7. the latest gas turbine technologies · turbine will have an output of 330 mw and a net...

Gas Turbines for Power Plants 7. The Latest GT Technologies 1 / 38

7. The Latest Gas Turbine Technologies


Developmental Trends 2 1

GE – HA Gas Turbines 7 2

Siemens – H Technologies 12 3

MHI – G & J Technologies 22 4

Market 33 5


Increased TIT

• To enhance the efficiency of gas turbine

• To enhance the efficiency of steam cycle

• Require advanced materials

• Require cooling technologies

Increased GT power output

• To reduce the cost of electricity

• To reduce the first installation cost

Enhanced operating flexibility

• Air cooling steam cooling air cooling

Reduced O&M cost

• Remote control

• Service packages, including LTSA

Less emissions

• Advanced DLN combustor

• Carbon capture and storage/sequestration (performance drop of 8 percent for 9FB.05 with 3-pressure

HRSG, when post-combustion CCS is applied)

• The development of hydrogen-fired gas turbines

Developmental Trends


Compressor

Parameters Previous Designs New Designs

Airfoil shape 2D double circular arc or NACA 65 3D or CDA(Controlled Diffusion Airfoils)

Number of blades Large Reduced

Mass flow rate Small Large

Stages Repeating Unique

Chords Shorter Longer

Aspect ratios Low/modest High

Tip clearance Larger Smaller (20~50 mils)

Pressure ratio Low/modest High

Blade loading per stage Low/modest High

Operating margin Wide (4~5%) Narrow (2.5~3.5%)

Leading edge Thick Thin

Operation Dry Wet

Cost Low High

Source: Gas Turbine Engineering Handbook, M.P. Boyce

http://www.google.co.kr/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjFvL7g99_UAhWGnJQKHUgGAmkQjRwIBw&url=http://www.flowcontrolnetwork.com/axial-compressor-considerations/&psig=AFQjCNHuiVzLawwJF_HPOfU6YVjCvHWPlw&ust=1498718460452707


Combustor


NOx level High Very low

Type of flame Diffusion flame with stable combustion Premix/DLN with instability (pulsations)

Number of injection

points of fuel nozzles Single / simpler Multiple / complex

Operation / Control Simple operation with simple controls Staged operation with complex

controls/tuning

Cooling design Simple Complex

Cost Low High


Diffusion Combustor Premixed Combustor


Turbine


Airfoil shape 2D reaction type 3D advanced vortex blades

Number of blades Large Reduced

Number of stages 3 4

Chords Shorter Longer

Expansion ratio Low/modest High

Cooling Simple design Complex design

Cooling medium Air Air steam air

Blade materials Equi-axed castings DS and SC castings

Coatings Oxidation / TBC Oxidation / TBC

Margin to melting Large Small

Cost/stage Lower Ultra-high


https://www.google.co.kr/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRxqFQoTCJOf_vDG38gCFcMZlAodxWoMoQ&url=http://www.bine.info/en/topics/energy-generation/power-plants/news/effizientestes-kraftwerk-der-welt-eroeffnet/&psig=AFQjCNFnhF5xmx81y1CCGvGER1e7oDiKOA&ust=1445928429165284


Developmental Trends 1

GE – HA Gas Turbines 2

Siemens – H Technologies 3

MHI – G & J Technologies 4

Market 5


GE

GE are in a unique position because they incorporate both industrial gas turbines and jet engines for aviation.

Industrial gas turbines has been developed in a Power System Division, internally.

GEAE and GE CR&D.

GE became a leader in gas turbine technology by the successful operation of the first advanced “F” gas

turbine.

GE has launched their HA gas turbines in 2014.


Streamlined maintenance with quick-removal turbine roof, field-replaceable blades, and 100 percent

borescope inspection coverage for all blades

4-stage turbine with 3D aerodynamic hot gas path, cooling and sealing improvements, single-crystal and

directionally solidified blades, and double-wall casing for improved clearance control

14-stage advanced compressor with 3D aerodynamic airfoils with superfinish, 3 stages of variable stator

vanes, and field-replaceable blades

DLN 2.6+ combustor with axial fuel staging is proven through 45,000 starts and >2 million hours

Combustor enables improved turndown and greater fuel flexibility

Reduces need for on-site gas compression; fuel pressure requirements as low as 435 psi/30 bar

