Professional Documents
Culture Documents
GAS TURBINES
Vivek Ghate
GMS CPP
vivek.ghate@ril.com
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Index
1. Basics of Gas Turbines.
2. Major Components of Gas Turbines.
3. Categories of Gas Turbines.
4. Performance Comparison of various makes of Gas Turbines.
5. GEs range of Gas Turbines.
6. Factors affecting the performance of Gas turbines.
7. Gas Turbines at RIL.
8. Maintenance factors of Gas Turbines based on the fuel used.
9. The Hot gas path components & its metallurgy.
10. Gas Turbine Control Systems.
11. Performance Benchmarking.
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GAS TURBINE
A gas turbine, also called a combustion turbine, is a rotary
engine that extracts energy from a flow of combustion gas.
It has an upstream compressor coupled to a downstream
turbine, and a combustion chamber in-between.
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GAS TURBINE
By heating up compressed air, expanding it in nozzles
mechanical/rotational energy is obtained.
Buckets
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Brayton Cycle
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Gas Turbine
Major Components
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Compressor
Turbine
Combustion chamber
Starting means
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COMPRESSOR
17 stage axial flow compressor.
Extractions 5th stage: bearing cooling and sealing air.
11th stage: Air bleed valves for surge control.
17th stage: Atom air compressor and pulse air.
TURBINE
3 Stage Impulse Turbine
COMBUSTION CHAMBER
10 combustors in annular space.
2 nos. Igniters in combustor no 1 & 10.
4 nos. Flame scanners in the combustor no 2,3 & 7,8.
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Categories of
Gas Turbines
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Frame Type Heavy - Duty Gas Turbines: Large power generation units ranging
from 3 MW to 480 MW in a simple cycle configuration. Efficiency 30 to 39 %.
Aircraft - Derivative Gas turbines: These are power generation units, which are
prime mover of aircraft in the aerospace industry. Efficiency 35 to 45%.
Industrial Type - Gas Turbines: In the range of 2.5-15 MW. Used extensively
for compressor drive trains. Efficiency Less than 30%.
Small Gas Turbines: In the range from about 0.5-2.5 MW. They often have
centrifugal compressors & radial inflow turbines. Efficiency 15 to 25%.
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Solar Turbine
Rolls Royce
Siemens
MHI
GE
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Gas Turbine
Heat Turbine Exhaust
Output Efficiency Pressure Flow
MODEL Make Rate Speed Temp
(MW) % Ratio (kg/sec)
(kcal/kwh) (rpm) (C)
501-KB5S Rolls Royce 3.897 2960 29.1 10.3 14200 15.4 560
Zorya
UGT-
Mashproek 20 2389 36 19.4 3000 72.2 412
15000+
t
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Gas Turbine
Gas Turbines up to 60 MW.
Various Manufacturers are:
Rolls Royce
Siemens
Alstom
IHI
Mitsubishi
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RB211 6761 DLE 2000 32 2188 39.3 21.5 94.55 4850 503.33
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LM 6000
1997 46 2123.3 40.5 30 130.45 3000 445
PC SPRINT
LM 6000
1997 45.48 2123.5 40.5 30 130.91 3000 450
PD SPRINT
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Ansaldo Energia
ISO BASE HEAT TURBINE EXHAUST
EFFICIENCY PRESS FLOW
MODEL YEAR RATING RATE SPEED TEMP
% RATIO (kg/sec)
(MW) (kcal/kwh) (rpm) (Deg C)
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CC 193.2 50 1656.2
MS9001E
SC 126.1 50 2546.0
CC 117.7 50 1573.0
MS6001FA
CC 75.9 50 2460.3
CC 64.3 50 1752.0
MS6001B
SC 42.1 50 2682.6
CC 67.2 50 1583.3
MS6001C
SC 45.4 50 2348.1
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GE H-System
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S 109H
109H System Combined Cycle Power Plant
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COMBINED CYCLE
Output 390.8 MW 407 MW 410 MW
