BHEL Heavy Duty Gas Turbines

- Recent Developments

Recent developmentsRecent developments

• Up-rated Models

• New Models

• Large Advance class Gas Turbines

• Areas of Improved design

• Advanced materials and coatings

• IGCC

UpratedUprated VersionsVersions

•• FrFr--6B 6B PG6581BPG6581B•• FrFr--9E 9E PG9171EPG9171E•• FrFr--6FAe+6FAe+ PG6111FAPG6111FA

New ModelsNew Models

•• FrFr--6C 6C PG6591CPG6591C•• FrFr--9FA 9FA PG9351FAPG9351FA•• FrFr--9FB PG9371FB9FB PG9371FB

PG6581 B PG6581 B –– ImprovementsImprovements

•• Increased Shaft speed Increased Shaft speed –– 51635163•• Increased firing temperature Increased firing temperature ––

1140 deg C1140 deg C•• Improved turbine sealingImproved turbine sealing•• Reduced compressor leakage Reduced compressor leakage ––

Brush sealBrush seal•• 1313thth stage air for cooling Stage 2 stage air for cooling Stage 2

NozzleNozzle•• Improved N#1,B#1Improved N#1,B#1•• High performance exhaust High performance exhaust

diffuserdiffuser•• Split Accessory BaseSplit Accessory Base

PG6561 PG6581Output, kw 39620 42100

SC Heat Rate, kcal/kwhr 2700 2680

Exhaust Flow, tons/hr 519 530

Exhaust Temp, deg C 532 548

ISO,Base,Gas

PG6581B PG6581B –– Stage 1 NozzleStage 1 Nozzle

•• Enhanced cooling of Enhanced cooling of platforms and platforms and aerofoilsaerofoils..

•• Improved leakage control Improved leakage control –– chordalchordal hinge and hinge and additional additional splinespline seal.seal.

PG6581B PG6581B –– Stage 1 BucketStage 1 Bucket

•• New Bucket profileNew Bucket profile•• Optimized cooling Optimized cooling

configurationconfiguration•• Existing GTD111DS Existing GTD111DS

material and coating material and coating technologytechnology

PG6581B PG6581B –– Stage 1 ShroudStage 1 Shroud

•• Redesigned internal Redesigned internal cooling systemcooling system

•• Improved leakage controlImproved leakage control•• HR 120 materialHR 120 material

Circumferential Circumferential braided seal locationbraided seal location

ImpingementImpingement SleeveSleeve

PG6581B PG6581B –– Stage 2 NozzleStage 2 Nozzle

•• Optimization of cooling Optimization of cooling ( 13 stage bleed air).( 13 stage bleed air).

•• Existing material and Existing material and coating technology.coating technology.

PG6581B PG6581B –– Stage 2 BucketStage 2 Bucket

•• Enhanced cooling of airfoil.Enhanced cooling of airfoil.•• Contoured tip shroud for Contoured tip shroud for

creep life improvement.creep life improvement.•• Nickel Base alloy material.Nickel Base alloy material.

PG6581B PG6581B –– Exhaust DiffuserExhaust Diffuser

•• Improved performanceImproved performance•• Minimum design changesMinimum design changes•• Enlarged exhaust plenum Enlarged exhaust plenum

bottom and extensionsbottom and extensions•• Enlarged internal diffuser Enlarged internal diffuser

profile ring extensionprofile ring extension

PG9171E PG9171E –– Latest EvolutionLatest Evolution

PG9171E PG9171E+

Output, kw 123400 126100

Heat Rate, kcal/kwhr 2545 2545

Exhaust Temp, deg C 544 543

Exhaust Flow, tons/hr 1502 1505

PG9171E PG9171E –– Latest improvementLatest improvement

•• Turbine Sealing Turbine Sealing improvementimprovement

•• Improved First stage Improved First stage shroud shroud

•• One piece design, HR120 One piece design, HR120 material with cloth material with cloth splinesplinesealseal

PG9171E PG9171E –– Latest ImprovementsLatest Improvements

•• Improved 2Improved 2ndnd Stage Stage Shroud SealingShroud Sealing

•• Non pressurized Non pressurized diaphragmdiaphragm

•• Brush SealBrush Seal

PG9171E PG9171E –– Latest ImprovementsLatest Improvements

•• High performance exhaust High performance exhaust diffuser.diffuser.

