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Copyright ®1998 by ASME All Rights Reserved Printed in U.S.A.

GAS TURBINE UPRATING PROGRAMME DEVELOPMENT AND TESTING OF THE GT1 1 NM

Christoph Schneider

Vladimir Navrotsky

Prith Harasgama

ABB Power Generation

Baden, Switzerland

ABSTRACT The next sections detail the main changes to the

ABB has approximately 200 GT11N and GT1ID type
gas turbines currently operating in simple cycle and
combined cycle power plants. Most of these machines are
fairly mature with many approaching the end of their
economic life. In order that the power producer may
continue to operate a fleet with improved performance,
Advanced Air Cooling Technology and Advanced Turbine
Aerodynamics have been utilized to uprate these engines
with the implementation of a completely new turbine
module.
The objective of the uprating program was to
implement the advanced aero/cooling technology into a
complete new turbine module with:
• Improved power output for the gas turbine
• Increase the GT cycle efficiency
• Maintain or improve the gas turbine RAM (Reliability,
Availability & Maintainability)
• Reduce the Cost of Electricity
• Maintain or reduce the emissions of the gas turbine
The GT11NM gas turbine has been developed based
on the GT11N which has been in operation since 1987 and
Midland Cogeneration Venture (MCV-Midland, Michigan)
was chosen to demonstrate the uprated GT11NM. The
upate/retrofit of the GTIIN engine was conducted in
May/June 1997 and the resulting gas turbine - GT1 1NM
has met and exceeded the performance goals set at the
onset of the development program.
turbine and the resulting performance improvements as
established with the demonstration at Midland, Michigan.
BACKGROUND OF THE GT11 D AND GT11 N TYPE
GAS TURBINES
Market introduction of the GT11 type engines began
in 1971 and to date approximately 200 machines are in
operation. There are two engine power ratings, these have
been designated with a letter or number after the series
type, "GTI I" being the main series type. The GT11D5
being the latest in the GT11D series. These engines have
been continuously uprated and systematic value has been
delivered to the power producer by improving performance
and reducing operating costs. A summary of the Type-11
engines in operation is shown below, Table-1.
Table 1: Number of Gas Turbines in Operations
GT Type Machines in Year of
Operation Introduction
GT11D 111 1971
GT11N 87 1987
The reliability and availability of the GT11N have
been excellent. Overall, the GT11N is one of the fleet
leaders of all gas turbine types of this power rating; with
availability exceeding 95% and reliability exceeding
99.4%, see Figures 1 & 2.

Presented at the International Gas Turbine & Aeroengine Congress & Exhibition
Stockholm, Sweden — June 2–June 5, 1998
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 Figure 1: Reliability of GT1 1 N and all US Fleet of Similar Rating

100.009b

95.00%

90.00 % '--------•-

8500/ ^'----------

80.00 % tc ■^^^ - --^^^

w' REUAB1UTY -..----.

0 1 2 3 4 5 6 7 8 9 1i

Figure 2: Availability of GT11N and All US Fleet of Similar Rating

iiip^"0 1

90.00 /o
.• ..■■•^ -1 —_
=i

■■

t- I...■^■■..■

■■■■
85.00%,o
Q' AVAILABILITY ■■■■
80.00%
m Q---- ------

0 1 2 3 4 5 6 7 8 9

The performance of the current GT1 1D5 and GTI IN additional complication was the utilization, by some power
gas turbines is shown in Table2 producers, of backup fuels such as diesel oil and crude oil
in some instances.
Table 2. Performance of the GT11 Type Gas
Turbines Development Goals for the Turbine Uprating
The main objectives for the turbine retrofit was that all
GT Type GT11D5 GT11N other parts of the gas turbine would remain unchanged. In
Power (MW) 73.3 81.8 particular the uprate would maintain the same compressor,
Efficiency (%) 31.4 32.1 combustor, rotor, GT outer casings and all major support
structure and foundations. The only parts to be modified
In developing the new family of retrofit (uprated) were:
turbine modules for the GT1 IN and GTI 1D5 gas turbines, • all turbine vanes, blades and heat shields
all field experience from the operating GT's was used. In • turbine vane carrier
this respect one criteria emerged as a performance driver • modified turbine exhaust diffuser struts
from all power producers, this was that the RAM of the The performance goals were to improve the turbine
uprated engines should be no worse than today's engines. power output by, on average 5% multiplicatively and the
In fact, most power plant operators put improved RAM efficiency by 3% multiplicatively. As will be shown later,
ahead of improved power output and heat rate. An these goals have been significantly exceeded in the
GT11NM.

