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WELCOME TO IInd SESSION

• BHEL – GE GAS TURBINES COLLABORATION STATUS

• GAS TURBINE FUNDAMENTALS

• DESIGN FEATURES OF BHEL GAS TURBINES


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 & Auxiliaries


Combined Cycle Engineering

Area : Compressive - Engineering


manufacture, E&C & Services
License for manufacture of rotor
and HGP components
HEAVY DUTY GAS TURBINE MODEL DESIGNATION

PG 6 58 1 (B)

SERIES POWER NO. OF SERIES


APPLICATION SHAFTS
M- Mech.. Drive FRAME Approx. 1 or 2
1, 3, 5, 6, 7, 9 output power
PG- Pkgd. Gen.. in Hundreds,
Thousands, or 10
Thousands of
Horsepower

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 fuel
and standard Inlet/Exh. Pr. drops
POWER(29.5 %)

EXHAUST
FUEL GAS
(100 %) TURBINE HEAT
(67 %)

MISC.
(3.5 %)

OPEN CYCLE GAS TURBINE TYPICAL PERFORMANCE


GAS TURBINE REQUIREMENTS

Factors considered in selecting gas turbine


Y High efficiency
Y High specific output (output/kg of air flow)

Key Parameters of GT Affecting Above


Y Firing temperature
(Limited by metallurgy/cooling technology)
Y Pressure Ratio
MAJOR FACTORS AFFECTING
GAS 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 INJECTION
ON OUTPUT & HEAT RATE
INLET CHILLING PROCESS
12000 C
3
1104 0 C
9000 C

Q in
6000C

TEMPERATUR 4
E
Q out D

2 Gas Cycle
3000 C
C
B Steam Cycle
45 C
0

00 C 1 A E
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%


Constructional Features of BHEL Gas Turbines

‹ Heavy Duty Industrial Type


‹ Skid concept to reduce site-work
‹ Horizontally split casing for easy maintenance
‹ Axial type compressor with Built-up Rotor
‹ Wide Fuel flexibility : Gas & Liquid(light/Heavy)
Mixed Firing also
‹ Cannular Combustion system with water/steam injection
‹ /DLN combustors to meet stringent emission limits
‹ Suitable for Mechanical/Power Generation/Single shaft
‹ CCP applications
GT Rotor/Stator Arrangement
Compresor Rotor
‹ Each wheel(stage) is bladed & statically balanced

‹ Through bolts for wheels assembly

‹ Total Rotor is dynamically balanced

Turbine Rotor
‹ Each wheel(stage) with buckets & balanced

‹ Through bolts for wheels assembly

¾ Compressor & Turbine Rotor are built-up type

¾ Compressor & Turbine Rotor joined by distance piece

to form one Rotor


¾ Compressor Stator Vanes & Turbine Nozzles are fixed in

Comressor & Turbine Casing


GT Cutaway Showing Casing Cross Section
COMBUSTION SYSTEM
™ Multiple 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 emission
™ Each Combustor consisting of fuel nozzle, liner &
transition piece (for connecting to turbine)
™ Retractable electric spark plugs & UV flame detector
™ Cross 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 converter
™ Electrical clutch
™ Hydraulic Ratchet/Rotor turning
™ Accessory Gear Box consisting of
- Over speed trip mechanism
- Lube oil pump
- Hydraulic oil pump
- Fuel oil pump
- Atomizing air compressor
- Water pump
™ Accessory 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 exchangers
™ Duplex filter (5 micron) with downstream SS piping
™ Main Hydraulic oil pump (shaft driven), AHP(AC)
with 0.5 micron filter
™ Cooling 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 valve

™ 5 micron high pressure filter

™ Flow 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
9E DESIGN FEATURES
™ 17 Stage axial Compressor
™ Turbine & Accessory bases are skid mounted
™ Accessory base contains starting system, Lube oil console,
shaft driven accessory gear box driving Lube, Fuel,
hydraulic oil and atomizing air compressor
™ Honey comb seals for 2nd & 3rd stages
™ 1st & 2nd stage buckets & Nozzles are air cooled
™ Motor/ SFC starting facility
™ Hot end drive
™ Completely packaged and factory assembled, tested.
PLANT ARRANGEMENT OF 9E

™ 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
MS9001E
Performance Gas Distillate

