power-gen middle east - ge power &...

© 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.

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,

manufacture, development, or derivation of any repairs, modifications, spare

parts, or configuration changes or to obtain government or regulatory approval

to do so, if consent is given for reproduction in whole or in part, this notice and

the notice set forth on each page of this document shall appear in any such

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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* 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


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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

4

• 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)


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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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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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


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


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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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


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


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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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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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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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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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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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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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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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


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Start up tests ongoing

> 3,000 data streams from the assembled test train


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


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


Maintaining 50 in 60 momentum >25 units technology selected for planned projects

HA … experience and validation driving rapid order growth

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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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