gt traning_m701f_cilegon (text).pdf

Instruction of Mitsubishi Gas turbineInstruction of Mitsubishi Gas turbine

Mitsubishi Heavy Industries Ltd.Takasago Machinery Works

CILEGONCILEGONCOMBINED CYCLE POWER PLANTCOMBINED CYCLE POWER PLANT

2

MHI BUSINESS CONFIDENTIAL

This document contains information proprietary to Mitsubishi HeaThis document contains information proprietary to Mitsubishi Heavy Industries, LTD. It is submitted in confidence and is to be uvy Industries, LTD. It is submitted in confidence and is to be used solely for the purpose for which it is furnished and returnesed solely for the purpose for which it is furnished and returned upon request.d upon request.This document and such information is not be reproduced, transmiThis document and such information is not be reproduced, transmitted, disclosed or used otherwise in whole or in part without thtted, disclosed or used otherwise in whole or in part without the written authorization of Mitsubishi Heavy Industries, LTD.e written authorization of Mitsubishi Heavy Industries, LTD.

MITSUBISHI HEAVY INDUSTRIES, LTD.MITSUBISHI HEAVY INDUSTRIES, LTD.Takasago Machinery WorksTakasago Machinery Works

CONTENTS

1. Mitsubishi Gas turbine’s History and Development2. Gas turbine’s Performance3. Construction Features4. Detail Structure of Gas turbine5. Material6. Gas turbine Cooling System7. Combustion System8. Spin Cooling Operation9. Gas Turbine New Technology

3




1. MITSUBISH GAS TURBINE’S HISTORY AND DEVELOPMENT

4




History of Mitsubishi Gas Turbine

5




World Wide Experience

Argentina 5Argentina 5

U.K. 13U.K. 13

Total : 431unitsTotal : 431units

India 10India 10

Chile 1Chile 1

Netherlands 1Netherlands 1

Japan 147Japan 147

Bangladesh 4Bangladesh 4

Thailand 16Thailand 16

Syria 4Syria 4

Indonesia 19Indonesia 19Indonesia 19

Turkey 5Turkey 5 U.S.A. 36U.S.A. 36Italy 5Italy 5

Mexico 17Mexico 17Philippines 7Philippines 7

Vietnam 3Vietnam 3Algeria 6Algeria 6

Honduras 1Honduras 1

Hong Kong 7Hong Kong 7Iran 11Iran 11Kuwait 4Kuwait 4 Macao 3Macao 3

Nigeria 2Nigeria 2 Pakistan 1Pakistan 1

Peru 3Peru 3

Qatar 6Qatar 6Saudi Arabia 26Saudi Arabia 26

Singapore 4Singapore 4

SlovakiaSlovakia 22

Spain 7Spain 7

U.A.E. 6U.A.E. 6

Australia 4Australia 4

Dominican Dominican Republic 1Republic 1

Brazil 4Brazil 4

Azerbaijan 1Azerbaijan 1

Taiwan 22Taiwan 22

Malaysia 3Malaysia 3

China 10China 10

Egypt 2Egypt 2

As of Sep. 2003

New Zealand 1New Zealand 1

6




First M701F Gas Turbine Started Operation

7




Japan M701F ×1 1993 Thailand M701F 2on1×2 1996

Thailand M701F2on1×1 1997

Chile M701F1on1×1 1999

Turkey M701F2on1×2 2000

Japan M701F1on1×4 1999

Argentina M701F 2on1×1 1999

UK M701F 1on1×3 2001

UK M701F 2on1×1 2001

Bangladesh M701F 1on1×1 2001

Viet Num M701F 3on1×1 2001

Singapore M701F 1on1×2 2001

Argentina M701F 2on1×1 2001

India M701F 1on1×1 2001

Operating Experience of F series Gas Turbine (50Hz)

