01 intro & theory gt r03

1Copyright 2004 Nuovo Pignone S.p.A. Copyright 2006 Nuovo Pignone S.p.A.

Heavy Duty Gas TurbineOverview

21 - Gas Turbine General Overview

2 - Operating Principles

3 - GT Componentes Description

Describe the gas turbine thermodynamic cycle, main parameters and performance

Installation layout Main equipment location

Describe in detail all gas turbine componentes and their functions

Training Program

3Training Program

5 - Gas Turbine Control System Basic of Control and Protection System, Start-up and Shut-down sequences

4 - Main GT Auxiliary Systems Describe the Auxiliary systems, P&ID

6 Maintenance Overview Scheduled and BorescopeInspection, Disassembling and reassembling procedures, Components acceptability criteria

4Gas Turbine is an engine as a four cycle reciprocating

engine

Its an high technology engineIt an high speed rotating machine (3.00030.000 rpm)In industrial application may drive generators (GD = Generator Drive) or pumps and compressors (MD = Mechanical Drive)Its used for mobile application as aircraft ships etc. Power range of gas turbine is between 100 kW and 350 MWIts efficiency is between 25% and 40%High specific power (light and powerful machine)May use a large typology of fuels (gas and liquid types)It may operate continuously without stop as long as for one year

Additionally for power higher than 500 kW it has

Low cost of installed kwLow maintenance costs

What is a Gas Turbine?

5What is a Gas Turbine?

The primary scope is.

To produce mechanical energy at low cost and

continuously!!

6 IT DRAWS IN AIR FROM THE SURROUNDING ENVIRONMENT IT COMPRESS IT TO HIGHER PRESSURE

IT INCREASES THE ENERGY LEVEL

OF THE COMPRESSED AIR BY ADDING AND BURNING FUEL IN COMBUSTION CHAMBER

IT DIRECTS HIGH PRESSURE, HIGH

TEMPERATURE AIR TO THE TURBINE

SECTION, WHICH CONVERTS

THERMAL ENERGY INTO

MECHANICAL ENERGY

THAT MAKES

THE SHAFT REVOLVE;

THIS SERVES,

ON THE ONE HAND, TO

SUPPLY USEFUL ENERGY

TO THE DRIVEN

MACHINE, COUPLED TO

THE MACHINE BY MEANS OF

A COUPLING AND, ON THE OTHER HAND,

TO SUPPLY ENERGY NECESSARY FOR AIR COMPRESSION,

WHICH TAKES PLACE IN A COMPRESSOR DIRECTLY WITH THE TURBINE SECTION

IT EXHAUST LOW PRESSURE, LOW TEMPERATURE

GASES RESULTING FROM THE ABOVE-MENTIONED TRANSFORMATION INTO THE ATMOSPHERE.

FUEL

FUEL

How a Gas Turbine Works

7Nuovo Pignone

GAS TURBINES GAS TURBINES GENERAL GENERAL OVERVIEWOVERVIEW

8HEAVY DUTY

INDUSTRIAL USE PGT/GE SERIES

JET

INDUSTRIAL USE

TWO SHAFTS PURE AEREONAUTICAL

INDUSTRIAL & MARINE USELM SERIES

PENGIUN TURBINES

SINGLE SHAFT

Gas Turbine Families

99High Efficiency, Reliability & Availability 9 Low Life- Cycle Costs9 Application Flexibility9 Fuel Flexibility9 Low EmissionsMS 5001 MS 5001 26.3 MW26.3 MW

GE 5GE 5--11 5.5 MW5.5 MW

GE 10GE 10--11 11.2 MW11.2 MW

LM 2500+/PGT 25+ LM 2500+/PGT 25+ 31.3 MW31.3 MW

MS 6001B MS 6001B 42.1 MW42.1 MW

LM 6000 LM 6000 44.7 MW44.7 MW

MS 7001EA MS 7001EA 85.1 MW85.1 MW

MS 9001EMS 9001E 123.4 MW123.4 MW

LM 1600/PGT 16 LM 1600/PGT 16 14.2 MW14.2 MW

LM 2000/PGT 20 LM 2000/PGT 20 18.1 MW18.1 MW

GE 5GE 5--22 5.6 MW5.6 MW

GE 10GE 10--22 11.7 MW11.7 MW

LM 2500/PGT 25 23.2 MWLM 2500/PGT 25 23.2 MW

MS 5002C MS 5002C 28.3 MW28.3 MW

MS 5002EMS 5002E 30.0 MW30.0 MW

MS 5002DMS 5002D 32.5 MW32.5 MW

Solid Technology Base ... For Every Application

Multi ShaftSingle Shaft

Gas Turbines Product Range

10

Output : 5.220 Kw Efficiency : 26,9 % Heat Rate : 13.422 kJ/kWh Ex. Gas Flow : 24,6 kg/s Ex. Gas Temp. : 524 C Nominal Speed : 11.140 rpm