Heat Rate 1517.5 kcal/kwh 1435 kcal/kwh 1488 kcal/kwh
Efficiency 56.70% 57.70% 57.8%
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H Class Comparison
GE Siemens
(S109H) (8000H)
Combined Cycle
Output 520 MW 530 MW
Heat Rate 1435 kcal/kwh 1435 kcal/kwh
Efficiency 60 % 60 %
Pressure
23 19.2
Ratio
Flow 687 kg/sec 820 kg/sec
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Compressor Fouling
Size Influence
Thermodynamic Influence
Ambient condition Influence
GT Speed
Inlet & Exhaust Pressure Loss
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Compressor Fouling
Fouling rate is a function of
Environment
Wind Direction
Filtration System
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Size Influence
Greater Dimensions
Higher Output
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Thermodynamic Influence
Mainly determined by the design of the
engine
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Increased Output
Unchanged Unit Efficiency
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Decreased Output
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GT Speed
Ref: GE perf.curve
GTF6SP
GT - MW change with speed at different ambient
temperature range
37
36 35.925 36 36.075 36.075
35.4 35.7
35 34.95
34 34.35 34.2 34.35
33.9 34.05
33.75 33.6 33.45
33 33.15
32.7
33.3
32.85 33.075 33.3
32.4 32.55 32.46
32 32.1 32.25
31.8 32.1 32.34
31.5 31.65 31.5 31.5
31 30.75 30.975 31.05 30.75 31.05
31.35
30.45 30.45 30.6
30 30.3 30.3
MW
30 29.85 30 29.7 30
29.625 29.4 29.4 29.55
29 28.8
29.1
28.65 28.875 28.65
29.025
29.325
28.65
28 28.35
27.975 28.2
27.75
28.2 27.975
28.35
27.6 27.6 27.6 27.6
27 27.225
26.85
27.15 27.15 27 27.3
26.475 26.4 26.7 26.55
26 26.1 26.025 26.1
25.35 25.65 25.35 25.575
25 24.975 24.9
24.6
24 24.3
23.925
24.3
23.55
23 23.175
22.8
22 22.125
21
20
95 96 97 98 99 100 101 102 103 104 105
speed %
5degC 15degC 20degC 25degC 30degC
35degC 40degC 45degC 50degC
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Power
Efficienc Firing
ISO Heat Flow consumed by
Model y Temp
Output Rate (lb/sec) Compressor
% (Deg C)
%
Fr 5 26.3 3022 28.5 273 63.86 957
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NET
T1 T2 T3 T4 WORK TURBINE COMPRESSOR
OUTPUT WORK POWER %
(MW) (C) (C) (C) (C) RATIO (MW) (MW)
LM6000
45.48 15 535 1260 450 0.358 127 82 64.20
PC
SGT 700 29.06 15 416 1140 518 0.355 82 53 64.47
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40 80
% POWER CONSUMED BY
THE COMPRESSOR
EFFICIENCY, %
30 70
20 60
10 50
0 40
MODEL Fr - 5 MS-6541 Fr-9E Fr-9FA
Efficiency % %
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40 1500
1000
20 750
500
10
250
0 0
Model Fr - 5 MS-6541 Fr 9E Fr - 9FA
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Comparison
Power Firing
ISO Heat Efficiency Flow
Model consumed by Temp
Output Rate % (lb/sec)
Compressor % (Deg C)
For every 100 Deg F/55.5 Deg C increase in firing temperature, the
efficiency increases about 1.5%. So, 223 Deg C rise in firing temp
increases the efficiency by 6%. Leading to improvement in heat rate by
165 kcal/kwh.
7 % reduction in compressor power consumption improves the heat rate
by 211 kcal/kwh.
Remaining 2 % improvement in Heat rate as a result of:
GTD-222 Stage 2 Nozzle
Stage 2 & 3 Honey Comb Shrouds
86i IGV setting
Higher RPM Load Gear
High Pressure Packing Brush Seal
Improved Cooling Stage 1 Nozzle
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Maintenance Factors
of Gas Turbine
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Requirements:
Withstanding Higher Firing Temperature.
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Type of fuel
Firing Temperature
Cyclic Effects
Steam or Water Injection Quality of Air
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Results Creep
Distortion
Reduced life
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Cyclic Effects
Each stop and start of a gas turbine subjects the
hot gas path to significant thermal cycles.
