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• BHEL – GE GAS TURBINES COLLABORATION STATUS
• GAS TURBINE FUNDAMENTALS
• DESIGN FEATURES OF BHEL GAS TURBINES
WELCOME TO IInd 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 & AuxiliariesCombined Cycle Engineering
Area : Compressive - Engineeringmanufacture, E&C & ServicesLicense for manufacture of rotorand 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) PG6111(FA) 75900 35.0(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 fueland standard Inlet/Exh. Pr. drops
FUEL(100 %)
GASTURBINE
POWER(29.5 %)
MISC.(3.5 %)
EXHAUSTHEAT(67 %)
OPEN CYCLE GAS TURBINE TYPICAL PERFORMANCE
GAS TURBINE REQUIREMENTS
Factors considered in selecting gas turbine
High efficiencyHigh 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 -6)
4 INCHES H2O INLET DROP PRODUCES :
• 1.50% POWER OUTPUT LOSS• 0.50 % HEAT RATE INCREASE• 1.2 DEG.F EXHAUST TEMP. INCREASE
4 INCHES H2O EXHAUST DROP PRODUCES :
• 0.50 % POWER OUTPUT LOSS• 0.50 % HEAT RATE INCREASE• 1.2 DEG.F EXHAUST TEMP. INCREASE
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
BC
D
E1
2
3
4
00 C450 C
3000 C
6000C
9000 C
Q out
Heavy Duty Industrial TypeSkid concept to reduce site-workHorizontally split casing for easy maintenanceAxial type compressor with Built-up RotorWide Fuel flexibility : Gas & Liquid(light/Heavy)
Mixed Firing alsoCannular 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 RotorEach wheel(stage) is bladed & statically balancedThrough bolts for wheels assemblyTotal Rotor is dynamically balanced
Turbine RotorEach wheel(stage) with buckets & balancedThrough bolts for wheels assemblyCompressor & Turbine Rotor are built-up typeCompressor & Turbine Rotor joined by distance pieceto form one Rotor
Compressor Stator Vanes & Turbine Nozzles are fixed in Comressor & Turbine Casing
GT Rotor/Stator Arrangement
COMBUSTION SYSTEMMultiple 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 emissionEach Combustor consisting of fuel nozzle, liner &transition piece (for connecting to turbine)Retractable electric spark plugs & UV flame detectorCross fire tubes connecting combustors for flame propagation
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 converterElectrical clutchHydraulic Ratchet/Rotor turningAccessory Gear Box consisting of- Over speed trip mechanism- Lube oil pump- Hydraulic oil pump- Fuel oil pump- Atomizing air compressor- Water pumpAccessory 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 exchangersDuplex filter (5 micron) with downstream SS pipingMain Hydraulic oil pump (shaft driven), AHP(AC) with 0.5 micron filterCooling 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 valve5 micron high pressure filterFlow 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
MS9001E - Basic Product Information
CONSTRUCTIONAL FEATURES:
Compressor Stages 17
Turbine Stages 3
Number of Combustors 14
Pressure Ratio 12.6
Firing Temperature (°C) 1124
GT Speed (rpm) 3000
17 Stage axial CompressorTurbine & Accessory bases are skid mountedAccessory base contains starting system, Lube oil console,shaft driven accessory gear box driving Lube, Fuel, hydraulic oil and atomizing air compressorHoney comb seals for 2nd & 3rd stages1st & 2nd stage buckets & Nozzles are air cooled Motor/ SFC starting facilityHot end driveCompletely packaged and factory assembled, tested.