PGT 5/1

The PGT5/1 heavy-duty gas turbine has been designed with modular concepts to facilitate accessibility and maintainability. The gas generator consists of a 15-stage, high efficiency, axial-flow compressor directly coupled to a two stage turbine. The PGT5 has a single combustion chamber system which is rugged, reliable and able to burn a wide range of fuels, from liquid distillates and residuals to all gaseous fuels, including low BTU gas. It is specially designed for small power generation and cogenerationPERFORMANCE (@ ISO CONDITIONS; MD)

KEY DATA

Weight: 28.000 Kg

11

PGT 5/2 The PGT5/2 heavy-duty gas turbine has been designed with modular concepts to facilitate accessibility and maintainability. The gas generator consists of a 15-stage, high efficiency, axialflow compressor directly coupled to a single stage turbine. The low pressure shaft is a single-stage, high-energyturbine, with variable second stage nozzles which grant maximum flexibility for mechanical drive service. The PGT5/2 has a single combustion chamber system which is rugged, reliable and able to burn a wide range of fuels, from liquid distillates and residuals to all gaseous fuels, including low BTU gas. Typical applications include pump drive for oil pipelines andcompressor drive for gas pipelines. Also used in PG

PERFORMANCE (@ ISO CONDITIONS; GD & MD) Output : 5.450 Kw Efficiency : 26,9 % Heat Rate : 13.422 kJ/kWh Ex. Gas Flow : 24,6 kg/s Ex. Gas Temp. : 524 C Nominal Speed : 11.140 rpm

KEY DATA

Weight: 28.000 Kg

12

GE 5/1KEY DATA

Single Shaft ideal Prime Mover for Industrial Cogeneration

50Hz or 60Hz Power Generation 11 stage Compressor scaled from GE10 DLE Combustion System High Reliability & Maintainability Compact Package Low Maintenance Cost.

PERFORMANCE (@ ISO CONDITIONS; MD) Output : 5.500 Kw Efficiency : 30,7 % Heat Rate : 11.740 kJ/kWh Ex. Gas Flow : 19,6 kg/s Ex. Gas Temp. : 574 C Nominal Speed : 16.630 rpm

Weight: 23.900 Kg

13

GE 5/2 (New Product)KEY DATA

PERFORMANCE (@ ISO CONDITIONS)

Twin Shaft driver for Centrifugal Compressors and Pumps 3D Aero Advanced static and brush seals New coatings Advanced compressor design Optimization of clearances

Output : 5.600 Kw Efficiency : 31,5 % Heat Rate : 11.428 kJ/kWh Ex. Gas Flow : na kg/s Ex. Gas Temp. : na C Nominal Speed : na rpm

Weight: 24.000 Kg

14

MD GD

Output : 10.660 10.220 Kw Efficiency : 32,5 31,4 % Heat Rate : 11.250 11.540 kJ/kWh Ex. Gas Flow : 42,3 42,1 kg/s Ex. Gas Temp. : 493 484 C PT Nominal Speed : 10.800 10.800 rpm

The PGT10 A/2 design goals are: high performance, high reliability and availability, easy maintenance concepts. High technology design: High pressure ratio, firingtemperature level in line with second generation gas turbines, variable axial compressor stator vanes and power turbine nozzles. The PGT10 combustion system consists of a single combustion chamber suitable for a large variety of gaseousand liquid fuels. Typical applications for PGT10 are natural gas compression, centrifugal pump drive and process application, Offshore applications.

PGT 10 A (two shaft)KEY DATA


Weight: 34.000 Kg

15

GE 10/1KEY DATA Derivative of PGT10A - 2.000.000+

hours experience High efficiency high pressure ratio Compressor with

less stages - 11 Vs 17 DLN combustion system available Good Reliability & Maintainability Low maintenance cost

PERFORMANCE (@ ISO CONDITIONS; GD)


Model available may Have combustion chamber horizontal or vertical according customer request

Weight: 34.000 Kg

16

KEY DATA

PERFORMANCE (@ ISO CONDITIONS; MD)

Turbine designed and developed by Nuovo Pignone Since reliability and availability to worldwide customers while keeping witheasy maintenance concepts. Two shafts for mechanical drive and single shaft for power generation and cogeneration applications. The GE10 Gas Turbine, with its ability to burn different fuels(natural gas, distillate oil, low BTU fuel), can be installed in many countries with different environmental conditions continental, tropical, offshore and desert. Oxides (NOx) reduction in order to meet present and future standards for pollutant emissions.