Reaches turndown as low as 30 percent of gas turbine baseload output within emissions compliance

Fuel flexible to accommodate gas and liquid fuels with wide gas variability, including high ethane (shale) gas

and liquefied natural gas

GE HA Gas Turbine

https://www.google.co.kr/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwiblpfiypTNAhWGKJQKHQJgBbEQjRwIBw&url=https://powergen.gepower.com/products/heavy-duty-gas-turbines/9ha-gas-turbine.html&psig=AFQjCNH3qOz0S6TGN8GfzCfu7M186CWT_w&ust=1465343090509952


The air-cooled HA turbines are an evolution of GE’s earlier steam-cooled H-class turbine, which saw

disappointing sales as a result of concerns with its overly complicated design and low serviceability. The

new HA, by contrast, was heavily tested and designed for simplicity - GE is spending more than $2 billion

developing and launching it, including $200 million on a full-scale test plant in Greenville, S.C. - and it has

seen strong early interest.

The 50-hertz 9HA and 60-hertz 7HA both come in two different models. The 9HA.01 is rated at 397 MW in

simple cycle mode and 592 MW in 1 x 1 combined cycle mode, while the 9HA.02 is rated at 470 MW in

simple cycle and 700 MW in combined cycle. The 7HA.01 and 7HA.02, meanwhile, are rated at 275 MW

and 405 MW, and 337 MW and 468 MW, respectively.

Exelon will take delivery of the 7HA gas turbines in 2016, and begin operating them by mid-2017. Each

turbine will have an output of 330 MW and a net combined-cycle efficiency rating that exceeds 61 percent.

The HA turbines are the largest and most efficient in the world and build on GE’s previous H-class

technology, which was launched in 2003 and has now accumulated significant operating time. Unlike the

previous H-class turbines which relied on steam cooling, the new HA turbines rely on air for temperature

regulation.

The air-cooled version of the turbine is just much simpler and more cost-effective.

The steam-cooled turbine was technically elegant, but it was expensive to operate. Air cooling makes the

turbine cheaper to maintain because there are no steam circuits to tear down before accessing key

components. That adds up to lower life cycle costs.

HA turbines can transition from zero to full power in ten minutes. When combined with steam turbines in a

combined-cycle plant, they can be at full power in 30 minutes.

HA Gas Turbines


109D-14 Steam Turbine

180 MW

Steam inlet capabilities of 165 bar/600C/600C

Drum-type rotor (HP, IP & LP) with high reaction bucket

Advanced 1060 mm (42) and 850 mm (33.5) LSB with improved aerodynamic and dovetail configurations

Common LP hood architecture for both cooling tower and air-cooled condenser applications

109D-14 Steam Turbine






Market 5


1st stage DS blade

SGT5-8000H


The company had used readily available materials for critical components, such as turbine blades, since

they did not have direct access to a jet engine company.

Technology alliance with P&W performance improvement in the V94.3A and V84.3A engines that were

introduced in 1994 and 1995.

Acquisition of WH (1998).

WH left aircraft business in 1960.

Siemens has developed SGT5-8000H and verified 60.75 percent efficiency in combined cycle. This H-class

rated at 375 MW without steam cooling in simple cycle operation, 570 MW in combined cycle operation.

The design initiated in 2000 and prototype operation started at the Irsching in Germany in 2007. The gas

turbine prototype test ended during summer 2009 and the plant turned into a single-shaft configuration.

This engine is air-cooled which gives higher operational flexibility and shorter starting time.

This engine is the first common design since the merger of Siemens KWU and Westinghouse. The

intension was to combine the best practice from both companies’ existing portfolios with advanced

technologies.

The entire first stage and the fourth stage rotor blade can be removed and replaced without lifting the cover.

This design gives less maintenance cost.

Siemens


H Technologies - Siemens


H Gas Turbine - Siemens

Siemens has decided to not continue with the concept of steam cooling.

This could be due to many problems experienced with the W501G gas turbines due to steam leakages.

W501G uses steam cooling for combustor and transition pieces and the first-stage turbine nozzle vanes.

Siemens H-class has reverted back to DS blades because SC blades are expensive.


Design Features of SGT5-8000H

The compressor having a specific flow of 820 kg/s @ 3,000 rpm has four variable stators for flow control and

low-speed stall avoidance.