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 Figure 3: Target performance goals for all turbine retrofits (60Hz & 50Hz approx. 300 Units)

Relative efficiency inprovement (%) Outlet Power (%)

105 106

105

104
103
103
102
g Existing
C I 102
m 101
M°Qdied
w
-100
m
o tot
a.
p Existing
• l dlfied
100
99
99
98
98

97
97
GT11NM GT13DM GT11DM G19DM
GT11NM Gr130M GT110M GT9DM
Turbines
Turbines

One of the major goals in the turbine uprating program
is that the same basic turbine is utilized across the entire
fleet of 60Hz and 50Hz gas turbines to benefit all power
producers with the same approximate potential increase in
power and efficiency, Figure-3.
excluded due to poor experience in clogging of the cooling
holes and subsequent degradation of airfoil life. This has
posed a significant challenge to the cooling design of the
turbine airfoils to deliver adequate component durability
with minimum cooling air consumption.

Clearly any turbine uprating program must deliver
robust turbine components capable of operating in a hostile
fuel environment. Various gas turbine fuels, such as diesel
oils and crude oils, as well as the more benign environment
of natural gas combustion must be satisfied. Based upon
these requirements, film cooling of the turbine airfoils was
Figure 4: Growth Path and Retrofit for GT11D5 and GT11N Gas Turbines
The overall growth path and uprating goals for the gas
turbine is shown in Figure-4. Here it is clear that the major
elements of any uprating program must be conducted in a
phased manner such that the power producer realizes an
improvement in performance of invested capital equipment
over a period of time, in this case over 20 to 30 years.
GT11N M
P = 89.2 MW
e ey r)=33.6

co a^ GT11N ee^^
=SMW
=1%

y
v GT11DM
00 P=76.3 MW
i v >1=32.1
ine retrofit
JaJ Tucb
-GT11D5
o GT11D5
P=73.3 MW
'153800H
Tl = 31.4 %
87 Unit

1987 1997 Time

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 New Turbine Design
The new design led to a turbine module which would
fit both GT11N and GT11D5 engines, a "family design",
wherein the airfoil & cooling design was very much aligned
towards the latest generation of the OEM's Gas Turbines.
The field experience of more than 600 GT's was used and
implemented in the new design. All the new GT's were
equipped with the same vane carrier (except minor changes
when scaling from 60Hz to 50Hz). The new vane carrier
was redesigned according to the latest state of the art
design, using modern technologies to improve the
efficiency of cooling and improve durability.
The blading was developed with major improvements
in aerodynamics and cooling efficiency. All turbines were
equipped with state of the art airfoils providing better
aerodynamics. Additional improvement of the turbine was
achieved by redistribution of stage loading by redesigning
the turbine channel (meridional flow path), which is now
more equally distributed on all 5 stages. The overall
changes made in the GT are shown on Figure-5

Figure 5 Changes to GT11N for Uprating to GTIINM

:

■Turbine airfoils LI Vane carrier Ii Exhaust gas casing struts

of the various airfoil aerodynamic concepts were employed.

Turbine blading in the first two stages are now cooled
By simulating all possible concepts, the optimal solution
in a more efficient way, allowing the air to pass through
could be chosen prior to final design and manufacturing.
several additional cooling channels with enhanced
Finally the airfoils are laboratory tested for both
impingement and turbulator cooling systems. During the
aerodynamic loading and cooling efficiency as shown on
development phase three dimensional computer simulations
Figures 6 & 7.

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 Figure 6 : Aerodynamic Changes for GTIINM Airfoils, Improved Airfoils Lead to Lower Losses
6a Channel Changes

.AI LII I I UI VII I

Main features
- Increase in channel height reduces throughflow velocity and thereby reduces losses

- Increase in hub radius of rotating blades reduces RIT

• Exit flow uniformity improved by increased channel height

6b Airfoil Technology

S '

.I...I..I^... .........I.

Figure 6b shows the improved Mach number Consequently the modified airfoils have higher efficiency.
distribution on the graph labeled "Modified Turbine" which
has a smoother flow field and lower possibility of shocks.

