1 Research sponsored by the U.S. Department of Energy’s Federal Energy Technology Center, under contract DE-FC21-95MC31173and the Chicago Operations Office, under contract DE-AC02-92CE40960 with Solar Turbines Incorporated, 2200 Pacific Highway,P.O. Box 85376, San Diego CA 92186-5376.

1

Industrial Advanced Turbine Systems Program Overview1

S. Gates (619) 595-7428(steve_gates@solarturbines.com)

Solar Turbines IncorporatedP.O. Box 85376

San Diego CA 92186-5376

IntroductionEarly in this decade, the U.S.Department of Energy (DOE)recognized the fact that gas turbineswere playing an ever-expanding role inthe power generation industry. Despitethe fact that such machines have been inexistence for more than 50 years, theirimprovements in efficiency, emissions,cost and reliability have been largelyincremental, having typically followedimprovements in materials and otherenabling technologies. In response tothis dichotomy, DOE initiated the fourphase Advanced Turbine Systemsprogram in 1990 and chartered theprogram with the following goalsrelative to then state-of-the-art industrialturbine products:

• 10% improvement in busbar cost ofelectricity.

• 15% improvement in efficiency.• Single-digit NOx emissions.• Reliability equal to or greater than

currently available products.

Now, more than 8 years into the future,the development program undertaken bythis unprecedented public-privatepartnership is entering its fourth andfinal phase. The design phase of theprogram is behind us and thecomprehensive field evaluation phase ofSolar Turbines’ ATS program is nowwell underway and will continue for thenext year. With one field evaluation

machine in operation and 5 morescheduled to follow in short order, wewill address the status of the Solar’sMercury 50 program and its progress vs.the four fundamental goals that were setforth more than 8 years ago.

The Mercury 50 was introduced to thepublic in December 1997 at the ASMETurbomachinery symposium in Orlando,Florida as a single shaft, optimizedrecuperated engine, nominally sized at4.3 MWe with better than 40%efficiency at the busbar. Thisenvironmentally superior systemincorporates a highly flexiblecombustion system that can beconfigured for either ultra-lean premixedor catalytic combustion. The Mercury50 is targeted to meet the rapidlyexpanding demand for highly efficient,environmentally superior turbine-basedpower systems in the industrial powergeneration and emerging distributedgeneration markets.

Development EffortsFormal development of the Mercury50 began in September 1995 andemphasized the use of system-leveldesign solutions that take advantage of awide variety of demonstratedtechnological advancements, eachproviding sufficient margin to assure thesuperior durability and availability thatare required by industrial gas turbineusers. A combination of innovative

1 Research sponsored by the U.S. Department of Energy’s Federal Energy Technology Center, under contract DE-FC21-95MC31173and the Chicago Operations Office, under contract DE-AC02-92CE40960 with Solar Turbines Incorporated, 2200 Pacific Highway,P.O. Box 85376, San Diego CA 92186-5376.

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primary and backup design solutionshave been carefully blended to offermaximum cycle efficiency andemissions reductions with minimal risk,as adequate design margin is maintainedwithin each selected technology. Thematerials used in the manufacture of theMercury 50 turbine are a key elementin the durability equation and represent amix of current turbine materials as wellas next-generation alloys that arerelatively new to industrial turbines.One of the most significant Mercury50 innovations is the layout of the coreengine, around which the package hasbeen synergistically designed. Theresulting design offers significantadvantages in terms of cost, performanceand maintainability and is central to itsability to meet the key product goalsstated at the beginning of the program.

Solar’s Mercury 50 engineering designactivities were concluded in July 1998.The engine test phase of the programcommenced in December 1998 toevaluate the performance and durabilitycapabilities of this unique engine prior tothe commencement of field evaluationtests. The fourth and final industrialsystem demonstration phase of theprogram begins in December 1999 andwill be marked by startup of the DOEHost Site demonstration machine atRochelle Municipal Utilities. This

machine is scheduled to run for 8,000hours, during which time it willdemonstrate its capability to meet thefour fundamental goals of the program.As a precursor to this milestone event,evaluation of an early pre-commercialversion of the Mercury 50 began inSeptember of 1999, coincident withstartup of the machine at a remotemining site in Australia.

