Gas Turbine Basics

• 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

EFFECT OF STEAM INJECTIONON OUTPUT & HEAT RATE

INLET CHILLING PROCESS

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

GT Cutaway Showing Casing Cross Section

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

Gas Turbine

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

FRAMEFRAME--9E GAS TURBINE9E 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 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

FRAMEFRAME--5PA GAS TURBINE5PA GAS TURBINE

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

MS 6001B GT CROSS SECTION

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

FRAMEFRAME--9E GAS TURBINE9E GAS TURBINE

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)