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
PERFORMANCE (@ ISO CONDITIONS)
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)
Output : 11.250 Kw Efficiency : 31,4 % Heat Rate : 11.481 kJ/kWh Ex. Gas Flow : 47,5 kg/s Ex. Gas Temp. : 482 C Nominal Speed : 11.000 rpm
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.
Output : 11.615 Kw Efficiency : 32,5 % Heat Rate : 11.121 kJ/kWh Ex. Gas Flow : 46,9 kg/s Ex. Gas Temp. : 488 C Nominal Speed : 7.900 rpm
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
Output : 14.252 13.735 Kw Efficiency : 36,2 34,9 % Heat Rate : 9.939 10.314 kJ/kWh Ex. Gas Flow : 47,4 47,4 kg/s Ex. Gas Temp. : 493 493 C PT Nominal Speed : 7.900 7.900 rpm
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
PERFORMANCE (@ ISO CONDITIONS)
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
Output : 28.340 32.580 Kw Efficiency : 28,8 29,4 % Heat Rate : 12.470 12.239 kJ/kWh Ex. Gas Flow : 124,3 141,4 kg/s Ex. Gas Temp. : 517 509 C PT Nominal Speed : 4.670 4.670 rpm
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
PERFORMANCE (@ ISO CONDITIONS)
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
PERFORMANCE (@ ISO CONDITIONS)
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
Cpm=average specific heatat costant pressure
4
3
2
1
50
Mesured in
gaskgKj
)( 23)(1 23 TTcQ TTpm =
Heat supplied to the combustion chamber
Cpm=average specific heatat costant pressure
4
3
2
1
51
Mesured in
gasehxaustkgKj
_
)( 14)(2 14 TTcQ TTpm = Heat suppl. to atmosphere with exhausted gas
Cpm=average specific heatat costant pressure
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
HD GT Axial Compressor Design
80
HD GT Axial Compressor Design
81
Random blades are selected for an automated check for the curvature, thickness, width and so
farth.
HD GT Axial Compressor Design
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
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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
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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
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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
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