Heavy Duty Gas Turbine

Overview

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GE /
23 June 2009
Copyright 2004 Nuovo Pignone S.p.A. Copyright 2006 Nuovo Pignone S.p.A.
Training Program

1 - Gas Turbine General - Overview Installation layout Main

equipment location

2 - Operating Principles Describe the gas turbine

thermodynamic cycle, main
parameters and performance

3 - Description of GT Componentes Describe in detail all gas turbine

componentes and their
functions

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23 June 2009
Training Program

4 - Main GT Auxiliary Systems Describe the Auxiliary systems,

P&ID

5 - Gas Turbine Control System Basic of Control and Protection

System, Start-up and Shut-down
sequences

6 Maintenance Overview Scheduled and Borescope

Inspection, Disassembling and
reassembling procedures,
Components acceptability
criteria

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23 June 2009
What is Gas Turbine?

Gas Turbine is a
rotating thermic
machine
Its an high technology engine
It an high speed rotating machine (3.00030.000 rpm)
In industrial application may drive generators (GD = Generator Drive) o 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 MW
Its 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 also for one year

Additionally for power higher than 500 kW it has

Low cost of installed kw

Low maintenance costs
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23 June 2009
What is Gas Turbine?

The primary scope is.

To produce mechanical
energy in continuously!!

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23 June 2009
A Gas Turbine works in the following way
IT DIRECTS HIGH PRESSURE, HIGH
TEMPERATURE AIR TO THE TURBINE
SECTION, WHICH CONVERTS
FUEL THERMAL ENERGY INTO
MECHANICAL ENERGY
THAT MAKES
THE SHAFT REVOLVE;
THIS SERVES,
ON THE ONE HAND, TO
SUPPLY USEFUL ENERGY
TO THE DRIVEN
FUEL MACHINE, COUPLED TO
THE MACHINE BY MEANS OF
A COUPLING AND, ON THE OTHER HAND,
IT EXHAUST
TO SUPPLY ENERGYLOW
ITPRESSURE,
NECESSARY FORLOW
INCREASES AIR TEMPERATURE
THECOMPRESSION,
ENERGY LEVEL
GASES RESULTING FROM
OF THEWHICH THEPLACE
TAKES
COMPRESSED ABOVE-MENTIONED
ITINADDING
AIR BY DRAWS AIRTRANSFORMATION
A COMPRESSOR
AND
IN DIRECTLY
IT COMPRESS
BURNING
FROM FUEL
THE WITHINTO
IT THETHE ATMOSPHERE.
TO HIGHER PRESSURE
TURBINE
IN COMBUSTION
SURROUNDING SECTION
CHAMBER
ENVIRONMENT
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23 June 2009
GE Gas Turbines

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23 June 2009
Gas Turbine Families
HEAVY DUTY JET

SINGLE SHAFT TWO SHAFTS PURE AEREONAUTICAL

PENGIUN TURBINES

INDUSTRIAL & MARINE USE

LM SERIES

INDUSTRIAL USE INDUSTRIAL USE PGT/GE SERIES

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23 June 2009
Gas Turbines Product Range
Solid Technology Base
GE 5-1 5.5 MW
GE 5-2 5.6 MW
... For Every Application
GE 10-1 11.2 MW 9 High Efficiency,
GE 10-2 11.7 MW Reliability & Availability
LM 1600/PGT 16 14.2 MW 9 Low Life- Cycle Costs
LM 2000/PGT 20 18.1 MW 9 Application Flexibility
LM 2500/PGT 25 23.2 MW 9 Fuel Flexibility
MS 5001 26.3 MW 9 Low Emissions
MS 5002C 28.3 MW
MS 5002E 30.0 MW
LM 2500+/PGT 25+ 31.3 MW
MS 5002D 32.5 MW
MS 6001B 42.1 MW
LM 6000 44.7 MW
MS 7001EA 85.1 MW
MS 9001E 123.4 MW Multi Shaft
Single Shaft
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23 June 2009
GE 5/1
KEY 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)

Weight: 23.900 Kg
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
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23 June 2009
GE 5/2 (New Product)
KEY DATA
Twin Shaft driver for Centrifugal
Compressors and Pumps
3D Aero
Advanced static and brush seals
New coatings
Advanced compressor design
Optimization of clearances

PERFORMANCE (@ ISO CONDITIONS)