8




USA2on1×2 1993

Japan1on1×4 1994

Japan1on1×2 1995

Mexico2on1×1 2001

Japan3on1×1 1995

Japan1on1×7 1997

Mexico2on1×1 2001

Mexico2on1×2 2003

Mexico1on1×1 2003 Taiwan

1on1×1 2003

Operating Experience of F series Gas Turbine (60Hz)

9




Takasago 330MW Combined Cycle Power Plant Powered by First M501G

10




2. GAS TURBINE’S PERFORMANCE

11




Principle of Gas Turbine

12




Structure of Gas Turbine

211

13




Mitsubishi M701F Gas Turbine

14




Gas Turbine Longitudinal Section

15




Gas Turbine Cycle -Ideal Cycle-

16




Gas Turbine Cycle Performance

17




Compressor Performance (1/2)

18




Compressor Performance (2/2)

19




Turbine Performance (1/2)

20




Turbine Performance (2/2)

21




Gas Turbine Cycle Loss

②

①

22




Gas Turbine Ambient Temperature Characteristic

23




3. CONSTRUCTION FEATURES

24




Fundamental Structure of Gas Turbine

25




Design Features of “F” Series Gas Turbine (1/3)

26




Torque Pin in Compressor Disc

Turbine Curvic Coupling① Stacked Disc Type Rotor

PROVEN FEATURES

Disc ContactSurface

Torque Pin

Spindle Bolt④　Cold End Drive ⑥ Tangential Strut

③ Air-cooled Turbine

② Cannular Type Combustor

Fuel Fuel NozzleNozzle CombustorCombustor

BasketBasket

Transition Transition PiecePiece

Curvic Coupling

Spindle Bolt Disc


27




PROVEN FEATURES⑤⑤ROTOR COOLINGROTOR COOLING


28




Proven Design Features of Mitsubishi GT

29




4. DETAIL STRUCTURE OF GAS TURBINE

30




Inlet Casing Section

31




Variable Mechanism for Inlet Guide Vane

32




Thrust Bearing Structure②

SupplySupply

Drain

Drain

Shenzhen Eastern Power Plant Second Design Meeting

33




Journal Bearing Structure③

Supply

Shenzhen Eastern Power Plant Second Design Meeting

34




Bearing Seal Structure

：Labyrinth LO Seal

35




Compressor Casing

36




Compressor Diaphragms

37




Combustor Arrangement (Dry Low NOx Type)

38




Cross Flame Tube

39




Location of Spark Plug & Flame Detector

Spark Plug Flame Detector

40




Compressor & Combustor Casing with Dry Low Nox Combustor

Turbine CasingCompressor & Combustor Casing

Transition Piece

Bypass Valve

Fuel Nozzle Basket

AirAir

FuelFuel

Combustion GasCombustion Gas

By pass AirBy pass Air

41




Fuel Nozzle (Dry Low Nox type 1/2)

Fuel Oil （Pilot）

Fuel Gas （Pilot）

Fuel Oil （Main）

Fuel Gas （Main）

42




Fuel Nozzle (Dry Low Nox type 2/2)

43




Combustor Basket (Dry Low NOx Type)

Cooling Air(Compressor Discharge Air)

44




Transition piece (Dry Low NOx Type)

45




By bass Valve Mechanism（1/2）

Bypass BodyBypass Body

Bypass Ring

ActuatorActuator

Connection RodConnection Rod

Bypass ElbowBypass Elbow

46




By bass Valve Mechanism（2/2）

47




Turbine Casing Assembling

TrunnionTrunnionBearingBearing

TrunnionTrunnion ArmArm

Rotor Cooling Air Rotor Cooling Air Bleed FlangeBleed Flange

#2#2～～4 4 Turbine Vane Turbine Vane Cooling Air Supply FlangeCooling Air Supply Flange

48




Trunnion Support

49




Turbine Vane Assembly

50




Bore Scope Inspection Holes/Thermocouple for Disk Cavity Temperature Measurement

51




Hot GasHot Gas

Compressor / Turbine Inter Stage Seal Structure

High PressureHigh PressureLow PressureLow Pressure

Seal AirSeal Air

Compressed AirCompressed Air

Pressure Diff.Pressure Diff. Low PressureLow PressureHigh PressureHigh PressurePressure Diff.Pressure Diff.