SummarySolar’s Mercury 50 is the culminationof a development effort that has beenmore than 8 years in the making andrepresents a revolutionary approach inan industry that has long depended uponevolutionary solutions. It has beendesigned to offer superior performanceand operating flexibility at a price that iscompetitive with alternative powergenerating technologies. It represents abalanced approach to the tradeoffbetween the benefits of new technology,low cost and high reliability that istargeted directly at the needs of theindustrial power generation marketplace.This report highlights Solar’s ATSprogram progress over the past year andwill discuss the design activities, testresults and field evaluation preparationsalong with a brief overview of futureplans, commercialization efforts andmarketplace activities.

Dave Dave EsbeckEsbeck Vice President, Engineering

Dave Dave EsbeckEsbeck Vice President, Engineering

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Program SponsorshipProgram Sponsorship

• Chicago Operations Office− Steve Waslo - Contracting Officer’s Technical

Representative

• Washington Headquarters

− Denise Swink - Deputy Assistant Secretary,Industrial Technology

− William Parks - Director, Cross-Cutting Technologies

− Patricia Hoffman - ATS Program Manager

• FETC - Morgantown

− Mary Gabrielle - Contracting Officer

ATS Program Management ATS Program Management DOE Office of Industrial TechnologyDOE Office of Industrial Technology

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IntroductionIntroduction

• Introduction & Overview Dave Esbeck

• Review of Accomplishments Steve Gates

− Mercury Engine Design

− 2nd Generation Hardware

− Package Design

− Summary of Test Results

• Commercialization Activities- Overview

• Update - Rochelle Site Mr. Ray Schwartz Preparations Rochelle Municipal Utilities

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Mercury 50 LayoutMercury 50 Layout

• Industrial Single-ShaftGenerator Set

• Optimized RecuperatedCycle

• Modular Construction− 10-Stage Axial

Compressor− 2-Stage Axial Turbine− Annular Combustor

• 4.2 MWe

• 40% Busbar Efficiency

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Program GoalsProgram Goals

• Efficiency

• Environment

• Fuel Flexibility

• Reliability and Maintainability

• Cost of Power

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15% Improvement in Efficiency15% Improvement in Efficiency

Program Goals - EfficiencyProgram Goals - Efficiency

• Based on Lower Heating Value (LHV)of Natural Gas

• Compared to Best Available 1991 IndustrialTurbomachinery Technology

• Comparable in Size Range

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Program Goals - EnvironmentProgram Goals - Environment

• Environmental SuperiorityUnder Full- and Part-LoadConditions

• No Post-CombustionCleanup Devices

• Emissions Acceptable inSevere Non-Attainment Areas- NOx, CO, UHC

• “Single-Digit” NOx

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Program Goals - Fuel FlexibilityProgram Goals - Fuel Flexibility

• Natural Gas Fired ATS Systems

• Adaptable to Biomass andCoal-Derived Fuels

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Program Goals - ReliabilityProgram Goals - Reliability

• Reliability and Maintainability- Equivalent to Best Available Circa 1991

• Addressing “RAM-D”

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Program Goals - Cost of PowerProgram Goals - Cost of Power

• Busbar Energy Costs at 10% Less than 1991State-of-the-Art Turbine Systems

−Total Cost of Ownership (Fuel,Maintenance, Amortization)

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Steve Gates Steve Gates Director,

Developmental Engineering

Steve Gates Steve Gates Director,

Developmental Engineering

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Mercury 50 EngineMercury 50 EngineDesign OverviewDesign Overview

Mercury 50 EngineMercury 50 EngineDesign OverviewDesign Overview

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Mercury 50 LayoutCenter Frame

Mercury 50 LayoutCenter Frame

RECUPERATOR

TURBINE

COMBUSTOR

COMPRESSOR

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Mercury 50 LayoutCombustor ModuleMercury 50 LayoutCombustor Module

8 ULP Injectors

Augmented Backside-Cooled(ABC) Combustor Liner

Closed-Loop CO Control

Compensating Geometry Design

Flexible Design- Accommodates Either UltraLean-Premixed (ULP) orCatalytic Combustion

Extension of SoLoNOxTechnology

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Mercury 50 LayoutTurbine Module