The compressor uses the latest blade technology and 3D design features.

The turbine has four stages with the first three unshrouded and active clearance control. The active control is

achieved by pushing the rotor inwards with a hydraulic system. This feature on a single shaft unit results in

the necessity of cylindrical compressor blades. This gives both high turbine efficiency and rapid start

capability.

The fourth stage offers the possibility for a large exhaust area.

The engine has three extractions at stage 5, 8, and 11 and one internal at the hub of stage 5. the outer

extractions feed turbine stage 2, 3, and 4 whilst the internal is used for thermal conditioning and purging of

stage 4 rotor blade attachment.

The first three stages are directionally solidified with angle wings for good rim sealing.

The first two stage blades use TBC.


Parameter SGT5-8000H SGT6-8000H

GT output 375 MW 274 MW

Combined cycle output 570 MW 410 MW

Combined cycle efficiency 60.75% 60%

Pressure ratio 19.2 20

Exhaust mass flow 820 kg/s 600 kg/s

Exhaust temperature 625C 620C

NOx 25 ppm 25 ppm

CO 10 ppm 10 ppm

HP steam data 170 bar/600C

IP steam data 35 bar/600C

Start-up time [after overnight shutdown] ~40 minutes


Irsching 4 CCPP


Characteristics of Steam Cycle


The H technology use a three-pressure reheat steam cycle with initial

steam conditions of 2500 psig (170 bar) /1100F/1100F (600C/600C).

The higher initial steam pressure, the higher performance.

Cutaway of Bugok 3



GS EPS

• 1-on-1 configuration

• Capacity: 410 MW

• GT: 274 ; ST: 136 MW

안산 복합화력발전소


안동천연가스발전소 (남부발전)

• 1-on-1 configuration







Market 5


MHI started gas turbine business in the 1990s as a licensee of WH. WH make an alliance with MHI to

develop advanced technologies and to solve financial difficulties.

MHI and WH developed 501F together. The compressor designed by MHI and hot section was designed by

WH. Currently, 501F are sold individually after Siemens purchased WH.

The WH’s W501G and MHI M501G were developed separately by both parties since the end of their

collaboration.

MHI launched their latest J-class unit 2011, offering 61 percent efficiency (LHV) at 670 MW.

The engine has TIT of 1,600C.

MHI has F, G, and J machines covering 58-61 percent efficiency.

Their second generation G-class (M701G2) uses technology developed for the H-class.

MHI has introduced variants of steam cooling from G-class, except for M501GAC.

There is a strong driver for steam cooling in DLE-technology because the flame temperature should be in

the range of 1,500-1,600C for low emissions.

Large cooling air is required to cool combustor liner and transition piece when a film cooling is employed.

The G2-version has an increased mass flow by 17 percent and an increased pressure ratio for higher

performance.

The J-class has combined cycle efficiency of 61 percent.

MHI


Model TIT (C)

Cooling Media Performance NOx

(ppm) Turbine Liner Gas Turbine Combined Cycle

M501DA 1250 air air 114MW 34.9% 167MW 51.4% 9

M501F 1350 air air 153MW 35.3% 229MW 52.8% 25

M501F3 1400 air air 185MW 37.0% 285MW 57.1% 9

M501G 1500 air steam 254MW 38.7% 371MW 58.0% 25

M501G1 1500 air steam 267MW 39.1% 399MW 58.4% 15

M501J 1600 air steam 320MW 460MW 61.0% 25

M701J 1600 air steam 470MW 40.0% 680MW 61.2% 25

Mitsubishi Gas Turbine Product Line


Compressor: PR = 21:1, 14 stages, average stage pressure ratio = 1.24

Combustor: type = can, liner coolant = steam

• The air-cooled M501GAC gave up steam cooling to enhance starting ability because steam cooling

requires longer starting time.

Turbine: TIT is 1,500C, 4 stages,

• The first two stages have cylindrical tip for application of active clearance control to minimize leakage

loss.

M501GAC

M501G

G-Class Design Features


G Series Combustor

(Supply)

Steam

(Return)

(Return) Bypass valve

Premixing nozzle

Pilot nozzle


A rough rule of thumb is that 55C(100F) increase in TIT gives a 10 to 13% output increase and a 2 to 4%

efficiency increase.

