NTPC DLN Systems Vamsi[1]

NTPC Workshop

Dry Low NOx (DLN) Systems

Vamsi Duraibabu

September 14, 2010HyderabadIndia

2© General Electric Company

© 2010 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior permission of the copyright owner.

Copyright 2010 General Electric Company. Proprietary.

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.

GE Energy

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© 2010 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior permission of the copyright owner.

Emissions Technology AdvancementNO

x( p

pm )

Technology Enablers• 3D Reacting Flow

• Advanced Materials / Coatings

• Active Fuel Staging

• Smart GT Controls

‘85 ‘90 ‘10‘95

DLN +DLN +

DLN - Dry Low NOxDLN - Dry Low NOx

25 PPM25 PPM

Water InjectedWater Injected

42 PPM42 PPM

9 PPM9 PPM

15 PPM15 PPM

< 5 PPM< 5 PPM

Leader in Low Emissions Technology

4© General Electric Company

© 2010 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior permission of the copyright owner.

Dry Low NOx (DLN) Technology EvolutionNOx

CO

Stability

&

Premix

Range

Reliability

&

Component

Life

DLN 1.0

( 6B / 9E )

DLN 1.0+

( 7EA )

DLN 2.0

( 9FA )

DLN 2.6

( 6FA )

DLN 2.0+

( 9FA+e )

DLN 2.6+

( 9FB )

DLN Design

“ A Four

Sided Box ”

DLN Technology – 30 years of Design Evolution

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© 2010 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior permission of the copyright owner.

DLN Combustion System - Summary

1327

1411

1327

1327

1288

1135

Firing Temp ( oC )

9FA+e

9FBA

9FA+e

6FA+e

9FA

6B

9E

GT Model

40%

38%

30 mg/Nm3

30 mg/Nm34DLN 2.6+

60%50 mg/Nm33DLN 2.0+

50%30 mg/Nm34DLN 2.6

60%50 mg/Nm34DLN 2.0 #

65%

75%30 mg/Nm32DLN 1.0

Turndown * ( % GT Load )

Emission (NOx 15% O2)

No. of Fuel

Circuits

DLN Type

# Not Offered for New units

* ISO Day ( 15 oC , 60% RH )

6© General Electric Company

© 2010 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior permission of the copyright owner.

DLN 1.0 System – Frame 6B & 9E

• The original Dry Low NOx Combustion System, first fielded in early ’80’s.

• Operates in Diffusion mode, Piloted-premixed mode, and Fully premixed mode.

• Can be retrofitted on to existing turbines to replace Diffusion flame combustors

• Second largest single-digit NOx DLN fleet, behind the 7FA+e.

Lean Premixed System

FUEL STAGING

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© 2010 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior permission of the copyright owner.

DLN 2.0+ System - Frame 9FA+e

Premix

PM1

PM4PM4

PM4 PM4

DiffusionD5

D5

D5

D5

D5

Sub Piloted PremixD5

D5

D5

D5

D5

PM1

Piloted PremixD5

D5

D5

D5

D5

PM1

PM4

PM4PM4

PM4

Premix

PM1

PM4PM4

PM4 PM4

DiffusionD5

D5

D5

D5

D5

Sub Piloted PremixD5

D5

D5

D5

D5

PM1

Piloted PremixD5

D5

D5

D5

D5

PM1

PM4

PM4PM4

PM4

FUEL STAGING

Ignition - 95% Speed

95% Speed - 10% Load

10% - 50% Load

50% - 100% Load

• DLN-2+ retains the basic architecture of the DLN-2

• Fuel nozzle ( Swozzle Design ) redesigned with cleaner aerodynamics for improved Flame Holding Margin & Pressure drop.

• Accept fuels with wide wobbe Index ranging from 28 to 52.

Swirl-Stabilized Premixed System

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© 2010 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior permission of the copyright owner.