PG6111FA PG6111FA –– Key featuresKey features

•• Increased Firing Increased Firing temperaturetemperature

•• Increased air flowIncreased air flow•• Higher pressure ratioHigher pressure ratio•• Robust rotor design, Robust rotor design,

No startup dwell timeNo startup dwell time

PG6111FA PG6111FA -- PerformancePerformance

Advance Class TechnologyAdvance Class Technology

•• Quantum jump in firing temperaturesQuantum jump in firing temperatures•• Higher efficiencies ( Simple & CC )Higher efficiencies ( Simple & CC )•• More power from single unitsMore power from single units•• Superior metallurgy Superior metallurgy •• Novel Cooling techniquesNovel Cooling techniques•• Novel sealing methodsNovel sealing methods•• Improved emissions Improved emissions •• Better topping machines for a combined cycleBetter topping machines for a combined cycle

Advance Class TechnologyAdvance Class Technology

•• EE-- FF-- HH--

Firing temperature C Firing temperature C 11241124 1400 ~ 14501400 ~ 1450

Exhaust temperature CExhaust temperature C 543543 610 NA610 NA

Combined cycle eff. % Combined cycle eff. % 52 52 58 6058 60

Power ( GT) MW ( FrPower ( GT) MW ( Fr--9) 9) 126.1 126.1 279 ~300 279 ~300

HGP Cooling HGP Cooling Air Air AirAir SteamSteam

Blade Casting Blade Casting DS SC DS SC SCSC

Simple cycle Simple cycle effeff % % 33.733.7 3838 NANA

NoxNox ppmppm 42/25 25/15 42/25 25/15 25/1525/15

““FAFA”” Technology Provides Both Increased Technology Provides Both Increased Output and Increased EfficiencyOutput and Increased Efficiency

• Combined Cycle Plants With Two Gas Turbines

8000

7000

60000 100 200 300 400 500 600 700 800

“F” Technology

“E” Technology

9FA

7FA6FA

9E7EA

6B

Hea

t Rat

e (B

TU

/kW

-hr)

Rating MW

•• Flow back of F Technology into mid range Gas turbinesFlow back of F Technology into mid range Gas turbines•• Evolutionary design based on proven technologiesEvolutionary design based on proven technologies

−− Built on 6BBuilt on 6B’’s track records track record−− Flow down of F technologyFlow down of F technology

Advanced class GAS TURBINE in the 40 MW range.

Gas Turbines : New Models PG6591CGas Turbines : New Models PG6591C

030

Comparision of 6B vs 6C

6B6B

−− 18 Stage compressor18 Stage compressor

−− IGVIGV

−− 10 combustion 10 combustion chamberschambers

−− Std/DLN1 CombustorStd/DLN1 Combustor

−− 3 Stage turbine3 Stage turbine

6C6C

−− 12 Stage compressor12 Stage compressor

−− IGV and 2 variable IGV and 2 variable stator bladesstator blades

−− 6 combustion chambers6 combustion chambers

−− DLN 2 CombustorDLN 2 Combustor

−− 3 Stage turbine3 Stage turbine

030

Comparision of 6B vs 6C

Fr-6B Fr-6C

Model PG6581B PG6591C

ISO Rating MW 41.7 45.4

Heat Rate Kcal/kwhr 2695 2348

Air Flow kg/sec 143 122

Pressure ratio 12.2 19.6

Firing Temp. °c 1140 1327

Exhaust Temp. °c 547 581

GT Speed rpm 5163 7100

030

Comparision of 6B vs 6C – Key Benefits

•• Improved operability Improved operability −− Fast and reliable startFast and reliable start−− NoxNox turn down to less than 50 %turn down to less than 50 %

•• Improved performanceImproved performance−− 5% improvement in efficiency over 6B5% improvement in efficiency over 6B−− 7.5 % improvement in output over 6B 7.5 % improvement in output over 6B −− 3 stages of guide vanes for higher part load 3 stages of guide vanes for higher part load

efficiencyefficiency−− Low Low NOxNOx emissions 15 emissions 15 ppmppm NOxNOx and 9 and 9 ppmppm COCO

•• LayoutLayout−− Axial exhaustAxial exhaust−− F class modular arrangement of skidsF class modular arrangement of skids

All compressor blades are field replaceable without rotor removal

030

Description Fr 9FA

ISO Rating 255600 MW

Heat Rate 2332 Kcal/KWH

Simple Cycle Efficiency 36.9 %

Combined Cycle Efficiency up to 56.2%

Air Flow 647 kg s/sec

Firing Temp. 1327 °c

Exhaust Temp. 602 °c

Pr. Ratio 16.5

RPM 3000

Overall Wt.(Turbine Base 280 T

Overall Dimensions( Turbine ) 11.0 x 5.0m x 5.0m

Rotor Wt/Length 77T / 10.0 m

Gas Turbines : New Models Gas Turbines : New Models PG9351FAPG9351FA

Gas Turbines : New Models Gas Turbines : New Models PG9371FBPG9371FB

Fr-9FB : PG9371FB

Fr-9FB : PG9371FB

Gas Turbines : New Models Gas Turbines : New Models PG9371FBPG9371FB

030

Plant Layout

Sealing TechnologySealing Technology

Better sealing technology through use ofBetter sealing technology through use of−− Honey comb seals. Honey comb seals. −− Brush seals.Brush seals.−− Cloth seals.Cloth seals.−− AbraidableAbraidable coating seals. coating seals.