GE 10/2

Weight: 40.000 Kg

17

PGT 16 First unit in operation 1991 Based on proven LM 1600 GG and

NP developed heavy duty power turbine High efficiency Proven reliability in MD and PG applications Effective DLE system

KEY DATA

PERFORMANCE (@ ISO CONDITIONS)MD GD


This turbine use some power turbine of PGT 10/A and GE 10/2

Weight: 19.000 Kg

18

PGT 25

Power Turbine developed by NuovoPignone in the early 80s

First unit installed in 1983 M.D. & P.G. fleet firing hours exceed

1,800,000


KEY DATA

PGT25 Power Turbine

MD GD

Output : 23.261 (shaft) 22.417 (el.) Kw Efficiency : 37,7 (shaft) 36,3 (el.) % Heat Rate : 9.560 (shaft) 9.919 (el.) kJ/kWh Ex. Gas Flow : 68,9 68,9 kg/s Ex. Gas Temp. : 525 525 C PT Nominal Speed : 6.500 6.500 rpm

Weight: 38.000 Kg

19

PGT 25+

PERFORMANCE (@ ISO CONDITIONS MD & PG)

Natural Gas Fuel Dry Operation

(no steam or water injection)

Base Load

Designed by Nuovo Pignone using G.E. LM 2500 Plus gas generator

The PGT 25 + is a last generator, 30 MW size

First unit in operation during 1997 Fleet firing hours exceed 100,000

KEY DATA

Output : 31.364 Kw Efficiency : 41,1 % Heat Rate : 8.754 kJ/kWh Ex. Gas Flow : 84,3 kg/s Ex. Gas Temp. : 500 C PT Nominal Speed : 6.100 rpm

20

MS 5001

PERFORMANCE (@ ISO CONDITIONS; GD)

Output : 26.300 Kwe Efficiency : 26,3 % Heat Rate : 12.650 kJ/kWh Ex. Gas Flow : 124,1 kg/s Ex. Gas Temp. : 487 C Nominal Speed : 5.100 rpm

The MS5001 single shaft turbine is a compact heavy-duty turbine designed for long life and easy maintenance. The MS5001 gas turbine is the ideal solution for industrial power generation where low maintenance, reliability and economy of fuel utilization are required. Low investment costs make the MS5001 package power plant an economically attractive system for peak load generation. The MS5001 is ideally suited for cogeneration achieving very high fuel utilization indexes Typical applications are industrial plants for cogeneration of power and process steam or in district heating systems.

KEY DATA

Weight: 87.430 Kg

21

MS 5002C / MS 5002D

MS5002C MS5002D


KEY DATA

Low capital & maintenance cost Long maintenance intervals Fleet leader in excess of

100.000 running hours More than 420 units worldwide

PERFORMANCE (@ ISO CONDITIONS) Weight: 110.000 Kg

22

MS5002E (New Product)

Features

Introductory Performance

Leverage GE Technology Moderate Firing Temperature Reliability & Efficiency as

Key Factors DLN System derived from

large Frames Twin Shaft - suitable for MD or PG

CTV Compressor Test

CTV Test Rig

zz Output Shaft : 30 MWz SC Efficiency : 36,4 %z LPT shaft speed : 6.100 rpmz Exhaust Temp. : 523 Cz NOx Emission : 25 ppm

Rotordynamic Test

Weight: 117.000 Kg

23

LM 6000KEY DATA

Most efficient GT in its class Proven high reliability and availability Generator & Mechanical drive applications 3 + millions cumulating operating hours

PERFORMANCE (@ ISO CONDITIONS PG; MD)

Output : 43.076 kW Efficiency : 41,3 % Heat Rate : 8.707 kJ/kWh Ex. Gas Flow : 131,0 kg/s Ex. Gas Temp. : 449 C PT Nominal Speed : 3.600 rpm

Weight: 31.000 Kg

24

MD GD

Output : 43.530 (shaft) 42.100 (el.) Kw Efficiency : 33,1 (shaft) 32,06 (el.) % Heat Rate : 10.852 (shaft) 11.230 (el.)

kJ/kWh Ex. Gas Flow : 145 145,8 kg/s Ex. Gas Temp. : 544 552 C Nominal Speed : 5.133 5.100 rpm

MS 6001 BKEY DATA


The MS6001 is a single shaft heavy-duty gas turbine. Itsdesign was based on the well proven mechanical featuresof the MS5001 in order to achieve a compact, high efficency unit. The MS6001 is widely applied in power generation applications for base, mid-range and peak load service. Other typical applications include driving of process machines, such as compressors, in LNG plants. Combined cycle plants based on MS6001 achieve veryhigh efficiencies with higher availability and reliability. Weight: 96.000 Kg

25

MS 7001 EAKEY DATA

MD GD

Output : 81.590 (shaft) 85.100 (el.) Kw Efficiency : 32,67 (shaft) 32,73 (el.) % Heat Rate : 11.020 (shaft) 11.000 (el.)

kJ/kWh Ex. Gas Flow : 278 300 kg/s Ex. Gas Temp. : 546 537 C Nominal Speed : 3.600 3.600 rpm


The MS7001EA is a single shaft heavy-duty gas turbine for power generation and industrial applications requiringthe maximum reliability and availability. With design emphasis placed on energy efficiency, availability, performance and maintainability, the MS7001EA is a proven technology machine with more than 500 units of its class in service. Typical applications in addition to the 60Hz power generation service are large compressor train drives forLNG plants.