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Advantage
139 C lower metal Temp.
Lower Temp. gradient.
Short length provide more stiffness and reduced cooling air.
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Turbine Components
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BUCKETS
Stage 1 Bucket (FS2H)
Design
The original designs sharp leading edge has
been blunted to allow more cooling air to flow
to the leading edge, which reduces thermal
gradients and cracks.
Materials
The original stage 1 bucket was IN- 738 is
changed to an Equiaxed (E/A) GTD-111, a
precipitation hardened, nickel-base super alloy,
a greater low cycle fatigue. It also provides the
industry standard in corrosion resistance.
Coatings
In 1997 the coating was changed again to GT-33
INCOAT. GT-33 is a vacuum plasma spray
coating, an increased resistance to through
cracking. INCOAT refers to an aluminide
coating on the cooling holes passages.
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BUCKETS
Stage 2 Bucket (FS2F)
Cooling
The new stage 2 buckets contains
internal air cooling ,allows
for higher firing temperatures.
Tip Shroud
Shroud leading edge was scalloped
& tip was thickened & shroud
tapered. It resulted in 25%
reduction in stress and
80% increase in creep life.
Materials
The original bucket was made of U-700,
the material was changed to GTD-111,
also a precipitation-hardened, nickel-
Scalloping of bucket shroud base super alloy, to improve rupture
Coating strength. In addition it has higher low
GT 33 INCOAT cycle fatigue strength
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BUCKETS
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NOZZLES
Stage 2 Nozzle (FS1P)
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SHROUD BLOCKS
The stage 1 shroud block was redesigned for the 2055F/ 1124C firing
temperature. The two piece design is film cooled using airflow from the stage 2
nozzle to inhibit cracking. The film cooling required additional flow which
translates into a performance loss. The main advantage of the two piece design
is that it allows the damaged caps to be replaced without Having to remove the
shroud block bodies or turbine nozzles. The body and hook fit are made of310
stainless steel and the cap is made of FSX-414.
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SHROUD BLOCKS
Stage 2 & 3 Shroud Honey Comb Seal
Honey Comb Shroud:
i. Reduces Leakage
ii. Greater Rub Tolerance
Requires Buckets with Cutter Teeth
Provides a performance improvement up to 0.6% in both
output and heat rate.
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MATERIALS
Turbine Blades
Turbine Nozzles
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MATERIALS
Combustors
Turbine Wheels
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MATERIALS
Compressor Blades
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Due to non-availability of spares, Mark IV system at RIL sites are under proposal
for upgrade to Mark VI. Expected cost is Rs. 200 lacs per unit.
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Analog Meters
Analog and Digital Meters; Solid CRT & LED VGA VGA
Display & Relay
State Annunciator Aux. Display Color Graphics Color Graphics
Annunciator
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Control system
Communicates with the turbine to
Measure, adjust the parameters
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Shut down
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NAP/KER
UNIT CONTROL DISPLAY
HSD
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<I> Station
Turbine Generator
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<I>
Station
IONET
DENET < QD1 > < CD >
POWER
STAGE LINK
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* Time is in Minutes
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Tf = Tx (Pcd/Pa) k
The firing temperature remains constant even with increase in MW, FSR & CPR
ratio with less exhaust temperatures.
Acceleration Control
0.35 %/sec
0.10 %/sec
0% 40% 50% 75% 95% 100%
TNH
Manual Control
Manual Control Loop Can be used to limit fuel to prevent over firing
and over riding active control.
IGV Control
IGV Control
IGV Schedule
Maintains higher Exhaust Temperature at partial loads for Combined Cycle Operation
IGV Control
Isothermal
CPD
Maintains higher Exhaust Temperature at partial loads for Combined Cycle Operation
Performance Benchmarking
Purpose of Benchmarking
Benchmarking at a Glance
Benchmarking at a Glance
Benchmarking at a Glance
Benchmarking at a Glance
Benchmarking at a Glance
Benchmarking at a Glance
Benchmarking at a Glance
Thank
You
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