ISO output (KW) 123400 121300


ISO heat rate (BTU/KW-HR,LHV) 10100 10170
ISO efficiency(%) 33.79 33.56
Exhaust flow (Kg/sec) 410.3 411.4
Exhaust temp. (°C) 543 543
Speed (RPM) 3000 3000
109E Combined cycle
ISO output (MW) 187.0 183
Efficiency (%) 51.2 50.6
209E Combined cycle
ISO output (MW) 377.0 370
Efficiency (%) 51.6 51.0
FRAME-9E GAS TURBINE
MS 5001PA
Basic Product Information

Construction
Compressor stages : 17
Turbine stages : 2
Number of combustors : 10
Pressure ratio : 10.3
Firing temperature : 963°C
Load gear box rating : 31500KW
Load gear design : Single helical
MS 5001PA DESIGN FEATURES

17 stage axial compressor


Turbine & Accessory bases are skid mounted
Accessory 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 cooled
Diesel/Motor/Expander starting facility
Hot end drive.
Completely packaged and factory assembled, tested.
MS5001PA
¾Performance Gas Distillate
¾ISO output (KW) 26300 25800
¾ISO heat rate (Btu/KW.HR),LCV 11990 12070
¾ISO efficiency(%) 28.46 28.27
¾Exhaust flow (Kgs/sec) 124.16 124.44
¾Exhaust temp. (°C) 487 488
¾Speed (RPM) 5100 5100
¾105 Combined cycle
ISO output (KW) 40 39
Efficiency (%) 42 41.5
¾205 Combined cycle
ISO output (KW) 80.5 78.5
Efficiency (%) 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
FRAME-5PA GAS TURBINE
MS 6001B
Basic Product Information

Construction
Compressor stages : 17
Turbine stages : 3
Number of combustors : 10
Pressure ratio : 11.8
Firing temperature : 1104°C
Load gear box rating : 54000KW
Load gear design : Double helical
MS 6001 DESIGN FEATURES

” 17 stage axial compressor


” Turbine & Accessory bases are skid mounted
” Accessory 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 cooled
” Diesel/Motor/Expander starting facility
” Hot end drive.
” Completely packaged and factory assembled, tested.
MS6001B
¾Performance Gas Distillate
¾ISO output (KW) 39620 38820
¾ISO heat rate (Btu/KW.HR),LCV 10710 10800
¾ISO efficiency(%) 31.86 31.6
¾Exhaust flow (Kgs/sec) 144.2 144.6
¾Exhaust temp. (°C) 532 532
¾Speed (RPM) 5133 5133
¾106B Combined cycle
ISO output (KW) 59.1 58
Efficiency (%) 48.1 47.4
¾206B Combined cycle
ISO output (KW) 119.5 117.2
Efficiency (%) 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
9E DESIGN FEATURES
™ 17 Stage axial Compressor
™ Turbine & Accessory bases are skid mounted
™ Accessory base contains starting system, Lube oil console,
shaft driven accessory gear box driving Lube, Fuel,
hydraulic oil and atomizing air compressor
™ Honey comb seals for 2nd & 3rd stages
™ 1st & 2nd stage buckets & Nozzles are air cooled
™ Motor/ SFC starting facility
™ Hot end drive
™ Completely packaged and factory assembled, tested.
PLANT ARRANGEMENT OF 9E

™ 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
MS9001E
Performance Gas Distillate

ISO output (KW) 123400 121300


ISO heat rate (BTU/KW-HR,LHV) 10100 10170
ISO efficiency(%) 33.79 33.56
Exhaust flow (Kg/sec) 410.3 411.4
Exhaust temp. (°C) 543 543
Speed (RPM) 3000 3000
109E Combined cycle
ISO output (MW) 187.0 183
Efficiency (%) 51.2 50.6
209E Combined cycle
ISO output (MW) 377.0 370
Efficiency (%) 51.6 51.0
FRAME-9E GAS TURBINE
GAS TURBINES FROM BHEL HYDERABAD
(as on Dec 2004)

TYPE NO OF GAS TURBINES


ORDER RECEIVED COMMISSIONED
FR-1 4 4
FR-3 16 16
FR-5 48 44
FR-5/2 2 2
FR-6B 55 47
FR-9E 13 9
FR-6FA 7 6
TOTAL 145 125
TOTAL BHEL GAS TURBINE LOGGED 7 MILLION FIRED HOURS
TOTAL MACHINES FIRING NAPHTHA 47 AND 1.6 MILLION HOURS FIRING EXPERIENCE

A : 006