Weight: 24.000 Kg
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
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23 June 2009
GE 10/1
KEY 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

Model available may Have combustion chamber horizontal or vertical

according customer request

PERFORMANCE (@ ISO CONDITIONS; GD)

Output : 11.250 Kw Weight: 34.000 Kg

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
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23 June 2009
GE 10/2
KEY DATA
Turbine designed and developed by Nuovo Pignone Since reliability
and availability to worldwide customers while keeping with easy
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.
Weight: 40.000 Kg
PERFORMANCE (@ ISO CONDITIONS; MD)
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
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23 June 2009
PGT 16
KEY DATA
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

This turbine use some power turbine of PGT 10/A and GE 10/2

PERFORMANCE (@ ISO CONDITIONS)

MD GD
Output : 14.252 13.735 Kw
Efficiency : 36,2 34,9 % Weight: 19.000 Kg
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
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23 June 2009
PGT 25
KEY DATA
Power Turbine developed by Nuovo
Pignone in the early 80s
First unit installed in 1983
M.D. & P.G. fleet firing hours exceed
1,800,000

PERFORMANCE (@ ISO CONDITIONS)

MD GD Weight: 38.000 Kg

Output : 23.261 (shaft) 22.417 (el.) Kw

Efficiency : 37,7 (shaft) 36,3 (el.) % PGT25 Power Turbine
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

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23 June 2009
PGT 25+
KEY DATA
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

PERFORMANCE (@ ISO CONDITIONS MD & PG)

Output : 31.364 Kw
Efficiency : 41,1 %
Heat Rate : 8.754 kJ/kWh
Natural Gas Fuel
Ex. Gas Flow : 84,3 kg/s
Dry Operation
Ex. Gas Temp. : 500 C (no steam or water injection)
PT Nominal Speed : 6.100 rpm Base Load
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23 June 2009
MS 5001 N
KEY DATA
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
Weight: 87.430 Kg
cogeneration of power and process steam or in district
heating systems.
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 17 /
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23 June 2009
MS 5002C / MS 5002D
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

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
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23 June 2009
MS5002E (New Product)
Features
Leverage GE Technology
Moderate Firing Temperature
Reliability & Efficiency as
Key Factors
DLN System derived from
large Frames
Twin Shaft - suitable for MD or PG Rotordynamic Test

Introductory Performance
z Output Shaft : 30 MW
z SC Efficiency : 36,4 %
z LPT shaft speed : 6.100 rpm
CTV Test Rig
z Exhaust Temp. : 523 C
z NOx Emission : 25 ppm CTV Compressor Test

Weight: 117.000 Kg 19 /
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23 June 2009
LM 6000
KEY 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)

Weight: 31.000 Kg
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
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23 June 2009
MS 6001 B
KEY DATA
The MS6001 is a single shaft heavy-duty gas turbine. Its
design was based on the well proven mechanical features of
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 very high
efficiencies with higher availability and reliability.
Weight: 96.000 Kg

PERFORMANCE (@ ISO CONDITIONS)

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
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23 June 2009
MS 7001 EA
KEY DATA
The MS7001EA is a single shaft heavy-duty gas turbine for
power generation and industrial applications requiring the
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.
PERFORMANCE (@ ISO CONDITIONS)
MD GD Weight: 121.000 Kg

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
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23 June 2009
MS 9001 E
KEY DATA
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

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
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23 June 2009
MS 9001 FA

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23 June 2009
MS 9001 H

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23 June 2009
Gas Turbines Service according load type

SINGLE SHAFT GAS TURBINES DOUBLE SHAFT GAS TURBINES

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23 June 2009
Gas Turbines Applications

Liquified Natural
Gas Plants
Gas Booster, Pipeline Petrochemical
and Re-injection Plants

Gas Turbines produced

by GE Energy

District
Power Generation and Heating
Cogeneration Plants
Offshore Applications
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23 June 2009
Gas Turbines Typical Loads

Centrifugal and Axial Electric Generators

Compressors
GE Energy
Gas Turbines

Reciprocating
Compressors Centrifugal Pumps

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23 June 2009
 Gas Turbine
Operating Principles

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23 June 2009
KEY TERMS

ISO conditions
Firing Temperature
Pressure Ratio
Heat Rate
Compressor Ratio

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23 June 2009
ISO conditions

Gas Turbine performance are declared in ISO condition and the constructors
have to declare fuel used to obtain declared performances.
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23 June 2009
ISO conditions

Ambient Pressure: 101325 Pa (14,7 P.S.I.A.)