52




Exhaust Casing Structure & Tangential Strut Structure

53




Exhaust Manifold Structure

54




Supports for Gas Turbine

55




Gas Turbine Rotor

Compressor Spindle BoltCompressor Spindle Bolt Turbine Spindle BoltTurbine Spindle Bolt

56




Compressor Rotor Assembly

57




Compressor Spindle Blot

58




Turbine Rotor Assembly

59




Disc ContactSurface

Torque Pin

Spindle BoltCurvic

Coupling

Spindle Bolt Disc

Comp. Rotor Torque Pin /Turbine Rotor Curvic Coupling

60




Compressor Blade Installation

61




Structure for Torque Tube Seal

62




5. MATERIAL

63




Major Material Used in Gas Turbine

64




Turbine Blade Material

65




Turbine Vane Material

66




Combustor Material

67




6. TURBINE COOLING SYSTEM

68




M701F Cooled Vane & Blade

69




Trend of Turbine Inlet Temperature

1400℃

70




Evolution of Turbine Inlet Temperature

71




Trend of Mitsubishi High Efficiency Gas Turbine

72




Technology for high Temperature Turbine

M701F

M701D

73




Trend of High Temperature Resistant Material Development

74




Trend of Turbine cooled Vane

/701D

/701F/701F

75




Trend of Turbine cooled blade

501F/701F

501D/701D

/701F

/701F

/701D/701B2

76




Thermal Barrier Coating (TBC)

77




Structure of TBC

78




Advanced Turbine Cooling

M701F

M701D

M701F

M701D

79




Cooling Method

80




Film Cooling

81




Pin Fin Cooling

82




Impingement Cooling

83




Turbulator

84




Row 1 Vane

85




Row 1 Blade

86




Row 2 Vane

87




Row 2 Blade

88




Row 3 Vane

89




Row 3 Blade

90




Row 4 Vane

91




Row 4 Blade

92




Secondary Flow System

93




Turbine Cooling Air Flow System

94




Turbine Rotor Air FlowTURBINE ROTOR COOLING AIR FLOW

95




Turbine Inner Seal Flow

96




Turbine Outer Seal FlowPREVENTION OF HOT GAS REVERSE FLOW

COOLING AIR

97




Temperature Monitoring Location

98




7. COMBUSTION SYSTEM

99




Requirement for Reducing NOx Level

100




Approach for Low Nox Combustion

101




Comparison Between diffusion Combustion and premix combustor

102




Mitsubishi Dry Low NOx Combustor

103




Dry Low NOx Combustor

104




Dry Low NOx Combustor Basket

105




NOx Emission Characteristic

106




Design Concept of Low NOx Combustor

107




DLN Control System

108




8. SPIN COOLＩNG OPERATION

109




Characteristics of blade tip clearance

A. Characteristics of tip clearance are estimated for the entire operational conditions including cold start and very hot start.

B. Reduction of clearance is observed at compressor blade ring right and left side while the engine restarts under very hot condition due to oval deformation ( ).

C. Reduction of clearance is observed at turbine casing bottom side during re-starting due to “cat back” deformation ( ).

: “Cat back“ deformation(Turbine side clearance is critical.)

: Oval deformation(Compressor side clearance is critical.)

Rotor

Blade ring

Rotor

Casing

Bottom side Clearance




Oval deformation of compressor blade ring at rear stage

CompressorBlade Ring

• Just after the shut down of GT, the rear stage compressor blade ring is shrunk rapidly accompanied with oval deformation due to rapid cooling.

• The rear stage compressor tip clearance each at right and left becomes critical due to the oval deformation. If the GT is re-started or spin under such a condition, rubbing is anticipated.

• Therefore, it is strongly recommended to re-start or spin the GT after 1.5 hour when rapid shrinkage is recovered.