Weight: 121.000 Kg

26

MS 9001 EKEY DATA

PERFORMANCE (@ ISO CONDITIONS PG & MD)

Output : 126.100 kW Efficiency : 33,8 % Heat Rate : 10.650 kJ/kWh Ex. Gas Flow : 418 kg/s Ex. Gas Temp. : 543 C PT Nominal Speed : 3.000 rpm

The MS9001E is a single shaft heavy-duty gas turbine. It was developed for generator drive service in the 50 Hertz market. The MS9001E is widely applied in power generation for base, mid-range and peak load service. Combined cycle plants based on MS9001E achieve very high efficiencies with higher availability and reliability than conventional thermal plants. Newest field of application is LNG for MD Weight: 217.500 Kg

27

MS 9001 FA

28

MS 9001 H

29

OUTPUT POWER

5 Mw

10,5 Mw14 Mw

23,2 Mw

29 Mw26 Mw

6 Mw

12 Mw

32,5 Mw

http://www.gepower.com/nuovopignone

For any further need,please find NP on Internetat the following andress:

2 Mw

Nuovo PignoneOutput Range

30

Gas Turbines Service according load type

SINGLE SHAFT GAS TURBINES DOUBLE SHAFT GAS TURBINES

Load Applic.

31

Heavy Duty Gas Turbine FamiliesHEAVY DUTY

INDUSTRIAL USE

TWO SHAFTSSINGLE SHAFT

HD GT Families

32

Gas Turbines Applications

Gas Booster, Pipelineand Re-injection

Liquified Natural Gas Plants

Offshore Applications

District Heating

Petrochemical Plants

Power Generation andCogeneration Plants

Gas Turbines producedby GE Energy

GT Applic. Field

33

Gas Turbines Typical Loads

Reciprocating Compressors

Centrifugal and Axial Compressors

Centrifugal Pumps

Electric GeneratorsGE Energy

Gas Turbines

34

Nuovo Pignone

GAS TURBINES GAS TURBINES OPERATING OPERATING PRINCIPLESPRINCIPLES

35

KEY TERMS

36

Gas Turbine performance are declared in ISO condition and the constructors have to declare fuel used to obtain declared performances.

ISO conditions

37

Ambient Pressure: 101.325 Pa (14,7 P.S.I.A.)

Ambient Teperature: 15 C (59 F)

Relative Humidity: 60%

Pressure drop in inlet/exhaust: 0 mm H2O

They are the conditions to refer for GT performances evaluation

ISO conditions

38

Section A refers the so called TURBINE INLET TEMPERATURE, wich is the average temperature of hot gas at plane A.Section C refers to the so-called ISO FIRING TEMPERATURE, wich is the average gas temperature at plane C, calculated as a function of the air and fuel flow rates via a thermal balance of combustion according to the ISO 2314 procedure.

FIRING TEMPERATURE

39

P

T

V

S

1

1

2

2

3

3

4

4

The difference in the interpretation of temperatures in section A and B consists in the fact that the section B temperature takesaccount of mixing with 1st stage nozzle cooling air, wich was not involved in the combustion process, but mixes with burnt gasesafter cooling the surface of the nozzle.

According to the NUOVO PIGNONE-GENERAL ELECTRIC standard, the temperature that best represents point (3) is the one in section B

FIRING TEMPERATURE

40

PRESSURE RATIO

41

uLQHR 1=

Heat Rate is the inverse of efficiency, in that it indicates the ratio between thermal energy, resulting from the combustion process, and mechanical energy, obtained on the power shaft.