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 Figure 7: Plexiglas Internal Cooling Model for Heat Transfer and Fluid Flow Visualization

GTI I NM Blade#1

❑ Fully Blade#1 of the retrofit has

been manufactured and tested for
internal cooling.
❑ Tests conducted at engine
representative conditions
❑ All main features verified by tests
❑ View shows instrumented Blade#1
installed in test facility

During the design of the turbine all work was
performed with CAE and CAD program integration. This
delivered a three-dimensional solid blade or vane model to
the casting foundry for manufacture. This sophisticated
modeling technology brings enormous improvements in
quality control because parts conform exactly to design.
The result is a durable product with built-in reliability and
very little part-to-part performance variance. Further
performance improvements were realized by the reduction
of leakage air by the use of advanced sealing technology, it
is expected that the leakage flow is reduced by a factor of
60% with the design of the new seals.

Figure 8 : Final Design of Blade Row-1 for the GTIINM

View of Full External

Solid Model

Internal Core
is Done as 3D Solid

Manufacturing Fully
Integrated with 3D Models
Better Quality Control
Better Durability

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 Figure 9: As Cast GT11NM Blade Row-1
Cooling system
The GTI INM has the same firing temperature as the
existing GT11N unit, consequently the uprate does not
affect other hot section lifetimes and also has the advantage
that Nox and other emission levels are also maintained at
current levels.
Demonstration of the GT11 NM Performance
The GTI 1NM has been demonstrated at Midland
Cogeneration Venture which is a mature combined cycle
power plant with twelve (12) GT1 IN gas turbines coupled
via heat recovery steam generators to two steam turbines.
Auxiliary firing is used to generate additional steam for the
steam turbines.
Test Program
The test program concentrated on overall performance
measurements of the gas turbine, durability measurements
on the new turbine module and overall operation of the GT
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Full blade
with the new turbine. As such a comprehensive test
program covering the variation of inlet guide vane settings
and steam injection for De-NOx control was carried out. In
particular the following measurements were integrated:
• turbine vane row-1 durability
• turbine inlet pressure
• turbine exit pressure
• turbine inlet segment temperatures and pressures
• overall GT pressures and temperatures
• vane carrier temperatures and cooling feeding
conditions
Typical instrumentation on vane row-1 for
temperatures and pressures are shown on Figure - 10, whilst
the overall instrumented vanes, heat shields and vane
carrier is shown on Figure - 11. This (Fig- 11) shows the
vane carrier about to be placed over the gas turbine rotor
and rotor blading prior to closing of the GT.
 Figure 10 : Vane Row-1 Instrumentation, Thermocouples (left) , Pressures (right)

Performance Measurements, Site Specific Conditions, following sections.

Midland Cogeneration Venture (MCV)
Given below are a selection of data taken at the host
site for the GTI INM at Midland, Michigan in the MCV
facility, the data are compared with an existing GTI IN unit
which was recently overhauled (Q1/1997) in order to
reference the GT11NM. The GT11NM is designated
Unit#7 and the GTI IN is designated Unit#9 in the
The performance measurements taken on units 7 and 9
for the determination of the I 1NM performance
improvement are shown below. The results of the
performance evaluation show that the expected gas turbine
performance improvement has been exceeded significantly.

Table 3: Performance Comparison with Unit 9

• • • • '•
KW Jo Deg
Re erence: nit 9 861T32% 0T3
U niF7AaWTT7TB5- `36T2% g44 -

DTfference 10775Thi3T VP in s
% Change +12.5% + . o -10.5% -

Table 4: Comparison of Unit 7 (GT11NM) with Unit 7 (GT11N) Before the Upgrade
'.
c 10 c eg
Ref erence: Urnf 7"Before 8 397 32:3°Tou '
— 1"655 "^y 52 —
Unit TAffe ^ Pgra a 97 C85^ -_^ _. "36.2^T ^ 943 ^- ' - 50 8
- -

Diffeience — 1 83 — 3:8 Poi n Fs ^^^'1^19—- -23.4

% Change +13.8% + . o -10.6% -
Note: It was also found that the mass flow has increased by 1.5% in the case of the GT11 NM

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 Figure 11 : Vane carrier instrumentation & closing of GT

The results of the performance calculation show that a

significant performance improvement has been achieved.
Almost the entire additional power output is made with
efficiency improvement of the turbine. Therefore, for the
same heat input, there is a significant increase in power
output. Figure - 12 shows the results of this calculation, the
difference between the two lines is the power increase for
the same heat input (fuel flow).
The testing of the gas turbine was carried out continuously
with data being taken over a period of 14 days so that site
ambient conditions on performance could be determined.
The results of these data are shown on Figure - 13, where
the power output vs. ambient temperature is plotted.

