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© 2014, General Electric Company. Proprietary information. All rights reserved.
Abu Dhabi, UAE | 12-14, October 2014
Power-GEN Middle East
Marcus H. Scholz
High efficiency gas turbine testing & validation
© 2014, General Electric Company. Proprietary information. All rights reserved.
© 2014, General Electric Company.
GE Proprietary Information - The information contained in this document is
General Electric Company (GE) proprietary information. It is the property of GE
and shall not be used, disclosed to others or reproduced without the express written consent of GE, including, but without limitation, in the creation,
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parts, or configuration changes or to obtain government or regulatory approval
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reproduction in whole or in part. The information contained in this document may also be controlled by the US export control laws. Unauthorized export or re-
export is prohibited.
GE Power & Water
All relative statements are with respect to GE technology unless otherwise noted.
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© 2014, General Electric Company. Proprietary information. All rights reserved.
* Trademark of General Electric Company.
Agenda
• Gas turbine industry trends
• Systematic approach to validation -
past & present
• 7F.05 gas turbine validation
• 9HA gas turbine unit #1 testing progress
• 9HA gas turbine unit #2 site progress
• Summary
© 2014, General Electric Company. Proprietary information. All rights reserved.
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© 2014, General Electric Company. Proprietary information. All rights reserved.
The industry trend … efficiency & temperature Advancing efficiency to lower the cost of electricity
Typical Efficiency vs. Temperature Relationship
1100 1260 1430 1600
52
54
56
58
60
62
2000 2300 2600 2900
Gas turbine firing temperature
H-Class F-Class E-Class
CC
eff
icie
ncy
F
C
Technology advances govern firing temperature … to lower fuel costs
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• H-class … >1430⁰C needed for >60% efficiency
• GE pioneered >1430C a decade ago with H-class technology
• Six H-class units in operation >200,000 operating hours
• Last decade … steam cooling used
• Today … offering largest H-class gas turbine with air cooling (HA gas turbine)
© 2014, General Electric Company. Proprietary information. All rights reserved.
Experience matters …
Fired starts
Global installed
base
Fired hours
4,500 units
189 MM hours
2.6 MM
starts
156
120
GE
Fleet All
Others
Reliability 97.8 97.4 +0.4
Availability 92.6 91.1 +1.5
Start Reliability
98.0 97.6 +0.4
Source: ORAP®. All rights to underlying data reserved: SPS®. Modified by GE. Rolling 12-month data Apr'13 - Mar'14.
Gas turbine installed base ~1,000 GW
Source: McCoy Power Reports, estimate based on reported orders.
GE’s leading experience feeds our technology advancements
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© 2014, General Electric Company. Proprietary information. All rights reserved.
GE’s product portfolio Reliable, flexible, efficient
Geared for 50Hz or 60Hz
60Hz gas turbines
50Hz gas turbines
43 MW
79 MW
90 MW
187 MW 227 MW
130 MW
265 MW 299 MW
470 MW
275 MW
397 MW GE GT-9HA
GE GT-9F
GE GT-9E
GE GT-7HA
GE GT-7F
GE GT-6F
GE GT-6B
GE GT-7E
330 MW
.03
.01
.03
.03
.04
.05
.01
.02
.03
.03
.05
.01
.02
World’s Largest 61%+ Net CC
Efficiency
51 MW
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© 2014, General Electric Company. Proprietary information. All rights reserved.
GE industry firsts
• Invented F-class, 1986 (60Hz)
• Pioneered H-class, 2003 (50Hz)
• First single-digit DLN combustor
• First to 1,000 units (>150 MW)
• First in reliability & availability
Today’s H-class
• Air cooled
• Superior flexibility
• Merge of F and H-class experience
• Industry leading output and efficiency
Succinct product growth of F-class and H-class heritage
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A continuous progression of performance … which builds upon experience
© 2014, General Electric Company. Proprietary information. All rights reserved.
Sub-System
Component
System
Science
• Rigorous validation approach….building on Aviation model
• Address high technical challenges early…understand and mitigate
• Systematic “stair-step” building block
• Increasing commonality between platforms
Systematic approach to validation
2001
2004
2003
2012
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A tiered process to build on reliability at final test
© 2014, General Electric Company. Proprietary information. All rights reserved.
Combustion lab since 2001
DLN 2.6+ lab tested
• 210 combustion tests per year
• Validating:
Emissions <25 ppm NOx (9HA)
Fuel range (MWI) ±10% (9HA)
Turndown 30% base load (9HA)
Combustion dynamics
Durability
... and field validated
• 67 operating 9 F-class gas turbine units • >1,300,000 fired hours
Subsystem level validation with proven fuel flexibility
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© 2014, General Electric Company. Proprietary information. All rights reserved.
Advanced compressor test in 2011
• Two fully assembled rotors • Fully instrumented • Full load in 2014
• Tested in June 2011 • Fully mapped compressor • 90% – 110% speed range
7F.05 compressor 2011 9HA compressor 2013
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Subsystem validation of capability with growth potential
© 2014, General Electric Company. Proprietary information. All rights reserved.
GE’s Aero Engine testing - “a decade of validation”
• Speed range… 1 RPM to >3900 RPM • Load range... 1 MW to 110% MW • Transients… • Instrumentation … > 3000 sensors • Data acquisition… terabites
Greenville South Carolina
Jet engine test cell Peebles, Ohio
GE off grid test stand
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World-class validation … inspired by aviation testing
© 2014, General Electric Company. Proprietary information. All rights reserved.