In generally expressed as kj/kWh

P T

V S11

2

2 33

4

4

4

3

2

1

HEAT RATE

42

HEAT RATE

THERMAL ENERGY THAT WE SPEND TO PRODUCE 1 UNIT OF MECHANICAL ENERGY

POWER & HEAT RATE

43

HEAT RATE

HEAT RATE IS THE INVERSE OF EFFICIENCY

Power & Heat Rate

44

If we think about a car, HEAT RATE is

MUCH MONEY FOR

OUR COMPANYLOW HEAT RATE

Power & Heat Rate

45

HIGH POWER & LOW HEAT RATE

MUCH MONEY FOR

OUR CUSTOMERS

Power & Heat Rate

46

COMPRESSOR RATIO

47

T

1

2

3

4

L

Fuel

C

CC

Combustion Expansion

ExhaustCompression

2 3

1 4

P

V

T

S

2

3

1

4

AirIntake

Exhaust

C - CompressorCC - CombustionT - TurbineL - Load

BRAYTON CYCLE

48

)( 12)( 12 TTcWc TTpm = Mesured inairinletkg

Kj_

Specific Compression Work

Cpm=average specific heatat costant pressure

4

3

2

1

49

)( 43)( 43 TTcWt TTpm = Mesured ingaskg

Kj

Specific Expansion Work


4

3

2

1

50

Mesured in

gaskgKj

)( 23)(1 23 TTcQ TTpm =

Heat supplied to the combustion chamber


4

3

2

1

51

Mesured in

gasehxaustkgKj

_

)( 14)(2 14 TTcQ TTpm = Heat suppl. to atmosphere with exhausted gas


4

3

2

1

52

This equation tell us that, by parityof heat Q1, introduced into the combustion chamber by fuel, efficiency will increase as heat Q2 dissipated into the atmosphere decreases

1

21 )(QQQ

cl=

Thermodynamic efficiency

4

3

2

1

( )...;;; clCCCTT f =

53

Measured in

cairtfuelairu WGWGGP += )(

sKj

Useful work supplied to the driven machine

Gair= amount of air

Gfuel= amount of fuel

4

3

2

1

54

P

T

V

S

1

1

2

2

3

3

4

4

In the Brayton Cycle the following parameters are very important :

THERMAL EFFICIENCY

SPECIFIC POWER )( skgKw

FIRING TEMPERATURE 3T

PRESSURE RATIO1

2P

P

MAIN PARAMETERS AFFECTING G.T. PERFORM.

55

Brayton Cycle: P1, P2

P2

P1

56

T3=?

Brayton Cycle: T1, T2 and T3

T1

T2

57

Brayton Cycle: T3

=10,5 963C

(1765F)

T3=f(T4,P2)

58

Brayton Cycle: T4

59

PROBLEM IS IN THE AXIAL

COMPRESSOR OF HEAVY DUTY

GAS TURBINES

Single and Double shaft: differences to use

60

G.T. for Generator Drive (mainly): Single shaft

61

Single shaft G.T. are preferred to drive Generators

SINGLE SHAFT GAS TURBINES MUST ROTATE AT CONSTANT SPEED (i.e. 5100 rpm forMS5001/6001, 3600 rpm for MS7001 and 3000 rpm for MS9001) TO AVOID SURGE OR STALL PROBLEMS ON

ITS INTERNAL AXIAL COMPRESSOR

SINGLE SHAFT GAS TURBINES HAVE BEEN MAINLY DEVELOPED TO DRIVE

ELECTRICAL GENERATORS BECAUSE THE GENERATOR IS A MACHINE THAT NEEDS

TO ROTATE AT CONSTANT SPEED

62

1-2 AIR COMPRESSION2-3 COMBUSTION3-4 EXPANSION

LOAD:Electric Generator (often), Compressor, Pumps (rarely)AUXILARY GEAR BOXDrives Auxiliaries (mainly Oil Pumps) and transmits torque from Starting Device

COMBUSTIBILE

AIR

LOAD

COMBUSTORS

EXHAUST GAS4

3

2

1

TURBINE

AXIAL

COMPRESSOR

AUXILIARY GEARBOX

STARTING MOTOR

60 MW 120 MW 60 MW(50%) (100%) (50%)**typical value for HD GT

Single Shaft G.T. Schematic

63

HEAVY DUTY Single Shaft G.E. Gas Turbine Production Range

SINGLE SHAFTS

MS 1001 (*)

PGT 2 (*)

PGT5/1

GE 5/1

GE 10/1

MS 5001

MS 6001 (**)

MS 7001 (**)

MS 9001 (**)

(*) Out of production, Upgrade are available

(**) These units are also used in mechanical drive applications where constant speed is required (i.e. LNG compression plants)

Single Shaft Gas Tubines for GD

64

Gas Tubines for Mechanical Drive: Two shafts

65

Two shafts Heavy Duty type is better to drive loads requiring speed changes infact

IF WE NEED TO DRIVE.

66

Two shafts can provide high speed range variation..

