Professional Documents
Culture Documents
Docslide - Us 7fa GT Classic Re Imagined Gea17911
Docslide - Us 7fa GT Classic Re Imagined Gea17911
Russ Martin
60 Hz Product Manager - Advanced Technology
Heavy-Duty Gas Turbine Combined Cycle
Jim Donohue
Marketing Program Manager - Advanced Technology
Heavy-Duty Gas Turbine Combined Cycle
2009 General Electric Company. All Rights Reserved. This material may not be copied or
distributed in whole or in part, without prior permission of the copyright owner.
Contents
I.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.
i
I. Introduction
Todays power generators find themselves in an uncertain world. Greenhouse gas legislation, fuel prices, renewable
portfolio standards, and financing constraints are but a few of the issues they face. In response to these demands, GE
has continued to evolve its F-class technology, which has been an industry standard for reliable, flexible, and economical
power generation for almost two decades.
The newest addition to GEs F-class gas turbine portfolio, the 7FA.05 version, delivers greater output and efficiency while
maintaining leadership in reliability, availability and the operational flexibility power generators need to achieve greater
revenue in all operating modes. In developing the newest version of the 7FA, GE has mined the wealth of knowledge that
comes from the largest and most experienced F-class fleet in the industry and combined it with proven technology from
across GEs broad portfolio of heavy-duty and aeroderivative gas turbines, as well as GEs aircraft engine models.
Model
Units
Hours
Starts
6FA
74
2.6+M
31K
7FA/B
715
19.0+M
520K
9FA/B
197
7.3+M
77K
This experience includes operation in duty cycles ranging from peaking to daily start/stops to base load operation as
illustrated in Figure 1.
2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.
1
Peaking Duty
157
23% of Fleet
Fired Starts
3,500
3,000
Cycling
326
47% of Fleet
2,500
10 Hours/Start
50 Hours/Start
7F - FA
7FA+ - 7FA+e
7FB
2,000
1,500
Base Load
207
30% of Fleet
1,000
500
0
10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000 100,000
Fired Hours
Figure 1. 7FA duty cycle for 2008 (base load, cyclic, peak).
Syngas applications
700+ units manufactured
19+ million operating hours
40% load with single-digit emissions compliance
2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.
2
7F
7FA
7FA
7FA
7FA
7FA
Revised Version
7F.01
7FA.01
7FA.02
7FA.03
7FA.04
7FA.05
7F
7FA
7FA+
7FA+e
PG 7191
PG 7221
PG7231
PG7241
Historical Version
Historical Designation
Performance Evolution
Figure 2 illustrates the evolution of the 7F technology since its inception. The remainder of this paper focuses on the next
step in the 7FA evolution and how it addresses customers needs today and in the future.
220
7FA.05 Version
38.5% Eff.
Compressor
GT output (MW)
210
200
7FA.04 Version
38.0% Eff.
190
7FA+e
36.2% Eff.
180
7FA+
35.7% Eff.
170
160
150
88
7FA
35% Eff.
Combustion/HGP
7F
34.5% Eff.
90
92
94
96
98
00
02
04
06
08
10
12
14
Years
Figure 2. 7F performance evolution.
2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.
3
Combined Cycle*
Output
211
627
38.5
57.5
8872
5934
CO (ppmvd)
*Combined-cycle values assume gas fuel, ISO base load conditions, 1.5" HgA steam turbine
backpressure, 2x1 combined cycle utilizing a GE 207D-11 ST, SCR, no duct firing and no CO catalyst.
Simple-Cycle Gas Turbine Output. The gas turbine output of the 7FA.05 version is incrementally improved over the 7FA.03
version by +33.6 MW (cold day @ 0F); +35.8 MW (ISO day @ 59F); and +37.4 MW (hot day @ 100F) as shown in Figure 3.
Figures 3 and 5 have a characteristic flat output rating from approximately 59F to 70F. In this ambient temperature
region, the 7FA.05 gas turbine operates with slightly closed inlet guide vanes and variable stator vanes, which become
opened fully at approximately 70F. In the region of constant base load output, the exhaust flow will increase, exhaust
temperature will stay approximately flat, and the exhaust energy will increase.
240
7FA.05
SC Output (MW)
220
Improved
Hot Day Output
+37.4 MW
7FA.04
200
7FA.03
180
160
140
-20
20
40
60
80
100
120
2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.
4
40%
Improved
Efficiency
+1.4 pt
7FA.05
SC Efficiency (LHV)
39%
7FA.04
38%
7FA.03
37%
36%
35%
34%
-20
20
40
60
80
100
120
Combined-Cycle Gas Turbine Output. The plant output of the 7FA.05 version in a 2x1 configuration is incrementally
improved over the 7FA.03 version by +111 MW (cold day @ 0F); +98 MW (ISO day @ 59F); and +105 MW (hot day @ 100F)
as illustrated in Figure 5.
It is important to note that in a fully duct-fired application, the 7FA.05 version can achieve more than 750 MW in a 207FA
configuration.
