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FlexEfficiency*50 Combined Cycle Power Plant
June 26, 2012
GE Energy
Advanced high efficient CCGT in support of grid stability
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All Rights Reserved. No part of this document may be reproduced, transmitted, stored in a retrieval system nor translated into any human or computer language, in any form or by any means, electronic, mechanical, magnetic, optical, chemical, manual, or otherwise, without the prior written permission of the General Electric Company.
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Agenda
• Todays’ generation needs
• Combined Cycles to balance varying grid loads
• Increasing operational flexibility requires a ‘total
plant concept’
• FlexEfficiency* 50 plant – designed for flexibility and
maintaining F-class life cycle cost
• Summary
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Customer requirementsIndustry changes
• Start-up fuel cost
• Start-up emissions
reduction (NOx)
• Looking for increased
revenues from
flexibility / capacity
• Part load operation
more frequent/
efficiency increase
• Additional turndown
• Changing merit order:1. Renewables2. Nuclear/Coal3. NGCC
Volatility of grid capacity
UK Generation profile – 2008 vs. 2030
Source: July 2009 Poyry Energy Consulting
??
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300
310
320
330
340
350
360
CO
2specific (g/kWh)
109FA 109FB.01 109FB.03 FlexEff*50
F-class combined cycles reduced CO2 - footprint
by 9+% 25 years of technology advancements
Technology advancements – specific CO2
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Operational flexibility – to support grid stability
Frequency response
Load response
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Frequency Response …3 Steps
Kinetic energy restored
Production
Consumption
Frequency
Demand Step
Kinetic energy consumed
Remaining static gapStabilizing dip
closing static gap
Initial state Final
time
PRIMARY RESPONSE SECONDARY RESPONSE
TERTIARYRESPONSE
0s to 30s 30s to 15minutes
+ 15minutes
IGV + OF (when required) Part load + rapid response
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Thermal generation … the throttle
•Gas turbine and combined cycle plants should have capability to respond to the needs of a highly renewable-penetrated grid
• Faster starting capability
• Higher start reliability
• Faster ramping capability
• Transient emissions compliance
• Lower turndown
• Smaller block size
• Better hot-day performance and grid support
Today’s gas generation technology is substantially more flexible
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Performance and turn down
Improvements:
• Better lapse rate through
design point optimization
• Bottoming cycle adaptation
• Model based control
• Real time plant optimization
• Higher average (effective)
efficiency over the entire
operating envelope
increases merit order
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CC Load 1.00.4
Faster Startup(Higher Annual Average
Load Factor)
Typical
Fle
xE
ffic
ien
cy50™
Fle
xE
ffic
ien
cy™
4 p
oin
ts
Better Part Load Eff.
Typical (normalized) part load of older CCGT vs. FlexEfficiency*50 part load curve
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Faster Start-up vs. Conventional start
Typically, the heat recovery
steam generator (HRSG)
requires purge sequence (no
purge credit) and steam
turbine temperature matching
at spinning reserve with
conventional gas turbine
exhaust temperature
adjustment
Rapid Response With Purge Credit
Smart Start
Purge
Credit
Conventional
Steam Bypasses ClosedGT Roll
Synch
LO
AD
Early EmissionsCompliance
TIME
Comparison of Rapid Response and conventional hot starts (overnight shutdown).
