GE Energy FlexEfficiency*50 A new standard of high efficiencyindianpowerstations.org/Presentations...
Transcript of GE Energy FlexEfficiency*50 A new standard of high efficiencyindianpowerstations.org/Presentations...
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FlexEfficiency*50 Combined Cycle Power Plant
NTPC O&M Conference New Delhi February 2012
GE Energy
A new standard of high efficiency
and operational flexibility
Copyright 2012 General Electric Company. Proprietary Information.
* Trademark of the General Electric Company.
Shyamal Duggal Krishnakumar PG
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All Rights Reserved. No part of this document may be reproduced, transmitted, stored in a retrieval system nor translated into any human or computer language, in any form or by any means, electronic, mechanical, magnetic, optical, chemical, manual, or otherwise, without the prior
written permission of the General Electric Company.
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Overview
• FlexEfficiency*50 plant – an integrated plant concept
• Gas Turbine Experience & Customer requirements
• Major equipment overview
• Validation and testing – full scale test facility
• Summary
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* Trademark of the General Electric Company.
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FlexEfficiency*50 Combined Cycle Power Plant • 510 MW, 50 Hz … 61%+ base load efficiency
• Start-up to full load <30 minutes • Ramp-rate >50 MW/minute • Plant turn-down to 40% load
A new standard in efficiency AND flexibility enabling integration of more renewable resources onto the power grid
a product of
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FlexEfficiency*50 plant single shaft
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Output (MW) 510
Efficiency (%, LHV) 60.3 (GTW launch) > 61% mature
Turndown (% B/L) < 40
Ramping rate 6 min. from turndown to base load (51MW/min)
CC part load efficiency Better lapse rate than current F-technology
Time to 95% load
(minutes) 28 hot/65 warm/110 cold (< 8 hours)/(8-72 hours)/(>72 hours)
NOx (mg/m3 @ 15% O2) 50 (30 optional)
CO (mg/m3) 30
Modified Wobbe Index (%) +/-10
Min. methane content (%) 75
Note: Based on 100% methane, ISO conditions, NOx @15% O2, and other standard plant assumptions
Gas turbine experience and Future customer requirements
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1987
1988
1992
1999
2002
2005
2007
2010
2011
9F platform product evolution Continual product improvement
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200 220 240 260 280 300
Power (MW)
Eff
icie
ncy
(%
) 9F.01
9FA.01
9FA.02
9FA.03
9FB.01
9FB.05
338
9FB.03
40
GE introduces F-class platform
First F-class Gas Turbine in operation
9F Gas Turbine tested at load, commercial operation
F-class gas turbine’s meets 1 million hours of operation
1st 9FB Gas Turbine introduced
9FB Gas Turbine FSFL testing, DLN 2+ introduced
1,000th F-class gas turbine unit shipped
F-class - 35 million hours and 700,000 starts
New 9FB Gas Turbine introduced
Over 230 9F Gas Turbine with 9 million fired hours and 90,000 fired starts.
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Future customer requirements Industry changes
• CO2 emission cost
• Start-up fuel cost
• Start-up emissions
reduction (NOx)
• Looking for increased
revenues from start –
stop cycle
• Part load operation
more frequent/
efficiency increase
• Additional turndown
Volatility of grid capacity
UK Generation profile – 2008 vs. 2030
Source: July 2009 Poyry Energy Consulting
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FlexEfficiency*50 plant with integrated solar
Integrated Renewable Combined Cycle Scope: − FlexEfficiency*50 plant
− 470 MW at site conditions
− +50 MW concentrated solar
− +20 MW wind turbines (>69% total plant peak efficiency)
Thermal Solar (CSP):
− Modular eSolar tower technology
− Direct steam generation
− Fully integrated in steam cycle
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TM
First launch project in Turkey, operation commencing 2015
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Fewer systems = simplification
Reduced plant footprint
• Air-cooled hot gas path – no steam/hybrid
• No external cooled cooling air
• Improved maintainability
Key features Full power train access
Generator in the middle with clutch
Steam turbine side exhaust
Left side air inlet
Advanced controls
Low centerline
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Key components Gas turbine
>40% SC efficiency industry leading OpFlex application
Integrated approach
Steam turbine
40% shaft efficiency
SS: 3 casing, lateral exhaust
MS: Opposed-flow HP/IP
Plant design
Smaller footprint, improved serviceability
Generator
Reduced site assembly, full grid code capability
Plant controls
Digital architecture, performance seeking algorithms