Ambient Teperature: 15 C (59 F)

Relative Humidity: 60%

Pressure drop in inlet/exhaust: 0 mm H2O

There are the condition to refer for evaluation of GT performance

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23 June 2009
FIRING TEMPERATURE
According to the NUOVO PIGNONE-GENERAL ELECTRIC standard, the
temperature that best represents point (3) is the one in section B

The difference in the interpretation of temperatures in section A and B

consists in the fact that the section B temperature takes account of T 3

mixing with 1st stage nozzle cooling air, wich was not involved in the
combustion process, but mixes with burnt gases after cooling the 2
surface of the nozzle. 4

P 2
S
3

4
1

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23 June 2009
PRESSURE RATIO

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23 June 2009
HEAT RATE

P 2 3 T 3

2
Q1
HR =
4

1 4 1

V S Lu
Heat Rate is the inverse of efficiency,
2 in that it indicates the ratio between
4
thermal energy, resulting from the
3
combustion process, and mechanical
energy, obtained on the power shaft.
1

In generally expressed as Kj/KWh

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23 June 2009
Power & Heat Rate
HEAT RATE

HEAT RATE IS THE

INVERSE OF EFFICIENCY

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23 June 2009
Power & Heat Rate

If we think about a car, HEAT RATE is

MUCH MONEY FOR

LOW HEAT RATE
OUR COMPANY 37 /
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23 June 2009
Power & Heat Rate

HIGH POWER & LOW HEAT RATE

MUCH MONEY FOR

OUR CUSTOMERS

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23 June 2009
COMPRESSOR RATIO

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23 June 2009
Brayton Cycle
Fuel
Air Exhaust
1 Intake
4
CC
3 C - Compressor
2 CC - Combustion
C T L T - Turbine
L - Load

Combustion Expansion
T 3
P
2 3

2 4

1 4
1
Compression Exhaust
V S

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23 June 2009
Brayton Cycle
T 3 3I

Theoretical Cycle
2I 4I
Real Cycle
2is
4is
P2

P1 1

S
Pressure drops are The hot gaes flowing the Exhaust gases flowing
caused by airfilter and combustion system are through this system are
silencer system subjected to friction subjected to friction

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23 June 2009
Specific Compression Work

Wc = c pm (T2 T1 ) (T2 T1 ) Mesured in

Kj
kg inlet _ air
2
4

Cpm=average specific heat

1
at costant pressure

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23 June 2009
Specific Expansion Work

Wt = c pm (T3 T4 ) (T3 T4 ) Mesured in

Kj
kg gas
2
4

Cpm=average specific heat

1
at costant pressure

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23 June 2009
Heat supplied to the combustion chamber

Q1 = c pm (T3 T2 ) (T3 T2 ) Mesured in

Kj
kg gas
2
4

Cpm=average specific heat

1
at costant pressure

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23 June 2009
Heat supplied to the atmosphere with exhaust gas

Q2 = c pm (T4 T1 ) (T4 T1 ) Mesured in

Kj
kg ehxaust _ gas
2
4

Cpm=average specific heat

1
at costant pressure

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23 June 2009
Thermodynamic efficiency

2
4

(Q1 Q2 )
cl =
1
Q1

This equation tell us that, by parity of

heat Q1, introduced into the
T = f (T ;C ;CC ; cl ...) combustion chamber by fuel,
efficiency will increase as heat Q2
dissipated into the atmosphere
decreases
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23 June 2009
Useful work supplied to the driven machine

Pu = (Gair + G fuel ) Wt Gair Wc

Kj
2
Measured in
4
s
3

Gair= amount of air

1

Gfuel= amount of fuel

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23 June 2009
Main parameters affecting gas turbine performance

In the Brayton Cycle are very important the following

parameters:
T 3

2
4

FIRING TEMPERATURE T3
1
PRESSURE RATIO P2
P1
P 2
S
THERMAL EFFICIENCY 3

SPECIFIC POWER Kw (kg )

s
4
1

V
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23 June 2009
Brayton Cycle: T1, T2 and T3

T3=?