Mercury 50 LayoutTurbine Module

Vortex-Cooled Leading EdgeCooling Circuit

Film / Impingement Cooled

Unshrouded; Highly Loaded

Shrouded Blade Design

Nominal Stage Loading

Uncooled Uncooled 2nd-Stage Bladed Disk2nd-Stage Bladed Disk

2nd-Stage Design, 2125°F TRIT 2nd-Stage Design, 2125°F TRIT 1st-Stage Bladed Disk1st-Stage Bladed Disk

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Mercury 50 LayoutACE Compressor Module

Mercury 50 LayoutACE Compressor Module

Variable Geometry ControlVariable Geometry Control

10-Stage Axial Design

9.1 Pressure Ratio

3-D Wide Chord Airfoils

40% Reduction in Blade Count

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Test ResultsTest ResultsTest ResultsTest Results

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ATS Mercury 50 AccomplishmentsATS Mercury 50 Accomplishments

Commissioned Dedicated Mercury50 Development and ProductionTest Cells

Completed 1st Round ofDevelopment Testing on Engines#1 & #2

Completed On-site PackageServiceability and Installation“Kaizen” Review

Created Significant CommercialInterest in ATS Product

Built, Tested and Shipped FirstCommercial Unit on Schedule

A T S 9 9 - 0 2 4

• All Bearings in ExcellentCondition

• Thrust Bearing Like New

• Skidding Non-Existent

• No Pitt ing or Contamination

Rolling Element BearingsRolling Element Bearings

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Blade Z-NotchInterlock

Blade Removal

2nd Turbine Disk Assembly2nd Turbine Disk Assembly

Shrouded Blade Design

Shroud “Z-Notch” InterlockFunctioning per Design Intent

No FPI Indications at Attachments

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Mercury 50 Development Test SummaryMercury 50 Development Test Summary

Over 700 Hours of Test2 Phases, 4 Engines, 5 Builds300+ Start Cycles

Critical New Content FunctioningAs Designed

Mercury-50 Test Program

0

100

200

300

400

500

600

700

800

900

SN001/1 SN002/1 SN002/2 SN003/2 SN004/1

Test Engine

Ho

urs

on

Te

st

Emissions: Exceeding Goal inTest Cell

Engine Performance on Plan

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Mercury 50 Package MaintainabilityKaizen Demonstration

Mercury 50 Package MaintainabilityKaizen Demonstration

• Service/ Maintenance/ Safety Audit

• Review Assembly/ Installation Plans

• Evaluate Field Tooling

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Engine #1 Modular Disassembly Engine #1 Modular Disassembly

CompressorModule

Combustor and Turbine ModulesCombustor and Turbine Modules

My Jacket

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CommercializationCommercializationCommercializationCommercialization

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Opportunity in Current Energy MarketOpportunity in Current Energy Market

• ENERGY USERS –Requirement forCompetitive andReliable Electricity

• ENERGY PROVIDERS –Need to Optimize Profits onEnergy Sales, Whether Gasor Electricity, While DeliveringCompetitive and Reliable Energy

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Broad Appeal in Diverse ApplicationsBroad Appeal in Diverse Applications

• Small Utility Base Load

• Grid Support

• On-Site Generation

• Remote Power

• CHP / Cogeneration

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Initial Customer InstallationsInitial Customer Installations

Phosphate MineQueensland,Australia

San Diego, Cal1. Manufacturer2. Hospital

ESCOLaredo, TX

Municipal UtilityChicago, Il

UniversityS. Carolina

Rural UtilityColorado

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ManufacturerSan Diego, California

ManufacturerSan Diego, California

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Phosphate MineQueensland, Australia

Phosphate MineQueensland, Australia

Mercury 50

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Ray Schwartz Ray Schwartz Rochelle Municipal Utilities

Ray Schwartz Ray Schwartz Rochelle Municipal Utilities

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972228-006

City of Rochelle, IllinoisCity of Rochelle, Illinois

• Located in North Central Illinois

• Intersection of I-39 and I-88

• Intersection of BNSF and UP - 120 Trains/Day

• Population at 10,000 and Growing

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Rochelle Industrial BaseRochelle Industrial Base