Comparison of F and G


J Design Features


Combined cycle efficiency = 61%

Compressor:

• PR = 23:1

• 15 stages ( average stage pressure ratio = 1.23)

• Four variable stators (to protect low speed stall)

• Specific flow = 862 kg/s @ 3,000 rpm (available in 2014)

• The first four stages are multiple circular arc (MCA) blades. The downstream stages are controlled

diffusion airfoil (CDA) designs.

Combustor:

• Type: can

• Liner coolant: steam

• The air-cooled M501GAC gave up steam cooling to enhance starting ability because steam cooling

requires longer starting time.

Turbine:

• TIT = 1,600C (Target of Japanese national project = 1,700C)

• 4 stages

• DS blades (because SX-blades are very expensive)

• The cooling air for stage one to three is pre-cooled by an external cooler

• Active clearance control by steam cooling

• The first two stages have cylindrical tip for application of active clearance control to minimize leakage

loss.

J Design Features


The turbine blade are first coated with MCrAlY (M: alloy such

as Co, Ni, CoNi, etc.) as a bond coat material which has

superior oxidation resistance, and then coated ZrO2 type

ceramics (YSZ: yttria partially stabilized zirconia) as a top coat

which has low thermal conductivity. It was investigated that the

new top coat material has about 20% lower thermal

conductivity than conventional YSZ with the same durability.

J Design Features


The film cooling effectiveness of the shaped hole with a rib was approximately 25% higher than that of the

shaped hole

J Design Features


Same NOx level as G-class having 100C lower TIT

because J employs a improved combustion system

10 units order from South Korea in 2012

• Yulchon 2 (MPC Yulchon Generation Co., Ltd): 2 units (2+1 cofiguration, 950 MW)

- MPC is an independent power producer (IPP) based in Hong Kong.

• 2nd-Pyeongtaek (Korea Western Power Co., Ltd ): 2 units

• Ulsan 4 power plants (Korea East-West Power Company): 2 units (950 MW)

• Dogducheon power plant (Korea Western Power Co., Ltd ): 4 units (1,900 MW)

J Design Features






Market 5


3 MW

1,589; 20%

3~10 MW

1,557; 21%

10~20 MW

215; 3% 20~50 MW

1,105; 15%

50~125 MW

682; 9%

125~180 MW

1,225; 15%

180 MW

1,280; 17% Power

No. of units Share

Based on Gas Turbine Sizes (2005-2014)

Market Share


Gas turbine manufacturers have chosen to market discrete sizes of gas turbines to take advantage of the

economies of standardized designs.

Therefore, part of a manufacturer’s long-term strategy must be to carefully evaluate market trends to

establish sizes that will be most attractive to potential customers and that will maximize their ability to

compete in the future.

Because gas turbines come in discrete sizes, if a power producer dictates a narrow range of electrical

output when specifying a gas turbine, some of the potential bidders will be precluded from the bidding

because they do not have an appropriately sized gas turbine.

Gas turbines are not customized to any appreciable extent.

Auxiliary packages and accessories associated with the machine may be customized, but in general, the

base machine is not.

50 Hz machines have larger capacity than 60 Hz ones. This is because 50 Hz machines have lower creep

strength than 60 Hz ones, if they have a same blade length. The total number of steam cooled gas turbines

is 71 since their release in the market (in 2011). The number of 50 Hz- and 60 Hz machine is 66 and 5,

respectively.

Gas Turbine Sizes

Market Share


Alstom

94; 7%

GE

524; 41%

MHI

256; 20%

Siemens

365; 29%

Others

41; 3%

Company

No. of units Share

Based on Power Class Larger than 180 MW (2005-2014)

Market Share


Source: Turbomachinery 2010 Handbook.

GE 49%

Siemens 17%

MHI 10.9%

Alstom 10.4%

Solar 7.7% Rolls-Royce 2.7%

United Tech 2% Other 8%

Based on Sales Volume in 2010

Market Share


질의 및 응답

작성자: 이 병 은 작성일: 2016.6.21 (Ver.7) 연락처: [email protected] Mobile: 010-3122-2262 저서: 실무 발전설비 열역학 증기터빈 열유체기술 발전용 가스터빈

7. the latest gas turbine technologies · turbine will have an output of 330 mw and a net...

Documents