gas turbine in half shell prior to first
FSNL test
bearings, rotor cooling, cavity temperatures andeffectiveness of the clearance control systems.
Following the testing, the gas turbine was disas-sembled in the factory and measured and scru-tinized for signs of wear and tear. The hardwarewas found to be in excellent condition.
The 9H gas turbine was rebuilt with productionturbine airfoils and pre-shipment tests per-formed in October and November 1999. Thisunit was fully instrumented for the field test tofollow and, thus, incorporated over 3500 gaugesand sensors (Figure 22).
This second 9H test series took seven fired startsand verified that the gas turbine was ready toship to the field for the final validation step.Many firsts were accomplished. The pre-ship-ment test confirmed that the rotating air/steamcooling system performed as modeled anddesigned. In particular, leakage, which is criticalto the cooling and life of the turbine airfoilsand the achievement of well-balanced and pre-dictable rotor behaviors, was well under allow-able limits.
Compressor and turbine blade aeromechanicsdata were obtained at rates of up to 108% of thedesign speed, clearing the unit to run at designand over-speed conditions. Rotor dynamics
were once again demonstrated, and vibrationlevels were found to be acceptable without fieldbalance weights.
The Mark VI control system demonstrated fullcontrol of both the gas turbine and the new HSystem™ accessory and protection systems.
The first 7H gas turbine was assembled andmoved to the test stand in December 1999(Figure 23). This 7H went through a test seriessimilar to that for the first 9H factory test.However, the 7H not only covered the 9H testobjectives described earlier, but also ran sepa-rately with deliberate unbalance at compressorand turbine ends to characterize the rotor sen-sitivity and vectors. The rotor vibrations showedexcellent correlation with the rotor dynamicmodel and analysis.
The 7H gas turbine is now back in the factoryfor disassembly and inspection, following thesame sequence used for the 9H.
Validation SummaryGE is utilizing extensive design data and valida-tion test programs to ensure that a reliable HSystem™ power plant is delivered to the cus-tomer. A successful baseline compressor testprogram has validated the H System™ compres-sor design approach. As a result of the 9H and
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Figure 22. 9H gas turbine in test stand for pre-ship-ment test
Figure 23. 7H gas turbine being installed in teststand
7H compressor tests, the H compressors havebeen fully validated for commercial service.The H turbine airfoils have been validated byextensive heat tests, materials testing in steam,TBC testing and steam purity tests. Test resultshave been integrated into detailed, three-dimensional, aerodynamic, thermal and stressanalysis. Full size verification of the stage 1 noz-zle design is being achieved through the steam-cooled nozzle cascade testing.
Both 9H and 7H gas turbines have undergonesuccessful factory testing and the 9H is nowpoised for shipment to the field and final vali-dation test.
ConclusionThe rigorous design and technology validationof the H System™ is an illustration of the GE NPIprocess in its entirety. It began with a well-rea-soned concept that endured a rigorous review
and validation process. This ensures the highestprobability of success, even before the productor shipping to customers and/or the producthas begun operation in the field.
The H technology, combined-cycle power plantcreates an entirely new echelon of power gen-eration systems. Its innovative cooling systemallows a major increase in firing temperature,which allows the turbine to reach record levelsof efficiency and specific work while retaininglow emissions capability.
The design for this “next generation” powergeneration system is now established. Both the50 Hz and 60 Hz family members are currentlyin the production and final validation phase.The extensive component test validation pro-gram, already well underway, will ensure deliv-ery of a highly reliable, combined-cycle powergeneration system to the customer.
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List of FiguresFigure 1. Combustion and firing temperatures
Figure 2. Impact of stage 1 nozzle cooling method
Figure 3. H combined-cycle and system description
Figure 4. 7H and 7FA footprint comparison
Figure 5. Mark VI – ICS design integrated with H System™ design
Figure 6. Cross-section H gas turbine
Figure 7. H Turbine - stage 1 nozzle and bucket – single crystal
Figure 8. GE validation process
Figure 9. 7H compressor rig test
Figure 10. Compressor map
Figure 11. Combustion system cross-section
Figure 12. Fuel injection system cross-section
Figure 13. Combustion mode staging scheme
Figure 14. Combustion test results – NOx baseload emissions as a function of combustion exit temperature
Figure 15. Combustion test results – comparable combustion dynamics data
Figure 16. Full-scale stage 1 nozzle complete band heat transfer test validates cooling design
Figure 17. Materials validation testing in steam
Figure 18. Thermal barrier coating durability
Figure 19. Nozzle cascade test facility
Figure 20. Rotating rig installed in test stand
Figure 21. 9H gas turbine in half shell prior to first FSNL test
Figure 22. 9H gas turbine in test stand for pre-shipment test
Figure 23. 7H gas turbine being installed in test stand
List of TablesTable 1. H Technology performance characteristics (50 Hz)
Table 2. H Technology performance characteristics (60 Hz)
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