• 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. OFSHAFTS

SERIES

M- Mech.. Drive

PG- Pkgd. Gen..

FRAME1, 3, 5, 6, 7, 9

Approx. output powerin Hundreds,Thousands, or 10Thousands ofHorsepower

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 %)

GASTURBINE

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

TEMPERATURE

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

High efficiency High specific output (output/kg of air flow)

Key Parameters of GT Affecting Above

Firing temperature (Limited by metallurgy/cooling technology) Pressure Ratio

MAJOR FACTORS AFFECTINGGAS 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 INJECTIONON 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 5001PABasic Product Information

Construction

Compressor stages : 17Turbine stages : 2Number of combustors : 10Pressure ratio : 10.3Firing temperature : 963°CLoad gear box rating : 31500KWLoad 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

Performance Gas DistillateISO output (KW) 26300 25800ISO heat rate (Btu/KW.HR),LCV 11990 12070ISO efficiency(%) 28.46 28.27Exhaust flow (Kgs/sec) 124.16 124.44Exhaust temp. (°C) 487 488Speed (RPM) 5100 5100105 Combined cycle ISO output (KW) 40 39 Efficiency (%) 42 41.5205 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 HOURSTOTAL MACHINES FIRING NAPHTHA 42 AND 1.4 MILLION HOURS FIRING EXPERIENCE

A : 006

TYPE NO OF GAS TURBINESORDER RECEIVED COMMISSIONED

FR-1 4 4FR-3 16 16FR-5 48 44FR-5/2 2 2FR-6B 52 47FR-9E 13 9FR-6FA 7 6TOTAL 142 128

GAS TURBINES FROM BHEL HYDERABAD(as on July 2004)