Integrated Total Plant Solution
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Gas turbine features
Steam turbine features
Plant features
Controls features
Flexibility … a complete plant approach
• Rotor architecture/clearances• Casings & cooling designs
• Architecture & clearances• thermal transient capability
• HRSG/ at temperation• Steam bypass• Temp & pressure control
• Integrated equipment & BOP• OpFlex* software utilization
Integrated components for overall plant response capability
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FlexEfficiency 50 Combined Cycle Power Plant
Efficiency and flexibility rely on
digital control architecture
Tops-down Total Plant Design
Bottoms-up Digital Plant Control
Heatrate
Reliability
Output
Turndown
Ramprate
Starttime
109D-14 Steam Turbine
W28 SPL Generator 3-Pressure drum
HRSG w/reheat
SSS Clutch
9FB.05 Gas Turbine
Integrated Plant Control
Y
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FlexEfficiency 50 plant operability
Accuracy
Control valve 90% more accurate
Repeatable
Calibration stability 8X longer… no drift
Measurement+
More measurements per device
(ex. flow instrument)
Predictive
Early warning horizon in months vs. minutes
Reliable
Hot stand-by thermocouples with on-line repair
Precision
Device digital measurement preserved as 32 bit data
…using the advantages of modern smart field devices
… to enhance the fundamental plant controllability
Expanded operating envelope(s)…
FlexEfficiency* 50 plantFlexEfficiency* 50 plant
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A different control paradigm
+_
Sensors
Effectors
Control
Control Schedules
+_+_
Sensors
Effectors
Control
Control Schedules
+_+_
+_+_
+_+_
+_+_
+_+_
+_+_
+_+_
+_+_
+_+_
Lo
op
S
ele
cti
on
S
tru
ctu
re
ARES - ParameterEstimation
Engine Model
Virtual Sensors
Sensors
Effectors
Physics-Based Boundary Models
Lim
it S
ch
ed
uli
ng
CDM
Good: Schedule-Based• Indirect boundary control• No explicit deterioration accommodation
• Coupled effectors
Better: Model-Based• Direct boundary control
• Accommodates deterioration
• De-coupled effectors
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Profitable MWh’s 1
Fuel Consumption 2FlexEfficiency =
1 Excludes MWh’s during min turndown2 Includes fuel consumption during start-up
FlexEfficiency - evaluating the mission
109FA.03
109FB.03FE50
Cyclic mission impacts material selection and life-cycle cost
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FlexEfficiency*50 Combined Cycle Power Plant• 510 MW, 50 Hz … 61%+ base load efficiency• Start-up to full load <30 minutes• Ramp-rate >50 MW/minute• Plant turn-down to 40% load
A new standard in efficiency AND flexibility enabling integration of more renewable resources onto the power grid
a productof
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350
330
310
290
270
250
230
210
50 Hz F- technology milestones
‘88 ‘90 ‘92 ’94 ’96 ’98 ’00 ’02 ‘04 ‘06 ’08 ’10 ‘12 ‘14
GT output (M
W)
Year
9FB.01
9F
9FA.01
9FA.03
DLN Combustion Single Crystal & DLN2
Material & Coating
Turbine
9H
9FB.03
> 2 decades adv. gas turbine
9FB.05
7FA.05
Compressor
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• 3D Aero, 14 stages
• Hybrid radial diffuser
• Non-integral bearing
• Oversized for grid code
Performance
Compressor Design Heritage
Maintainability• Field replaceable blades • Improved borescope access
• Blade health monitoring
• Automated water wash
3D aerodynamic airfoil
• GE90 & GEnx
• 7FA.05 compressor
validated in August 2011
Heritage
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DLN 2.6+ combustion system• Combines attributes of DLN 2+ and DLN 2.6 combustion systems
• Six fuel nozzles instead of five - increases
control
• Advanced coatings and materials - provides
increased durability
• Asymmetric fuel flow control – provides
operational flexibility
• Emissions < 25ppm NOx & CO
• Dual fuel capable
DLN2.6+ combustion system experience:
� 61 Operating 9FA/FB gas turbine units
� >800,000 Fired hours
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Power turbine technologyPerformance and improvements
• Hot gas path evolution • 3D aerodynamic design• Improved clearance management• 3 and 4 stages experience• Lessons learned
Hot gas path materials
• Single crystal (SX) technology• Aero technology transfer 2002• Largest operating fleet, FB & H
Super-alloy wheels
• Proven Ni-Fe Alloys• Aero-engine cyclic duty design• Applied to FA, FB & H gas turbine fleets