AS MS 5002, WHERE THE HP ROTOR(ROTOR OF AXIAL COMPRESSOR)

CONTINUE TO WORK AT CONSTANT SPEED (5.100 rpm),

WHILE THE LP ROTOR (ROTOR DRIVING THE LOAD) CAN CHANGE ITS NOMINAL

SPEED (100% = 4.670 rpm)

IN THE RANGE OF

50% (2340 rpm) TO 105% (4900 rpm)

67

Gas Generator (GG) turbine drives axial compressor and turbine auxiliary by means of gearbox.

Power Turbine (PT) drives the load, usually a centrifugal compressor or a pump, rarely an electric generator.

PT e GG works at different speed.

GG speed is constant during normal operation.

PT speed can change in the range 50-105% of its rated speed during operation.

The PT first nozzle is composed of variable vanes. In this way, by varying the angle of the vanes, its possible to manage the power sharing between GG and PT by the speed control of the two rotors.

COMBUSTOR(s)

AIR INLETLOAD

EXHAUST

GAS

AXIAL

COPRESSOR

VANES OF VARIABLE AREA NOZZLE

FROM STARTING ENGINE

TO AUXILIARY

GEAR BOX

GAS GENERATOR (GG)

POWERTURBINE

(PT)

GGSTAGES

PT

STAGES

Two Shafts G.E. G.T. Schematic

68

Speed/Load control in Two shafts G.E. HD GTIN THE G.E. H.D. TWO SHAFT GAS TURBINES, AS THE MS 5002, IN

ORDER TO CONTROL THE SPEED OF HP AND LP ROTOR, A SECOND STAGE VARIABLE NOZZLE SYSTEM IS USED

69

G.E. HD Two Shafts GT: 2nd st.Variable Nozzles

Opened Variable Nozzle :

Lowest Pressure Drop on the nozzle, i.e. HP Turbine

lowest back pressure

70

G.E. HD Two Shafts GT: 2nd st.Variable Nozzles

Closed Variable Nozzle :

Highest Pressure Drop on the nozzle, i.e. HP Turbine maximum back pressure

71

Two Shafts Gas Tubines for MD

HEAVY DUTY Two Shafts G.E. Gas Turbine Production RangeMS 1002 (*)

PGT5/2

GE 5/2 (**)

PGT 10/2

GE 10/2

MS 3002 (*)

MS 5002

(*) Out of production, Upgrade are available

(**) New model

(***)

some GE Single Shaft Gas Turbine can be used for MD applications. in special process as LNG, Methanol, etc

MS 6001, MS 7001, MS 9001

72

Firenze ( I ) Greenville ( U.S.A.) Belfort ( F )

9E

9FA

6FA 70

123

255

GT MWMachine

FR5

GE5

GE10

GT MW

30

5.5

11

Machine

6B 42.2

Machine

7H

9H

7FA

9FA

7E

172

400 (CC)

255

85

500 (CC)

GT MW

Heavy Duty G.T. G.E. Supply Chain

73

HEAVY DUTYHEAVY DUTYGAS TURBINESGAS TURBINES

COMPONENTS COMPONENTS DESCRIPTIONDESCRIPTION

ANDANDMAIN FEATURESMAIN FEATURES

Nuovo Pignone

74

Inlet casing:- directs the flow of outside air from the air inlet

equipment into compressor blading- Variable Inlet Guide Vane assembly- N1 bearing assembly- Thrust bearings, active and inactive- Low pressure air seals

Inlet Section Gas Turbine

75

Gas Turbine Axial Compressor

76

HD GT Axial Compressor Operation

COMPRESSOR

is the part of the engine where air is compressed

Compressor Discharge:(1) 30% is used for primary air (combustion air)(2) 5% is used to operation of gas turbine accessories:

-bleed air and seal air-gas turbine start and motor air-gas turbine anti-icing

(3) Remainder is used as secondary air to:- cool combustion gases- Provide film cooling of the gas generator turbine

77

HD GT Axial Compressor Operation

78

Airfoils with large thicknessesRotor stage discs linked by thick tension rods.Sliding Journal bearings Compressor Variable Inlet Guide vanes (IGV)(to control the air flow)

AIR

Journal BEARING

IGVDISCS TENSION RODS

HD GT Axial Compressor Design

79


80


81

Random blades are selected for an automated check for the curvature, thickness, width and so

farth.


82

HD GT Axial Compressor Assembly

Compressor Wheels:Rotor blades are inserted into

these slot and held in axial position by spacer pieces, which are in turn staked at each end of slot

83

is the part of the engine where air is mixed with fuel and burned with a

portion of the compressor air

COMBUSTOR(s)

The combustion casing allows compressor dischargeair to be directedthrough the flow sleeveand ultimately into the combustion liner

30%

30%

40%

HD GT Combustion Chamber(s) Operation

84

HD GT Combustion Chamber Design

LIQUID FUEL

- The air flow through the combustion chamber has three functions: oxidize fuel, cool the metal parts, condition the extremely hot combustion products to the desired turbine inlet temperature.