Major equipment overview
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9FB gas turbine overview 3D aero, scaled compressor
• 7FA Gas Turbine (version .05) heritage • 3-dimensional aerodynamic design • IGV + multi-stage VGV
DLN 2.6+ evolution combustion
• Proven DLN 2.6+ technology • F-class materials • Fuel flexibility … wide wobbe
3D aero turbine, increased T-fire
• 4-stage hot gas path • Advanced aero and sealing • Existing materials … air cooling
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Advanced compressor technology Performance • 3-D Aero, 14 stages • Hybrid radial diffuser
Operability
• IGV + multiple VSV stages • Non-integral bearing • Additional sensors • Model based controls
Maintainability
• Field replaceable blades • Improved borescope • Blade health monitoring • Automated water wash
Next generation of 3-D aerodynamic airfoil
Increased airflow
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Proven DLN 2.6+ combustion system
Emissions
25 ppm NOx, 9 ppm CO 25ppm CO max turndown
Experience
> 354,000 hours > 5,000 starts
Design
Dual-fuel capable Model based control
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Power turbine technology
Performance and improvements
• Hot gas path evolution • 3D aerodynamic design • Improved clearances • 3 and 4 stages experience • Lessons learned
Hot gas path materials
• Single crystal technology • Reduced oxidation • Reduced creep • Improved low cycle fatigue
Advanced shapes
Buckets and diffuser
3D Aero
Advanced aero features
Unsteady flow CFD tools
GE aircraft rig testing
Building on field, rig and shared GE Aviation experience
Validated CFD
Gas Temperature
CFD
Data
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109D-14 steam turbine – single shaft Key features
• Separate high pressure (HP), intermediate pressure (IP) and low
pressure (LP) configuration… improved clearance control
• HEAT* technology expanded into double flow LP
• HP, IP and LP drum rotor construction with
blinglet nozzles
• Enhanced 42” and 34” last stage bucket …
w/ improved aero and manufacturability
• Integrated SSS clutch in front standard …
increasing plant operational flexibility
• Single side exhaust hood …
reduced plant centerline height
• Common LP hood for once through, cooling twr and ACC
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Benefits
• High efficiency • Reduced site assembly • Improved cooling capability • Simplified alignment
• Improved serviceability • Increased reliability
Key features
One piece frame construction for installation
Fixator support for maintenance/ serviceability
Modular gas, seal oil and stator cooling water systems
Stator water cooling system and monitoring
Packaged static excitation and static starter
109 SS generator overview
Over 600 liquid-cooled generators in operation
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Tfire
Ma
PR
NOx
CO f/a
Tflame
Model based control GPS technology for your plant
Where am I? “Triangulates” true operating condition from real-time GE engineering models and available sensors, correcting for unique equipment deterioration and transients
Where can I go? Allows flexibility to find the optimum operating condition or maneuver around plant constraints, while observing all engineering limits
When will I arrive? Enables prediction of equipment capability for more intelligent bid and dispatch decisions
GT1
GT2
06:50 07:00 07:20 07:30
MW
Time
200
150
100
50
0
ST
03/12/09 07:21
Tx
CPR
Advanced controls delivering performance, operability and availability
Digital control architecture for operability and reliability
Fieldbus technologies – 50% less wire Easy installation and commissioning – one TA Skid validation and commissioning at supplier
World-class test facility
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Thorough validation plan
Inlet rig … blade durability
Variable Stator Vane
rig … durability
Diffuser rig … performance
Starter motor
Drive motor
Torque converter
Gear box
Compressor rig Gas turbine
driver
Exhaust rig … performance
Combustion rig … dynamics, emissions
Full-speed full-load engine test - Greenville
Component , system and unit validation
Compressor rig drive train - Greenville
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Summary
Base load efficiency > 61%
Flexible … Fast start, fast ramp rate, start reliability, turndown
Air cooling – simplified gas turbine and plant integration
F-class materials with air cooling … low life cycle cost
Rich fleet experience and aviation heritage
Validation + FSFL test gas turbine … compressor and turbine – full-scale factory test in Greenville, SC USA
Public launch and first commercial project announcement last June 2011 at POWER-GEN Europe
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Question & Answers
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