Rotating Part

Stationary Part

The Labyrinth Seal

Sealing LocationsSealing Locations

At present in F machinesAt present in F machines

Further advancementFurther advancement

Honey Comb SealHoney Comb Seal

Honey comb seals inserted Honey comb seals inserted between labyrinth seal teethbetween labyrinth seal teethHoney comb seal material softer Honey comb seal material softer than bucket and shroudthan bucket and shroudCutter tooth on bucket tipCutter tooth on bucket tip0.6 % improvement in output 0.6 % improvement in output and heat rateand heat rate

Brush SealBrush Seal

Brush seal on NozzleBrush seal on NozzleTypical Brush Seal elementTypical Brush Seal element

–– Both radial & axial sealing.Both radial & axial sealing.–– Flexible,allowsFlexible,allows shroud block shroud block misalignment.misalignment.–– Performance improvement of Performance improvement of up to 0.7 % in output and 0.5 % up to 0.7 % in output and 0.5 % in heat rate. in heat rate.

Shroud Cloth Seals

AbraidableAbraidable coating on shroudcoating on shroud

40 mil thick coating on the 140 mil thick coating on the 1stst

stage shroud block.stage shroud block.Bucket tips rub into the coating Bucket tips rub into the coating and form gas path.and form gas path.Misalignment of components Misalignment of components automatically taken care of.automatically taken care of.Reduced air leakage leads to Reduced air leakage leads to 0.4 % improvement in output & 0.4 % improvement in output & heat rate.heat rate.

Combination of cloth seal on shroud blocks and abraidable coating provides about 1.1 % increase in power and 0.8 % in heat rate.

Cooling TechnologyCooling Technology

Better cooling technique.Better cooling technique.Reduced cooling air requirement due to better materials. More Reduced cooling air requirement due to better materials. More air available for power generation.air available for power generation.Serpentine cooling path in 1Serpentine cooling path in 1stst stage buckets. stage buckets. Radial cooling holes in 2Radial cooling holes in 2ndnd stage buckets.stage buckets.Film cooling in Nozzles. Hollow Nozzles.Film cooling in Nozzles. Hollow Nozzles.Impingement cooling of Transition pieceImpingement cooling of Transition piece..

Cooling air circuitCooling air circuit

Internal cooling air circuitInternal cooling air circuit

Last stage wheel with cooling air Last stage wheel with cooling air extractionextraction

Cooling PassagesCooling Passages

First stage bucket cooling passagesFirst stage bucket cooling passages

First stage bucket cooling passages

First stage nozzle segments with cooling holes

Impingement cooling of Transition pieceImpingement cooling of Transition piece

Transition piece in two pieces.Transition piece in two pieces.Inner transition piece is Inner transition piece is surrounded by slotted sleeve.surrounded by slotted sleeve.Air jets impinge on the inner Air jets impinge on the inner transition piecetransition piece

Transition pieceTransition piece

Improved materialImproved material

Hayes HR120 ( NiHayes HR120 ( Ni--Cr alloy) Cr alloy) replaces 310SSreplaces 310SSSingle piece designSingle piece designReduced cooling air Reduced cooling air requirementrequirement

EquiaxedEquiaxed Vs DSVs DS

•• Directionally solidified 1st stage buckets for better creep Directionally solidified 1st stage buckets for better creep rupture strength rupture strength and fatigue lifeand fatigue life

Firing temperature trend and Bucket material capabilityFiring temperature trend and Bucket material capability

IGCC

Fuels

Products

• 2 Stage combustion

• Partial in Gassifier

• Complete in GT

Bitum. Coal

LigniteOrimulsion

Residual oils

Pet cokeBio Mass

Wastes

Gassification

Gasifier HX

Oxyg.

System

Cleanup

Electricity

Hydrogen

Ammonia

Methnol

Sulfur

Combined

Cycle

IGCC

Ambient Temp

Output

Low LCV Gas

Nat. Gas

Flat rated region

Nat Gas 2%Coal Gas 16%

Air 100%

• 20% Extra Output

Typically

• 14 % extra flow at same firing

Temp makes 28% more power 15 C

C.G Exhaust 116%NG Exhaust 102%

Thank YouThank You