- The air enters the combustion chamber and flows forward, entering the liner through holes and louvers in the liner wall.

- A portion of the air reaches the head end of C.C. and enters the liner through the cap where the axial swirler creates a vortex.

COMBUSTION CHAMBER WRAPPERLINERSPARKLING PLUG

GAS FUEL

BURNER

COMBUSTION AIR PORT

SLOTS OR HOLES FOR THE LINER COOLING AIR AIR FROM THE AXIAL COMPRESSORGAS CONVEYOR

TRANSITION PIECE

EXHAUST GAS

DILUITION ZONEREACTION

ZONE

COVER

85

DLN 1:

Dry LowNOx.

DRY Systems WET Systems

1) Steam Injection* This system consists of the injection of atomized steamin the combustion chamber to decrease flame temperature and so NOx.

Easy to install

Requires Steam

Increases maintenance

2) Water Injection * This system consists of the injection of atomized water in the combustion chamber to decrease flame temperature and so NOx.

Easy to install

Requires water

Increases maintenance

* Appliable for all GE HD GT

DLN 2:

Dry Low NOx.

NOx reduction for Heavy Duty Gas Turbines

86

TURBINEis the part of the

engine where the hot gases flowing from

the combustor produce the

mechanical power

The turbine can consist of several stages. Each stage is comprised of stationary row of nozzles where the high energy gases are increased in velocity and directed toward a rotating row of buckets, or airfoils, attached to the turbine shaft.

As the gas flows through the turbine rotating shaft, the gas kinetic energy is converted into horsepower.

HD GT Turbine Section

87

HD GT Turbine Section Operation

88

ROTATION AXIS

HD GT Turbine Section DesignRotor blades (Buckets) and stator nozzles withlarge thickness, with high corrosion and erosion resistance. They can accept also heavy fuel oil (residual

treated oil), but with more frequent maintenance intervals.

89

after the casting process, machining and grinding is done to the dovetail and to the sealing wings.

HD GT Turbine Sec. Manufacture & Assembly

90

the last step before shipping is to give to each bucket a weight and a serial number.

the bucket is then given a first and second coating

HD GT Turb.Sec. Blades Manuf. & Assembly

91

In the turbine there are stationary nozzles which direct the high-velocity flow of the expanded hot combustion

gas against the turbine buckets causing the turbine rotor to rotate.

HD GT Turbine Section: Nozzles Design

92

HD GT Turbine Section: Nozzles Design

93

Unlike the compressor blading, the turbine bucket tips do not run directly against an integral machined surface of the casing but against annular curved segments called turbine shrouds.

HD GT Turbine Section : Seals Design

94

Exhaust casing:- the frame consist of an outer cylinder and an inner cylinder

interconnected by radial struts.- directs the flow of hot gas coming from the turbine section into the

exhaust duct- Turing Vanes are installed to reduce hot gas path turbolence / losses

HD GT Exhaust Section

95

The gas turbine unit contains two/three or four main journal bearings, [depending on if the unit is single or two shafts type] used to support the gas turbine rotor. The unit also includes thrust bearings to maintain the rotor-to-stator axial position and to support the thrust loads developedon the rotor. These bearings and seals are incorporated in two, three or four housing, depending on the bearing number.

The GT bearings are pressure-lubricated by a fluid (oil) supplied fromthe lubricating system.

The fluid flows through branch lines to an inlet port provided in each bearing housing.

HD Gas Turbine Bearings

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HD Gas Turbine Journal Bearings

Type:

Elliptical

97

Type:

Load (Equalizing)Unloaded (Non-Equalizing)

HD Gas Turbine Thrust Bearings

98

Gas Turbine: Thrust Loads on Bearings

Normal Operation

Thrust is given by the prevalentaction of the compressor load since in the turbine there is no gas expansion (turbine load gradualy increases starting from flame-on). In the same way, turbine reduces its thrust following the power reduction, till the flame out, during shut-down.

Load on

Thrust action direction, on the G.T. Bearing, changes during starting and loading sequence due to the increased load on the turbine.It happens, therefore, in the opposite sequence during shut-down, because of turbine power decreasing.

(Example for a single shaft G.T. only)

Inactive Thrust Bearing

Load on

Thrust given by the action of the turbine becomes prevalent, respect to that one of the compressor, starting from flame-on and rising with the turbine load increasing(turbine power is about 200% of compressor power).