700
Improved
Hot Day Output
+105 MW
7FA.05
650
600
7FA.04
550
7FA.03
500
450
400
-20
20
40
60
80
100
120
2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.
5
58.0%
57.5%
7FA.05
57.0%
56.5%
7FA.04
56.0%
55.5%
7FA.03
54.5%
-20
20
40
60
80
100
120
Environment
In todays world of increased concern over climate change and the inevitable tightening of regulatory requirements, the latest
evolution of the 7FA maintains its legacy DLN2.6 combustion system to further improve emissions and operating flexibility.
Superior Combustion Technology. With its industry-leading DLN2.6 combustion system, and a model-based control
system that enables robust accommodation of ambient condition and fuel composition variations, the 7FA.05 version
produces more power by firing at higher temperatures while producing only single digit NOx and CO emissionsfrom
49% load up to 100% load.
Ecomagination*. Ecomagination is GEs commitment to imagine and build innovative technologies that help customers
address their environmental and financial needs, such as the need for cleaner, more efficient sources of energy. To join
the ecomagination portfolio, a system must complete the companys rigorous internal and third-party environmental
and operational evaluation.
The new 7FA gas turbine is part of GEs ecomagination portfolio. Its improved efficiency and higher output will result
in less fuel consumption and lower emissions on a MW-hr basis than currently available 7FA gas turbines across the
entire ambient temperature range, while maintaining the operational flexibility needed by customers to respond to
varying electricity demand conditions. A typical customer operating a GE 207FA combined-cycle plant with a 7FA.05
gas turbine instead of a 7FA.03 gas turbine for an equivalent net plant output of 627 MW could avoid the emission of
more than 19,000 metric tons of CO2 per year, equivalent to the emissions of approximately 3,800 cars on U.S. roads.
Flexibility
The compressors three Variable Stator Vane (VSV) stages enhance operational flexibility by allowing the control system
to adjust compressor airflow to accommodate varying fuel and ambient conditions, or in response to changing
operating conditions.
2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.
6
150
140
7FA.05
130
120
110
100
90
7FA.04
7FA.03
80
70
60
-20
20
40
60
80
100
120
Fast startup capabilities provide the ability to reduce NOx emissions during low load operation, leading to reduced
operating restrictions based on startup NOx limits and savings based on NOx trading credits.
Fuel heating capabilities allow operation on unheated fuel over an expanded portion of the startup sequence, leading
to reduced fuel consumption and reduced startup times for both cold and warm starts.
Component
7FA.03
7FA.04
7FA.05
Base Load
175
175
183
211
Min MW
87.5
73.5
97
103
% GT Turndown (ISO)
50%
42%
53%
49%
87.5
101.5
86
108
2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.
7
Maintainability
The compressors field-replaceable blades, along with additional borescope holes that allow for enhanced coverage,
enable improved maintainability and inspection capabilities and result in reduced outage times.
Improved monitoring and diagnostic capabilities are also included through additional sensors and instrumentation that
monitor blade health, along with advanced algorithms that enhance efficiency predictions.
Removable Compressor Blades. The 7FA.05 version compressor supports in-situ removable rotor blades. The enabling
technology is the circumferential dovetail slot design in contrast to an axial dovetail slot design. The circumferential
dovetail design allows the blades to slide circumferentially for removal at designated locations. Blade locks secure
the blades in position.
Improved Inspectability. The 7FA.05 version compressor casing includes improved inspection capability by the addition
and repositioning of borescope holes. The 7FA.05 version has three borescope hole locations on each stage as compared
to two per stage on the prior versions.
Borescope Locations
10 OClock
Visible
Top
2 OClock
2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.
8
Inlet
Re-routed piping
Exhaust
Scaled for flow increase
Oil Pumps
2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.
9
Platform
Introduction
Units
Hours
Starts
Technology Leveraged
B / EA
70s
1120
32+ Million
850K+
Materials
7 / 9FA
91 / 92
1170
30+ Million
600K+
All
7 / 9FB
02 / 05
43
190,000+
5,900+
HGP
7 / 9H
08 / 03
32,000+
150+
Compressor / HGP
6C
05
57,000+
470+
Compressor
GE10
03
254
1+ Million
26K+
Compressor
Compressor
GE's most advanced high efficiency compressor technology, based on the 6C and H platforms and built with GE Aviation
compressor technology practices, has been incorporated into the new 7FA turbine. The 7FA.05 version technology consists
of 14 stages specifically modeled for a higher flow rate, enabling greater output.
The airfoil design is based on the proven aerodynamic configuration of the 6C. The airfoils utilize a three-dimensional
aerodynamic configuration for improved efficiency. The first three stages of the compressor contain variable stator
vanes that provide the gas turbine with a wider operating envelope. The compressor flow path has been configured to
accommodate inlet conditioning with improved leading edge erosion tolerance.
The rotor is bolted steel construction with two sets of durable concentric tie bolts specifically planned to improve the
aerodynamic flow path. The rotor blades and wheels incorporate a circumferential dovetail that permits removing
the blades without pulling the rotor from the casing, thereby improving maintainability.