EA DS SX
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Turbine technology … Aero
Building on field rig and shared GE Aviation experience
Aero efficiency … GEnxEnhanced stage loading
and advanced aero
Advanced
shapes
Buckets and
diffuser
3D Aero
Advanced aero features
Validated CFD GE aircraft rig testing
Gas Temperature
CFD
Data
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109D-14 steam turbine – Single Shaft
Key features
• Separate high pressure (HP), intermediate pressure (IP) and low
pressure (LP) configuration… improved clearance control
• HEAT* technology expanded into double flow LP
• HP, IP and LP drum rotor construction with
blinglet nozzles
• Enhanced 1060mm and 850mm last stage bucket …
w/ improved aero and manufacturability
• Integrated SSS clutch in front standard …
increasing plant operational flexibility
• Single side exhaust hood …
reduced plant centerline height
• Common LP hood for once through, cooling tower and air condenser
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Benefits
• High efficiency• Reduced site assembly• Improved cooling capability• Simplified alignment• Improved serviceability• Increased reliability
Key features
� One piece frame construction for installation
� Fixator support for maintenance/ serviceability
� Modular gas, seal oil and stator cooling water systems
� Stator water cooling system and monitoring
� Packaged static excitation and static starter
109 SS generator overview
Over 600 liquid-cooled generators in operation
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Key features
� 3-pressure drum design with reheat
� Cycle enhancement with gas turbine & steam turbine equipment
� Improved fast start capability
� Modularized construction
� Internals designed for easier maintenance access
� Low pressure circuit minimizes flow accelerated corrosion
� Advanced monitoring & control
HRSG Improvements
Customer benefits
� Increased performance
� Improved operational flexibility
� Increased reliability
� Faster erection
� Better maintenance access
Designed for cyclic operation
World-class test facilities
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1. Component & Systems tests• Inlet and VSV rig – blade durability
• Diffuser rig – performance improvements
• Combustion test module – engine replica
• Exhaust rig
2. Advanced compressor test• Completed August 2011
• Arrive at complete compressor map
3. Gas Turbine full load test
• Fully assembled & instrumented engine
• Test all possible operating conditions
- Not only one site location!
Diffuser rig … performance
Validation & testing – the Concept:Variable Stator
Vane rig
Exhaust rig … performance
Combustion rig … dynamics, emissions
Component, system and unit validation
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2. Advanced Compressor Test
� Test completed in August 2011
• Compressor Test Vehicle (CTV) driven by .03 gas turbine for testing without grid connection (allows variable speed testing)
• Full compressor map,… operated to surge limit !
• Met/exceeded all test objectives
• 14-stage compressor is robust.
$170M investment to deliver proven operability and performance
Drive train
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Startermotor
Drivemotor
Torque converter
Gearbox
Compressortest vehicle (CTV)
Gas turbineDriver (.03)
Compressor
validated!
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Greenville, SC
3. Gas turbine Full Load testAn industry leading test facility
• Validation prior to customer delivery
• Full speed, full load, not-grid connected
• Testing beyond real world conditions
• Reduces onsite commissioning time
7FA.05 Test in 2012 ongoing• Fully Instrumented rotor
• Performance, Aeromechanics
• Combustion dynamics
• Operability on NG/liquid fuel
• Combustion and HGP thermal validation
• Grid code response
Drive trainTest conditions are more rigorous than during
8000 hours on a typical site !
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Summary
� Base load efficiency > 61%
� Flexible … Fast start, fast ramp rate, start reliability, turndown
� Air cooling – simplified gas turbine and plant integration
� F-class materials with air cooling … low life cycle cost
� Rich fleet experience and aviation heritage
� Validation + FSFL test gas turbine … compressor and turbine – full-scale factory test.
First commercial projects with COD 2015
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