Start-up and Shutdown

Active Thrust Bearing

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EXTERNAL FACTORS

EXTERNAL FACTORS

AMBIENT TEMPERATURE AMBIENT PRESSURE RELATIVE HUMIDITY GAS FUEL PROPERTIES

INTERNAL FACTORS

PRESSURE DROP IN THE INTAKE SYSTEM

BACKPRESSURE IN THE EXHAUST SYSTEM

AXIAL COMPRESSOR CLEANLINESS

G.T PERFORMANCES: Influence Factors

100

Effects of Amb. Temper. on P, HR, AF/EF

T

S

Exh. Temp. Heat rate

Press. ratio Air Flow Power Output

If Tamb

101

Effects of Amb. Temp. on Exh. Temp

102

Effects of Amb. Temp. (Part Load with Modulat. IGV)

Exhaust Temperature vs. Output Percent:

VIGV Control Mode

Exhaust Flow vs. Output Percent:

VIGV Control Mode

103

Effects of Ambient Pressure

T

S

If pambPr. ratio Air Flow Power Output

Exh.Temp. Heat rate

104

Effects of Ambient Humidity

If rH Mass flow Heat Rate Power Output

T

S

105

G.T PERFORMANCES: Influence FactorsINTERNAL FACTORS

EXTERNAL FACTORS

AMBIENT TEMPERATURE AMBIENT PRESSURE RELATIVE HUMIDITY GAS FUEL PROPERTIES

INTERNAL FACTORS

PRESSURE DROP IN THE INTAKE SYSTEM

BACKPRESSURE IN THE EXHAUST SYSTEM

AXIAL COMPRESSOR CLEANLINESS

106

Pressure drops effects on air intake system

INTAKE SYSTEM

Pressure drop in the intake system is caused by the friction of air flow through the silencers, and by the change in direction of the air path along the intake ducting.

Pressure drop causes loss of power (similar to the altitude effect) and the increase of specific fuel consumption (Heat Rate).

107

T

S

1'p

ppp 11' =

drop pressurep =

Pr. Ratio Mass flow Power Output

Exh. temp. Heat rate

drop pressurep =

Pressure drops effects on Air Intake system

108

Pressure drops effects on Exhaust systemBackpressure in the exhaust system comes from the same mechanism of intake pressure drop, with the addition of the pressure drop due to the boiler, in case of a combined cycle.

The increased back pressure reduces the expansion rate and the relevant amount of energy given by the turbine section.

As for the intake losses, this causes loss of power and increase of specific fuel consumption (Heat Rate).

109

T

S

4'p

ppp 44' +=drop pressurep =

Pr. ratio Mass flow Power Output

Exh. temp. Heat rate

drop pressurep =

Backpressure effects on Exhaust system

110

G.T PERFORMANCES: Influence FactorsCOMPRESSOR CLEANING CONDITIONS

111

CORRECTION FACTORS

Fpressure = 989/1013 = 0.977FkW- temperature ** 0,90FkWInlet system p *** = (100-1,7)/100 = 0,983FkWExh system p *** = (100-0,6)/100 = 0,994FHR- temperature ** 1,020FHR- Inlet system p *** = (100+0,45)/100 = 1,0045FHR- exh system p *** = (100+0,5)/100 = 1,005

SITE CONDITIONS

Pressure (mbar abs) 989Temperature (C) 30Inlet system p (mm H2O) 100Exhaust system p (mm H2O) 100

** From Temperature correction curve ** From Temperature correction curve

*** From perf. curves design data and notes*** From perf. curves design data and notes

ISO CONDITIONS (MS7001)

Temperature (C) 15Pressure* (mbar abs) 1013Output power*** (ISO kW) 85400 Heat Rate ***(kj/kWh) 10990Turbine speed (100% RPM) 3600

Site Output Power (kW) = ISOkW x 0.977 x 0,90 x 0,983 x 0,994 = 85400 x 0,86 = 73444

Site Heat Rate (kj/kWh) = Design HR x 1,020 x 1,0045 x 1,005 = 10990 x 1,029 = 11308

Site Heat consumption (Kj/s) = Site Output Power x Site HR = 73444 x 11308 / 3600 = 230710

Site thermal efficiency (%) = 3600/ Site Heat Rate = (3600/ 11308) x 100 = 31,80

Performance Calculation Exhample

112

1) Cooling inlet air

2) Steam and Water Injection

3) Peak Load

Inlet Temperature

Increase mass flow

Fire Temperature

WARNING !!

PERFORMANCE ENHANCEMENT METHODS

113

Inlet Cooling

114

Inlet Cooling: Evaporative Cooler Schematic

115

Inlet Cooling : Application Field

116

Inlet Cooling : System Balancing Care

117

Evaporative Cooling Vs. Inlet Chilling

118

Water Rates vs. Air Flow for Power Augmentation

Steam / Water Injection

01 intro & theory gt r03

Documents

gas turbine componentes

power range of gas turbine

turbine section

mechanical energy

high pressure

high temperature air

large typology of fuels

energy level