The compressor casing has been built to match the rotor and the existing DLN2.6 combustor interface. The casings
accommodate an advanced Blade Health Monitoring (BHM) system for stages 1 through 3. Additional borescope holes
have been included for enhanced inspection coverage.
Table 5 identifies the major components of the compressor and how the technology was borrowed from other GE
platforms. A check mark signifies previous experience with the material used in the 7FA.05 version, whereas a green
shaded background signifies prior model experience.
Combustion
The 7FA.05 version will employ the proven DLN2.6 combustor. The combustor has more than 12 million hours and
350,000 starts of operational experience. Minor modifications to the DLN2.6 combustion system will be required for
improved output and efficiency. Upgraded fuel nozzles will allow for a higher fuel flow rate and the transition-piece
cooling flow has been improved. Combustion lab tests have demonstrated emissions, durability, operability, dynamics
and exit profiles for these minor modifications.
2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.
10
Comment
B/E
VSVs
Rotor
Wheels
Circumferential Dovetails
Blades
Casings
Diffuser
Bearings
FA
FB
6C
GE10
Component
Comment
6/7/9FA
Comment
DLN2.6 model
No change
Transition Piece
Minor mod
Caps
DLN2.6 model
No change
End Cover
DLN2.6 model
No change
Fuel Nozzles
Minor mod
Turbine Section
The turbine section of the 7FA.05 version capitalizes on the recent 7FA.04 Hot Gas Path advancements. FB technology
and experience have been used in the design. Noted features are:
Three-dimensional aerodynamics airfoil shapes for the stage 1 nozzle and stage 1 bucket improving efficiency
More efficient stage loading
Improved cooling and sealing for improved efficiency
Improved clearances for improved efficiency
Nominal Tfire increase that still remains well within the FA experience
Materials. FB materials have been employed for the stage 1 nozzle and stage 1 bucket while H material has been
used for the stage 2 nozzle. The higher temperature-capable materials still operating in FA firing temperatures will further
improve the successful experience of the 7FA wear modes for low cycle fatigue, oxidation and creep, thus supporting
longer life and reduced repair costs.
Configuration. The first and second stages of the turbine section will consist of minor modifications to the 7FA.04 version
hardware to increase the flow passing capability. The third stage and distance piece will utilize a 7F Syngas design. The
turbine casing remains unchanged.
2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.
11
Comment
Stage 1
7FA.04 version
Stage 2
Stage 3
B/E
7/9FA
7/9FB
6C
7/9H
7FA.04 version
7F Syngas version
GE10
2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.
12
VIII. Conclusion
GEs 7FA is the most experienced F-class gas turbine in the world. The 7FA fleet has more units in service, and has
accumulated more operating hours and starts than any other F-class gas turbine. GE has utilized the wealth of knowledge
that comes from this F-class operating experience and combined it with technology from across GEs broad portfolio
of heavy-duty and aeroderivative gas turbines, as well as GEs aircraft engine models, to develop the 7FA.05 version
gas turbine.
The 7FA.05 version has been configured to have a minimal impact on existing customer reference plant designs. Minor
changes are needed to accommodate the higher airflow and associated output, but key parameters such as the required
fuel gas pressure and guaranteed noise level remain unchanged.
The 7FA.05 version delivers increased output and efficiency, which are of course highly valued in todays competitive
power generation segment, but does so without compromising the world-class operational flexibility, reliability, and
availability of the 7FA. The improved performance and operational flexibility have enabled the 7FA.05 version to become
part of GEs ecomagination portfolio, a rigorous internal and third-party environmental and operational evaluation.
Prior to delivering the first unit to a customer, the 7FA.05 version will undergo a battery of component level, subsystem
level, and system level tests, culminating in a Full-Speed Full-Load test in a new state-of-the-art test facility being
constructed at GEs Greenville, South Carolina, gas turbine manufacturing and test center of excellence. This testing
will enable GE to fully characterize the 7FA.05 version under real-life conditions, but in a laboratory setting.
GEs commitment to the 7FA gas turbine is a testament to the confidence GE has in this industry workhorse to continue
to serve the wide-ranging needs of its customers in an ever changing and extremely competitive segment.
2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.
13
List of Figures
Figure 1. 7FA duty cycle for 2008 (base load, cyclic, peak).
Figure 2. 7F performance evolution.
Figure 3. Simple-cycle gas turbine output.
Figure 4. Simple-cycle gas turbine efficiency.
Figure 5. Combined-cycle gas turbine output.
Figure 6. Combined-cycle efficiency.
Figure 7. Gas turbine turndown.
Figure 8. Removable compressor rotor blades.
Figure 9. Enhanced borescope inspection.
Figure 10. Reference plant model changes.
List of Tables
Table 1. GE F-class operational experience.
Table 2. 7FA model naming progression.
Table 3. 7FA gas turbine turndown comparison.
Table 4. 7FA.05 version configured from GE experience base.
Table 5. 7FA.05 version compressor model experience.
Table 6. 7FA.05 version combustion model experience.
Table 7. 7FA.05 version turbine model experience.
References
Availability & Reliability Source: ORAP; all rights reserved: SPS.
2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.
14