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23 June 2009
Brayton Cycle: T4

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23 June 2009
Brayton Cycle: P2

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23 June 2009
Brayton Cycle: T3

T3=f(T4,P2)

963C
=10,5
(1765F)

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23 June 2009
Main parameters affecting GT performance

lu
g
g = 0.85
lu

T 3 = kost
= 0.7

= 0.6

1 5 10 15

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23 June 2009
Main parameters affecting GT performance

lu g

g = 0.85 lu

= kost
= 0.7

= 0.6

800 1000 1200 T3 [k]

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23 June 2009
 Gas Turbine
Main Componentes

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23 June 2009
Inlet Section Gas Turbine

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 sea

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23 June 2009
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 accessoryes:
-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
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23 June 2009
HD GT Axial Compressor Operation

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23 June 2009
HD GT Axial Compressor Design
AIR

Journal BEARING
DISCS TENSION RODS
IGV

Airfoils with large thicknesses

Rotor stage discs linked by thick tension rods.
Sliding Journal bearings
compressor variable Inlet Guide vanes (IGV)
(to control the air flow)

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23 June 2009
HD GT Axial Compressor Design

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23 June 2009
HD GT Combustion Chamber(s) Operation
COMBUSTOR(s)
is the part of the engine
where air is mixed with fuel
and burned with a portion
of the compressor air

The combustion casing 30%

allows compressor
discharge air to be
directed through the
flow sleeve and
30%
ultimately into the
combustion liner
40% 61 /
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23 June 2009
HD GT Combustion Chamber Design
COVER SPARKLING PLUG
COMBUSTION CHAMBER WRAPPER
LINER
GAS FUEL

LIQUID FUEL
REACTION ZONE EX
DILUITION ZONE HA
US
TG
AS
BURNER

COMBUSTION AIR PORT

GAS CONVEYOR
AIR FROM THE AXIAL COMPRESSOR
TRANSITION PIECE
SLOTS OR HOLES FOR THE LINER COOLING AIR

- The air flow through the combustion chamber has three functions: oxidize the fuel, cool the
metal parts, the extremely hot combustion products 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.
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23 June 2009
NOx reduction for Heavy Duty Gas Turbines
DRY Systems WET Systems

1) Steam Injection* This system consists of

injection steam atomized in combustion
DLN 1: chamber to decrease flame temperature and
so NOx.
Dry Low NOx.
Easy to install
Requires Steam
Increase maintenance

2) Water Injection * This system consists

of injection of atomized water in combustion
chamber to decrease flame temperature and
so NOx.
Easy to install
DLN 2:
Requires water
Dry Low NOx.
Increase maintenance

* Appliable for all GE HD GT

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23 June 2009
HD GT Turbine Section Operation

TURBINE
is the part of the
engine where the hot
gases from the
combustor

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 conversion of the gas kinetic

energy into rotating shaft horsepower.
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23 June 2009
HD GT Turbine Section Operation

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23 June 2009
HD GT Turbine Section Design
Rotor blades (Buckets and stator nozzles with
large thickness, with high corrosion and erosion
resistance.
They can accept also fuel oil (residual treated oil)
although at expense of more frequent
maintenance.

ROTATION AXIS

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23 June 2009
HD GT Turbine Sec. Manufacture & Assembly

the bucket is then given a

first and second coating

the last step before shipping

is to give each bucket a
weight and a serial number.

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23 June 2009
HD GT Turbine Section Design

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.

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23 June 2009
HD GT Turbine Section Design
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.

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23 June 2009
HD GT Exhaust Section Gas Turbine

Exhaust casing:
- the frame consist of an outer cylinder and an inner cylinder
interconnected by radial struts.
- directs the flow of coming from turbine section into the
exhaust duct
- Turing Vanes

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23 June 2009
HD Gas Turbine Bearings

The gas turbine unit contains two or three main journal bearings used to
support the gas tiurbine rotor. The unit lso includes thrust bearings to
maintain the rotor-to-stator axial position and to support the thrust loads
developed on the rotor. These bearings and seals are incorporated in two
or three housing.

The main bearings are pressure-lubricated by fluid supplied from the

main lubricating system. The fluid flows through branch lines to an inlet
in each bearing housing.

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23 June 2009
HD Gas Turbine Journal Bearings
Type:

Elliptical

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23 June 2009
HD Gas Turbine Thrust Bearings

Type:
Load (Equalizing)
Unloaded (Non-Equalizing)
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23 June 2009
HD Gas Turbine Thrust Bearings

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23 June 2009