111




“Cat back” deformation of the gas turbine casing

• “Cat back” deformation of the gas turbine casing is caused by the casing metal temperature gradient between top and bottom halves.

• The casing metal temperature gradient is caused by natural convection.Hot air inside the casing is convected upward.

• Natural convection inside the casing occurs after shut down of the gas turbine (GT).• After a while if the GT is restarted, minimum clearance occurs at bottom side due to the

distortion.

112




Countermeasure (Use of spin operation)In order to reduce the casing thermal distortion, it is recommended to carry out the spin cooling operation after gas turbine shut down. In order to monitor the casing metal temperature difference after shut down and to optimize the spin cooling procedure, thermocouples are installed on each top and bottom casings as shown below.

Casing metal temperature gradient between top and bottom will be reduced due to spin cooling operation and casing distortion will be minimized.Bottom clearance will be restored due to reduced casing distortion.

1.5

113




Reliability enhancement by spin coolingMHI established the following guideline for spin cooling and recommend to carry out the spin cooling operation after shut down.

1) The GT cannot be restarted or spun within 1.5 hour after the shut down so as to avoid the compressor blade tip rubbing due to the compressor blade ring oval deformation. (Zone A in Figure 1)

2) The GT can be restarted during 1.5~6 hours after the shut down without spin cooling, provided the casing metal temperature difference is within the criteria. (Zone B in Figure 1)

Criteria for turbine casing: 60°C / for combustor casing: 35°C3) If the GT is planned to restart during 6~30 hours after the shut down, the spin cooling operation is required.

Because the casing metal temperature difference is estimated to exceed the criteria during this period without spin cooling. (Zone C in Figure 1)

4) After approx.30 hours from the shut down, the GT can be restarted without spin cooling operation, provided the casing metal temperature difference reduces within criteria level due to natural cooling. (Zone D in Figure 1)

5) In case of the restart timing of the GT is not predicted, it is recommended to carry out the spin cooling operation according to the standard procedure.

Time after GT shut down

Figure 1 : Trend of GT casing metal temperature difference without spin cooling

1.5 4.5

114




9. GAS TURBINE NEW TECHNOLOGIES

115




Steam Cooled Combustor

15001500℃℃

Flame Temp.Flame Temp.=1500=1500℃℃

Air SteamSteam（Supply）

Steam Cooling Circuit(MTFIN)

Steam(Supply)(Return)

（ ReturnReturn）

（（ReturnReturn））

Premix BurnerMulti NozzleMain FuelMain Fuel

Pilot FuelPilot Fuel

116




Progress of Cooling Method

117




Heat Resistant Material Technology(Super Alloy Technology)

118




Blade RingBlade Ring

From Combustor From Combustor Cooling OutletCooling Outlet

To Combustor To Combustor Cooling InletCooling Inlet

Cooling Steam From Cooling Steam From HRSGHRSG

Row 1 Row 1 VaneVane

Row 1 Row 1 BladeBlade

Steam Steam Cooling Cooling PassagePassage

Clearance Verified Clearance Verified by Clearance by Clearance MeasurementMeasurement

Normal Blade RingNormal Blade Ring

Steam Cooled Blade RingsSteam Cooled Blade Rings

RP

M. L

OA

D [%

]

Large ClearanceLarge Clearance During Starting UpDuring Starting Up

Small clearanceSmall clearance at Steady Stateat Steady State

Active Clearance Control（Steam Cooled Blade Rings）

119




Leaf seal at Torque TubeLeaf seal at Torque Tube

Leaf seal location

Significant leakage reduction compared to brush seals

120




Aerodynamically shaped tangential strut coverAerodynamically shaped tangential strut cover

Tangential Strut

121




Exhaust DiffuserExhaust Diffuser　　3D CFD Analysis3D CFD Analysis

Mach Number Distribution

Exhaust Flow

Reduced shock wave at leading edge

gt traning_m701f_cilegon (text).pdf

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