Thorough validation prior to first fire in the field Unique 50 Hz and 60 Hz full load, variable frequency facility
Compressor + GT validation
7F.03 fleet data (600+ units)
Pressure ratio
Co
rre
cte
d f
low
Example … 7F.05 results
System level validation on a lifecycle basis
• Unique facility validates full load and beyond
• Variable speed, load and pressure
• Validates extreme transient behavior
Validation schedule
7F.05 2012 • 9HA 2014 • 7HA 2015
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© 2014, General Electric Company. Proprietary information. All rights reserved.
7F.05 gas turbine acceptance and commercial operation validated in 2012 in GE’s test stand facility
Comparison basis: previous 7F versions
Commercial acceptance enabled by GE’s test facility
Timeline • Announced 2008 • Test Stand validation 2012 • COD 2014
Units on order 53 + tech selections 71
6 Units in service in Saudi Arabia
Clear customer choice for reliable, cost effective power generation
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© 2014, General Electric Company. Proprietary information. All rights reserved.
© 2014, General Electric Company. Proprietary information. All rights reserved.
Off-grid testing benefits
No grid restrictions… no “speed limit”
Replicates all ambient extremes and operational transients
Allows to derive full compressor operating map
Can explore repeated surge or stall events
Validates gas turbine prior to first fire
Exploring growth potential
Test bed capability exceeds any site operating envelope
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© 2014, General Electric Company. Proprietary information. All rights reserved.
Test stand validation for grid code compliance
Off-nominal frequency operation
• Successfully tested steady state operation between 90 -108% speed (54 – 64.8 Hz)
• Successfully performed 46 speed sweeps between 90-110% speed
7F.05 Loaded SS Off-speed Points
57.5 Hz
61.2 Hz
Mass flow
Typical grid frequency requirements
Load control validation
• Successfully tested grid step response
between -1% and +1% grid change
• Load changes >25% load /min.
+1% Frequency Shift at 140MW
Validation beyond global grid code requirements
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© 2014, General Electric Company. Proprietary information. All rights reserved.
DLN 2.6+
HA gas turbine evolution A systematic progression of proven technology
9H 2003
9HA 2014
7F.05 2012
9F.05 2005
4-stage VGV
4-stage turbine
14-stage compressor Field-replaceable blades 3-stage VGV
Advanced HGP
Note: Year denotes first operation
A decade of technology advances and lessons learned
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© 2014, General Electric Company. Proprietary information. All rights reserved.
9HA power turbine experience
Performance and enhancements
• Double wall casing for tighter clearances (H-
system) • Advanced Gas Path (AGP) experience from
7F.04 and 7F.05 gas turbines 51 in operation • 4-stage technology scaled from 9H gas
turbine • Aero engine sealing technology
Hot gas path materials
• Single crystal technology • Reduced oxidation and creep
• Improved low-cycle fatigue • Air-cooled hardware for flexibility benefits • “F” & “H” - turbine heritage
Hot gas path material selection supports longest rotor life
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© 2014, General Electric Company. Proprietary information. All rights reserved.
First 9HA gas turbine assembled and shipped Jan. 2014
Turbine features: • Superalloy rotor materials • F-class materials • Advanced cooling and sealing
Compressor features: • 14-stage, 3D aero configuration • Pressure ratio 21:1 • 3 stages VSV
Second generation “air cooled” H-class gas turbine … 61% + CC efficiency
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© 2014, General Electric Company. Proprietary information. All rights reserved.
© 2014, General Electric Company. Proprietary information. All rights reserved.
9HA gas turbine full load testing underway - October 2014 Results more relevant than 8,000 hour field operation
Capabilities
• Variable frequency & load testing
• Gas fuel and liquid fuel options
• Load shedding and grid response characterization
• Pyrometry and real time IR cameras
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9HA gas turbine #1 is fully dedicated to the test program
© 2014, General Electric Company. Proprietary information. All rights reserved.
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Start up tests ongoing
> 3,000 data streams from the assembled test train
© 2014, General Electric Company. Proprietary information. All rights reserved.
9HA instrumentation and number of sensors includes > 1000 thermal crystals
Stator vanes & blades • >120 rotating • >400 structures
Combustion system • >350
Hot Gas Path • >200 rotating • >800 structures
Complete test train contains > 500 rotating and > 3000 static sensors 21
© 2014, General Electric Company. Proprietary information. All rights reserved.
9HA gas turbine 2 site construction EdF Bouchain: Site works ongoing
ST condenser in place Main control and power train behind
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On schedule for commissioning end of 2015
© 2014, General Electric Company. Proprietary information. All rights reserved.
Maintaining 50 in 60 momentum >25 units technology selected for planned projects
HA … experience and validation driving rapid order growth
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© 2014, General Electric Company. Proprietary information. All rights reserved.
Summary
Component and subsystem tests build the foundation for
the final systems validation
9HA gas turbine 1 installed & rotating – firing imminent
Large 600MW Generator passed running test successfully
Industry leading testing & validation capability
acknowledged through early orders pipeline for
7F.05 and HA technology.
Commercial success is supported through insurance
& financing institutions
HA technology – a new standard in technology validation
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