DLN 2.6+ System - Frame 9FA+e / 9FB

DiffusionD5

D5

D5

D5

D5D5

Sub Piloted PremixD5

D5

D5

D5

PM1D5

D5

Piloted PremixD5

D5

D5

D5

D5

PM3

PM3PM3

PM1

Sub Premix

PM3

PM3PM3

PM1

D5

Premix

PM3

PM2

PM3PM3

PM1PM2

DiffusionD5

D5

D5

D5

D5D5

Sub Piloted PremixD5

D5

D5

D5

PM1D5

D5

Piloted PremixD5

D5

D5

D5

D5

PM3

PM3PM3

PM1

Sub Premix

PM3

PM3PM3

PM1

D5

Premix

PM3

PM2

PM3PM3

PM1PM2

DiffusionD5

D5

D5

D5

D5D5

Sub Piloted PremixD5

D5

D5

D5

PM1D5

D5

Piloted PremixD5

D5

D5

D5

D5

PM3

PM3PM3

PM1

Sub Premix

PM3

PM3PM3

PM1

D5

Premix

PM3

PM2

PM3PM3

PM1PM2

Ignition - 95% Speed

95% Speed - 20% Load

FUEL STAGING

20% - 30% Load

30% - 40% Load

40% - 100% Load

• Based on the DLN 2+ fuel nozzle with DLN 2.6 architecture

• Designed for Sub 9 ppm NOx / CO Emissions

• Fuel Staging Flexibility – Solution for Yellow plume

• New Unit or Retrofit

Advanced Swirl-stabilized System

9© General Electric Company

© 2010 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior permission of the copyright owner.

DLN2.6+ System w/ OpFlex AutoTuneModel Based Control Technology Applications

Fuel flexibility• Wobbe index variation• Eliminates combustion retuning requirement

Performance enhancement• Output & efficiency• Fuel Supply pressure reduction

Start-up fuel flexibility•Larger start up fuel variances

Start-up emissions improvements• Lower start up NOx

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Lo

op

S

ele

cti

on

S

tru

ctu

re

ARES - Parameter

Estimation

Engine Model

Virtual

Sensors

Sensors

Effectors

Physics-Based Boundary Models

Lim

it S

ch

ed

uli

ng

CDM

• Direct boundary control

• Accommodates deterioration

• Tuning schedules are adjusted

automatically

Key Features

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© 2010 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior permission of the copyright owner.

Gas Turbine Combustion Laboratory

• 10 Test stands for testing and validating all DLN Systems

• Capability of blending NG with H2, CO, CO2, N2 and Steam

• Advanced monitoring and diagnostic instrumentation (upto 400 sensors) for component validation

• Up to 230 High Pressure / High Temperature Tests conducted per year

World Class DLN Combustor Test Facility

Camera–Premixed Flame

Overview

Appendix

12© General Electric Company

© 2010 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior permission of the copyright owner.

DLN 2.6+ System - Frame 9FA/FA+e /FB

Super B

Thermal

Barrier

Coating

(TBC)

Extended Interval (EI) transition

piece cooling and sealing

DLN 2.6 style nozzle

arrangement (5+1)

Fuel flexibility retained

from DLN 2+

� 9FA+e (9351FA)� 20/20 mg/Nm3 NOx/CO to 50% load� 30/30 mg/Nm3 NOx/CO to 35% load1

� 24k combustion interval

� 9FA (9311FA)� 30/30 mg/Nm3 NOx/CO to 50% load� 24k combustion interval

� 9FB (9371FA)� 30/12.5 mg/Nm3 NOx/CO to 38% load� 12k combustion interval

� 9FA+e (9351FA)� 20/20 mg/Nm3 NOx/CO to 50% load� 30/30 mg/Nm3 NOx/CO to 35% load1

� 24k combustion interval

� 9FA (9311FA)� 30/30 mg/Nm3 NOx/CO to 50% load� 24k combustion interval

� 9FB (9371FA)� 30/12.5 mg/Nm3 NOx/CO to 38% load� 12k combustion interval

� 9FA+e launch in 2005(12 operating, 7 ordered)

� 9FB launch in 2007(18 operating, 32 ordered)

� 9FA (9311FA) launch in 2009(1 operating, 4 ordered)

� Dual fuel and wide wobbe capable

� 9FA+e launch in 2005(12 operating, 7 ordered)

� 9FB launch in 2007(18 operating, 32 ordered)

� 9FA (9311FA) launch in 2009(1 operating, 4 ordered)

� Dual fuel and wide wobbe capable

1 With OpFlex Extended Turndown software

13© General Electric Company

© 2010 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior permission of the copyright owner.

+_

Sensors

Effectors

Control

Control Schedules

+_+_

Sensors

Effectors

Control

Control Schedules

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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

ulin

g

CDM

Good: Schedule-Based• Indirect boundary control• No explicit deterioration accommodation

• Coupled effectors

Better: Model-Based• Direct boundary control

• Accommodates deterioration

• De-coupled effectors

A different control paradigm