• BHEL – GE GAS TURBINES COLLABORATION STATUS • GAS TURBINE FUNDAMENTALS • DESIGN FEATURES OF BHEL GAS TURBINES WELCOME TO 1ST SESSION COLLABORATION WITH GE, USA Models covered : Fr-1 / Fr-3 / Fr-5 / Fr-6B / Fr-6FA / Fr-9E / Fr-9EC / Fr-9FA / Fr-9H Period : Started in 1986 Valid upto 2006 Coverage : Gas Turbine & Auxiliaries Combined Cycle Engineering Area : Compressive - Engineering manufacture, E&C & Services License for manufacture of rotor and HGP components HEAVY DUTY GAS TURBINE MODEL DESIGNATION PG 6 58 1 (B) APPLICATION SERIES POWER NO. OF SHAFTS SERIES M- Mech.. Drive PG- Pkgd. Gen.. FRAME 1, 3, 5, 6, 7, 9 Approx. output power in Hundreds, Thousands, or 10 Thousands of Horsepower 1 or 2 004 GT MODELS AND RATING Model ISO Rating (kw) ISO Efficiency (%) (1) MS1002 5070 24.5 (2) MS3142(J) 10450 25.6 (3) PG5371(PA) 26300 28.5 (4) PG6581(B) 42100 32.0 (5) PG6101(FA) 70140 34.2 (6) PG9171(E) 123400 33.8 (7) PG9231(EC) 169200 34.9 (8) PG9351(FA) 255600 36.5 (9) PG9551(H) 380,000 - Note: ISO output is : 15 deg C, 60% RH, Zero MSL, Gas fuel and standard Inlet/Exh. Pr. drops FUEL (100 %) GAS TURBINE POWER(29.5 %) MISC. (3.5 %) EXHAUST HEAT (67 %) OPEN CYCLE GAS TURBINE TYPICAL PERFORMANCE ENTROPY • EFFICIENCY INCREASES BY 1 POINT FOR EVERY 600 C OF T3 •COMBINED CYCLE COMBINES BEST OF : – BRAYTON CYCLE VIZ: HIGH TEMP HEAT ADDITION (11040 C) – RANKINE CYCLE VIZ: LOW TEMP HEAT REJECTION (45 0C) EXPECTED COMBINED CYCLE EFFICIENCY = 48% TO 55% 1104 0 C 12000 C TEMPERATUR E Steam Cycle Gas Cycle Q in A B C D E 1 2 3 4 00 C 450 C 3000 C 6000C 9000 C Q out GAS TURBINE REQUIREMENTS Factors considered in selecting gas turbine v High efficiency v High specific output (output/kg of air flow) Key Parameters of GT Affecting Above v Firing temperature (Limited by metallurgy/cooling technology) v Pressure Ratio MAJOR FACTORS AFFECTING GAS TURBINE PERFORMANCE • Ambient Temperature • Altitude above Mean Sea Level (MSL) • Relative Humidity • Inlet Pressure Loss • Exhaust Pressure Loss • Steam / Water Injection for NOX Control • Type of Fuel PRESSURE DROP EFFECTS (FOR FRAME -5) * 4 INCHES H2O INLET DROP PRODUCES : • 1.75% POWER OUTPUT LOSS • 0.74 % HEAT RATE INCREASE • 1.4 DEG.F EXHAUST TEMP. INCREASE * 4 INCHES H2O EXHAUST DROP PRODUCES : • 0.71 % POWER OUTPUT LOSS • 0.71 % HEAT RATE INCREASE • 1.4 DEG.F EXHAUST TEMP. INCREASE EFFECT OF STEAM INJECTION ON OUTPUT & HEAT RATE INLET CHILLING PROCESS Heavy Duty Industrial Type Skid concept to reduce site-work Horizontally split casing for easy maintenance Axial type compressor with Built-up Rotor Wide Fuel flexibility : Gas & Liquid(light/Heavy) Mixed Firing also Cannular Combustion system with water/steam injection /DLN combustors to meet stringent emission limits Suitable for Mechanical/Power Generation/Single shaft CCP applications Constructional Features of BHEL Gas Turbines Compresor Rotor Each wheel(stage) is bladed & statically balanced Through bolts for wheels assembly Total Rotor is dynamically balanced Turbine Rotor Each wheel(stage) with buckets & balanced Through bolts for wheels assembly Compressor & Turbine Rotor are built-up type Compressor & Turbine Rotor joined by distance piece to form one Rotor Compressor Stator Vanes & Turbine Nozzles are fixed in Comressor & Turbine Casing GT Rotor/Stator Arrangement COMBUSTION SYSTEM Multiple Reverse flow can annular combustor - easy for maintenance - longer life due to lower dynamic forces - allows full scale shop testing for non-standard fuels - better temperature profile control - high efficiency & lower emission Each Combustor consisting of fuel nozzle, liner & transition piece (for connecting to turbine) Retractable electric spark plugs & UV flame detector Cross fire tubes connecting combustors for flame propagation GT Cutaway Showing Casing Cross Section NOx ABATEMENT Nox is generated by fixation of Nitrogen in combustor Nox generation depends on - Flame Temperature - Retention time in flame zone - Fuel bound Nitrogen Nox abatement methods - By steam/water injection in flame zone - By lean pre-mix mode (DLN combustor) - By SCR (Selective Catalytic Reduction) ACCESSORY BASE