9E DESIGN FEATURES
Machine suitable for indoor/outdoor installation
Skid mounted GT & Accessory packages
Accessory module and turbine module are mounted
on split base frame
Suitable for single shaft and multi shaft combined cycle
Side exhaust
On-base/Off-base enclosure
PLANT ARRANGEMENT OF 9E
MS9001E
Performance Gas Distillate
ISO output (KW) 123400 121300ISO heat rate (BTU/KW-HR,LHV) 10100 10170ISO efficiency(%) 33.79 33.56Exhaust flow (Kg/sec) 410.3 411.4Exhaust temp. (°C) 543 543Speed (RPM) 3000 3000109E Combined cycle
ISO output (MW) 187.0 183Efficiency (%) 51.2 50.6
209E Combined cycleISO output (MW) 377.0 370Efficiency (%) 51.6 51.0
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 compressorTurbine & Accessory bases are skid mountedAccessory 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 cooledDiesel/Motor/Expander starting facilityHot 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 cycleISO output (KW) 40 39Efficiency (%) 42 41.5205 Combined cycleISO output (KW) 80.5 78.5Efficiency (%) 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
MS 6001BBasic Product Information
Construction
Compressor stages : 17Turbine stages : 3Number of combustors : 10Pressure ratio : 11.8Firing temperature : 1104°CLoad gear box rating : 54000KWLoad gear design : Double helical
MS 6001 DESIGN FEATURES
17 stage axial compressorTurbine & Accessory bases are skid mountedAccessory base contains starting system, Lube oil console,shaft driven accessory gear box driving Lube, Fuel,hydraulic oil and atomizing air air compressor drives.Honey comb seals for 2nd & 3rd stages.1st & 2nd stage buckets & Nozzles air cooledDiesel/Motor/Expander starting facilityHot end drive.Completely packaged and factory assembled, tested.
MS6001B
Performance Gas DistillateISO output (KW) 39620 38820ISO heat rate (Btu/KW.HR),LCV 10710 10800ISO efficiency(%) 31.86 31.6Exhaust flow (Kgs/sec) 144.2 144.6Exhaust temp. (°C) 532 532Speed (RPM) 5133 5133106B Combined cycleISO output (KW) 59.1 58Efficiency (%) 48.1 47.4
206B Combined cycleISO output (KW) 119.5 117.2Efficiency (%) 48.7 48.0
PLANT ARRANGEMENTS OF MS6001B
• Machine suitable for Indoor/outdoor installation• Skid mounted GT & Accessory packages• Accessory module and Turbine module mounted
on Split Base Frame• Suitable for Single Shaft and multi shaft combined cycle• Side or top exhaust• On-base / Off-base enclosure
MS9001E - Basic Product Information
CONSTRUCTIONAL FEATURES:
Compressor Stages 17
Turbine Stages 3
Number of Combustors 14
Pressure Ratio 12.6
Firing Temperature (°C) 1124
GT Speed (rpm) 3000
17 Stage axial CompressorTurbine & Accessory bases are skid mountedAccessory base contains starting system, Lube oil console,shaft driven accessory gear box driving Lube, Fuel, hydraulic oil and atomizing air compressorHoney comb seals for 2nd & 3rd stages1st & 2nd stage buckets & Nozzles are air cooled Motor/ SFC starting facilityHot end driveCompletely packaged and factory assembled, tested.
9E DESIGN FEATURES
Machine suitable for indoor/outdoor installation
Skid mounted GT & Accessory packages
Accessory module and turbine module are mounted
on split base frame
Suitable for single shaft and multi shaft combined cycle
Side exhaust
On-base/Off-base enclosure
PLANT ARRANGEMENT OF 9E
MS9001E
Performance Gas Distillate
ISO output (KW) 123400 121300ISO heat rate (BTU/KW-HR,LHV) 10100 10170ISO efficiency(%) 33.79 33.56Exhaust flow (Kg/sec) 410.3 411.4Exhaust temp. (°C) 543 543Speed (RPM) 3000 3000109E Combined cycle
ISO output (MW) 187.0 183Efficiency (%) 51.2 50.6
209E Combined cycleISO output (MW) 377.0 370Efficiency (%) 51.6 51.0
TOTAL BHEL GAS TURBINE LOGGED 7 MILLION FIRED HOURSTOTAL MACHINES FIRING NAPHTHA 47 AND 1.6 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 55 47FR-9E 13 9FR-6FA 7 6TOTAL 145 125
GAS TURBINES FROM BHEL HYDERABAD(as on Dec 2004)