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 Figure 12 : Power Output vs. Heat Input

Power Output vs. Heat Input

100

98

96

94 ®M 101
0 •InMEMO
92 mURIIPi1uIRIIIII
CL 90
0
86
°
a
86

84

82

80
250
©EiuEmmiiiiai®n
255 260 265 270 275
Heat Input (MWI

Note that in Figs 12 & 13 , Unit#7, Before Upgrade is a performance. The nominal performance of an "As New"
GTI IN with approximately 24,000 operating hours. GT11N would have a power output approximately 1.0 to
Consequently there is a slight degradation of the unit's 1.5 MW higher than that shown on the Figures.

Figure 13 : Power vs. Ambient Temperature

Power Output vs. Ambient Temperature

104

100

96

• Unit 7 After Upgrade •

0 92 X Unit 7 Before Upgrade

3
0
3
L 88

) K XXC X, `
X ^(, X X
X X _ X X

I
84
xJx XXx _____

80 X
40 45 50 55 60 65 70 75 80 85 90 95
Ambient Temperature [Deg F1

10

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 The operating history of the GTI INM over a period of time of the GT under all ambient conditions. At present
has been evaluated in terms of reliable power output and (September 1997) the GT has operated for 2200 hours and
Figure - 14 shows the variation of power over a period of no deterioration of hot section parts have been evident.
two months. It can be seen that there is a reliable operation

Figure 14: Operating History of GT11NM vs. GT11N at MCV, Site Specific Conditions

Comparison of GTI I NM & GTI I N Power Output Measured

Simultaneously at Midland, Gas with DeNOx Steam, Under Site
Specific Conditions
074
100

90

80

70

§ 60

L 50
m

a
o 40

30

20

10

0
07/01/97 07/15/97 08/06/97 08/22/97 09/03/97
Date (MID/Y)

Finally, the emissions measurements show that in fact
there is a slight reduction in Nox produced by the GTI 1NM
in comparison to the GTI IN, Figure - 15 shows the relative
emissions performance of Unit-7 before and after the
upgrade.
There is a marginal potential to save some steam
injection flow in the power range above 80 MW and still
meet the emissions regulation of 42 PPM. However the
steam injection characteristic has not been changed from
the original setting prior to the upgrade. A reduction of the
100MW set point by 6 kpph is possible, which would result
in a full load NOx level of around 36 ppm, better than the
GTI IN value of 40 to 42 ppm.
turbines:
• The gas turbine performance in terms of power output
and efficiency have been realized and in fact exceeded
• The performance and durability testing of the new
turbine module has proved successful with all metal
temperatures and pressures being within the design
limits.
Operating costs of Combined Cycle Power Plants can
be diminished significantly by GT-Upratings and contribute
to higher competitiveness, even if some additional
investment is needed.

Conclusions The environmental impact of the uprating is favorable

with reductions in Nox
Summarizing the experience on GT & Plant
Performance Uprating Programs for the retrofit gas

11

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 Figure 15 : Steam Injection Adjustment & Emissions

Steam Mass Flow / NOx vs. Power Output

75
70 110
N 65 100
0 60 --^ current steam injection curve 90
,_., 55 c5
injection rate decreased by 6 k
> 50 C
p Q 45
-0 0 40
NOx limit 42 ppm 60
50
ma
'c
NOx with injection rate decreased by^kp^h X 38.9
N 35 40 E
30 Current NOx Ievel 30
v 25 20
20 10
15 0
0 10 20 30 40 50 60 70 80 90 100 110 120
Power Output [MW]

Acknowledgements:
The authors would like to thank ABB Power
Generation for permission to publish this paper.
Additionally, the entire GT Retrofit & Uprating team
consisted of 38 engineers and the authors extend their
thanks to the entire team. Participation in this program of
the US Government DOE Advanced Turbine Sytems,
Project Coordinator Abbie Layne, is also acknowledged.

12

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