972228-008

• Food Processing and Distribution Center- Rochelle Foods (Hormel) Food Processing- Kraft Foods Food Processing- Erie Foods International Food Processing- Del Monte Corp Canned Food Distribution Center- Total Logistics Control Frozen Food Distribution Center- Americold Frozen Food Distribution Center

• Other Industries- Eaton Corporation Electrical Parts- Silgan Container Corp Can Manufacturing

Growth from 19 to 38 Industries in 6 YearsGrowth from 19 to 38 Industries in 6 Years

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Physical ProfilePhysical Profile

• Service Area 100 Square Mile - Municipal and Rural

• Population - 18,000

• Surrounded by Commonwealth Edison

• Power Generation at Three Locations- Diesel Plant 20.0 MW from 10 Oil/Gas-Fired Diesel Units- Cogen Plant 11.5 MW from Steam Turbine Generator- Peaker Plant 5.0 MW from 2 Oil/Gas-Fired Diesel Units

• Dual 138KV Transmission Connections to Com-Ed Grid

• Two 138/13.8KV Substations

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Power SupplyPower Supply

• Purchase 95 to 98% of Power Wholesale- Several Varying Blocks of Firm/Interruptible Power- Hourly Interruptible Power for Load Following

• Generation Assets - Current Function- Economic Dispatch (Market Hourly vs In-House Cost)- Firm Up Interruptible Power- Sales to Wholesale Market- Emergency Back-up

• Total Output 1998: 180,000,000 kW-hr

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Annual Load Duration CurvesAnnual Load Duration Curves

40

35

30

25

20

15

100 1000 3000 5000 7000 9000

TIME SPENT AT/ABOVE LOAD, HOURS

LO

AD

,

MW

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Why Distributed Generation?Why Distributed Generation?

• Places Capacity Nearer Load

• Reduces Impact of Transmission Curtailments

• Age of In-House Generation Assets

• Cost of Service

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Why the Mercury 50?Why the Mercury 50?

• Operational Flexibility- Base Loading for Hedge Against Supply Interruptions- Intermediate Loading for Economic Dispatch- Peak Loading for Load Following and Economic Dispatch

• Multiple Location Potential- Commercial / Industrial Sites- Existing Cogen Plant- Existing Diesel Plant- Sub-Stations

• Low Environmental Impact

• Competitive Operating Costs

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Mercury 50 / Rochelle Site LayoutMercury 50 / Rochelle Site Layout

x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

CARON ROAD (30’-0’ ASPHALT)

EXISTING FENCE

OE OE OE OE OE OE OE OE OE OE OE OE OE OE OE OE OE OE

EXISTING OVERHEAD ELECTRICAL

FUEL GAS SKID CONTROL ROOM

SERVICE AREA

SERVICEAREA

PARKING LOT

LUBE OILCOOLER

EMISSIONSMONTIORNGTRAILER

EXISTINGSTEAMPLANT

BUILDING

NEWROAD

NEWACCESSGATE

GENERATOR SET

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Mercury 50 / Rochelle Site PhotoMercury 50 / Rochelle Site Photo

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Mercury 50 / Rochelle Site PhotoMercury 50 / Rochelle Site Photo

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Mercury 50 / Rochelle InterfaceMercury 50 / Rochelle Interface

• Direct Connection to 13.8KV System

• Unmanned Site

• Remote Start/Stop

• Fiber Optic Connection to SCADA

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Rochelle FutureRochelle Future

• Continued Steady Growth

• Intermodal Facility Strong Possibility

• Distributed Generation Role- Essential Element of Generation Fleet- Replacement for Existing Central Plant- Siting on Customer Premises Anticipated- Cogeneration Applications- Enhance Rochelle’s Competitive Edge

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SummarySummary

• Initial Development Activities Are Complete• Exceeded Original ATS Program Goals

−Only Durability Remains to Be Proven

• Field Evaluation Units Being Built and Shipped• Continue Further Refinements to Achieve Stretch Goals• Generated Significant Market Interest in ATS Product

Mercury 50 on Track for Full-Production Release in 2000Mercury 50 on Track for Full-Production Release in 2000

Clear Commitment to CommercializeClear Commitment to Commercialize

ATS99-092