Mainly consists of following systems - Starting system - Lube oil/Hydraulic oil system - Gas/Liquid fuel system In F-technology GT’s these systems are independent & off-base modules STARTING SYSTEM Electric Motor/Diesel Engine/Gas Expander Torque converter Electrical clutch Hydraulic Ratchet/Rotor turning Accessory Gear Box consisting of - Over speed trip mechanism - Lube oil pump - Hydraulic oil pump - Fuel oil pump - Atomizing air compressor - Water pump Accessory Coupling (Gear, Diaphragm, Membrane)) LUBE OIL & HYDRAULIC OIL SYSTEM Lube oil tank (as a part of base frame) with heater MOP(shaft driven), AOP(AC) & EOP(DC) Duplex (shell & tube) oil to water heat exchangers Duplex filter (5 micron) with downstream SS piping Main Hydraulic oil pump (shaft driven), AHP(AC) with 0.5 micron filter Cooling water supply - by wet cooling tower - air blast cooler GAS FUEL SYSTEM Stop/speed ratio valve, control valve (located in gas module) On-base SS piping Gas leakage detector & ventilation for Gas Module LIQUID FUEL SYSTEM Shaft driven booster pump (Gear/Screw type) Suction stop & bypass control valve 5 micron high pressure filter Flow divider (for equal fuel distribution) Additionally air atomization by - shaft driven air compressor (air extraction from last stage of compressor, cooled in AAP & boosted) - belt(diesel engine)/motor driven air booster compressor during start-up Gas Turbine MS 5001PA Basic Product Information Construction Compressor stages : 17 Turbine stages : 2 Number of combustors : 10 Pressure ratio : 10.3 Firing temperature : 963°C Load gear box rating : 31500KW Load gear design : Single helical MS 5001PA DESIGN FEATURES 17 stage axial compressor Turbine & Accessory bases are skid mounted Accessory base contains starting system, Lube oil console, shaft driven accessory gear box driving Lube, Fuel, hydraulic oil and atomizing air air compressor drives. 1st Nozzles air cooled Diesel/Motor/Expander starting facility Hot end drive. Completely packaged and factory assembled, tested. MS5001PA XPerformance Gas Distillate XISO output (KW) 26300 25800 XISO heat rate (Btu/KW.HR),LCV 11990 12070 XISO efficiency(%) 28.46 28.27 XExhaust flow (Kgs/sec) 124.16 124.44 XExhaust temp. (°C) 487 488 XSpeed (RPM) 5100 5100 X105 Combined cycle ISO output (KW) 40 39 Efficiency (%) 42 41.5 X205 Combined cycle ISO output (KW) 80.5 78.5 Efficiency (%) 42.3 42.0 PLANT ARRANGEMENTS OF MS5001PA • Machine suitable for Indoor/outdoor installation • Skid mounted GT & Accessory packages • Suitable for Single Shaft and multi shaft combined cycle • Side or top exhaust • On-base / Off-base enclosure FRAME-5PA GAS FRAME-5PA GAS TURBINETURBINE PG6581(B) BASIC PRODUCT INFORMATION CONSTRUCTIONAL FEATURES: Compressor Stages 17 Turbine Stages 3 Number of Combustors 10 Pressure Ratio 12.2 Firing Temperature (°C) 1140 GT Speed (rpm) 5163 Load Gear Box rating 54 MW Load Gear Box Design Double Helical 17 stage axial compressor Turbine & Accessory bases are skid mounted Accessory base contains starting system, Lube oil console, shaft driven accessory gear box driving Lube, Fuel, hydraulic oil and atomizing air compressor Honey comb seals for 2nd & 3rd stages Air cooled 1st & 2nd stage buckets & Nozzles Diesel/Motor/Expander starting facility Hot end drive Completely packaged and factory assembled, tested 6B DESIGN FEATURES Performance Gas Distillate ISO output (kW) 42100 41160 ISO heat rate (kcal/kwhr) 2680 2704 ISO efficiency(%) 32.1 31.8 Exhaust flow (kg/sec) 147 148 Exhaust temp. (°C) 548 549 Speed (rpm) 5163 5163 PG6581 (B) PERFORMANCE Machine suitable for Indoor/outdoor installation Skid mounted GT & Accessory packages Suitable for Single Shaft and multi shaft Combined cycle Side or top exhaust On-base / Off-base enclosure PLANT ARRANGEMENTS OF 6B MS 6001B GT CROSS SECTION TOTAL BHEL GAS TURBINE LOGGED 6.5 MILLION FIRED HOURS TOTAL MACHINES FIRING NAPHTHA 42 AND 1.4 MILLION HOURS FIRING EXPERIENCE A : 006 TYPE NO OF GAS TURBINES ORDER RECEIVED COMMISSIONED FR-1 4 4 FR-3 16 16 FR-5 48 44 FR-5/2 2 2 FR-6B 52 47 FR-9E 13 9 FR-6FA 7 6 TOTAL 142 128 GAS TURBINES FROM BHEL HYDERABAD (as on July 2004)