GE Energy FlexEfficiency*50 Advanced high efficient CCGT...

* Trademark of the General Electric Company.

FlexEfficiency*50 Combined Cycle Power Plant

June 26, 2012

GE Energy

Advanced high efficient CCGT in support of grid stability

Copyright 2012 General Electric Company. Proprietary Information.


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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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Agenda

• Todays’ generation needs

• Combined Cycles to balance varying grid loads

• Increasing operational flexibility requires a ‘total

plant concept’

• FlexEfficiency* 50 plant – designed for flexibility and

maintaining F-class life cycle cost

• Summary

* Trademark of General Electric Company.

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Customer requirementsIndustry changes

• Start-up fuel cost

• Start-up emissions

reduction (NOx)

• Looking for increased

revenues from

flexibility / capacity

• Part load operation

more frequent/

efficiency increase

• Additional turndown

• Changing merit order:1. Renewables2. Nuclear/Coal3. NGCC

Volatility of grid capacity

UK Generation profile – 2008 vs. 2030

Source: July 2009 Poyry Energy Consulting

??

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300

310

320

330

340

350

360

CO

2specific (g/kWh)

109FA 109FB.01 109FB.03 FlexEff*50

F-class combined cycles reduced CO2 - footprint

by 9+% 25 years of technology advancements

Technology advancements – specific CO2


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Operational flexibility – to support grid stability

Frequency response

Load response

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Frequency Response …3 Steps

Kinetic energy restored

Production

Consumption

Frequency

Demand Step

Kinetic energy consumed

Remaining static gapStabilizing dip

closing static gap

Initial state Final

time

PRIMARY RESPONSE SECONDARY RESPONSE

TERTIARYRESPONSE

0s to 30s 30s to 15minutes

+ 15minutes

IGV + OF (when required) Part load + rapid response

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Thermal generation … the throttle

•Gas turbine and combined cycle plants should have capability to respond to the needs of a highly renewable-penetrated grid

• Faster starting capability

• Higher start reliability

• Faster ramping capability

• Transient emissions compliance

• Lower turndown

• Smaller block size

• Better hot-day performance and grid support

Today’s gas generation technology is substantially more flexible

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Performance and turn down

Improvements:

• Better lapse rate through

design point optimization

• Bottoming cycle adaptation

• Model based control

• Real time plant optimization

• Higher average (effective)

efficiency over the entire

operating envelope

increases merit order


CC Load 1.00.4

Faster Startup(Higher Annual Average

Load Factor)

Typical

Fle

xE

ffic

ien

cy50™

Fle

xE

ffic

ien

cy™

4 p

oin

ts

Better Part Load Eff.

Typical (normalized) part load of older CCGT vs. FlexEfficiency*50 part load curve

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Faster Start-up vs. Conventional start

Typically, the heat recovery

steam generator (HRSG)

requires purge sequence (no

purge credit) and steam

turbine temperature matching

at spinning reserve with

conventional gas turbine

exhaust temperature

adjustment

Rapid Response With Purge Credit

Smart Start

Purge

Credit

Conventional

Steam Bypasses ClosedGT Roll

Synch

LO

AD

Early EmissionsCompliance

TIME

Comparison of Rapid Response and conventional hot starts (overnight shutdown).

Integrated Total Plant Solution


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Gas turbine features

Steam turbine features

Plant features

Controls features

Flexibility … a complete plant approach

• Rotor architecture/clearances• Casings & cooling designs

• Architecture & clearances• thermal transient capability

• HRSG/ at temperation• Steam bypass• Temp & pressure control

• Integrated equipment & BOP• OpFlex* software utilization

Integrated components for overall plant response capability

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FlexEfficiency 50 Combined Cycle Power Plant

Efficiency and flexibility rely on

digital control architecture

Tops-down Total Plant Design

Bottoms-up Digital Plant Control

Heatrate

Reliability

Output

Turndown

Ramprate

Starttime

109D-14 Steam Turbine

W28 SPL Generator 3-Pressure drum

HRSG w/reheat

SSS Clutch

9FB.05 Gas Turbine

Integrated Plant Control

Y

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FlexEfficiency 50 plant operability

Accuracy

Control valve 90% more accurate

Repeatable

Calibration stability 8X longer… no drift

Measurement+

More measurements per device

(ex. flow instrument)

Predictive

Early warning horizon in months vs. minutes

Reliable

Hot stand-by thermocouples with on-line repair

Precision

Device digital measurement preserved as 32 bit data

…using the advantages of modern smart field devices

… to enhance the fundamental plant controllability

Expanded operating envelope(s)…

FlexEfficiency* 50 plantFlexEfficiency* 50 plant

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A different control paradigm

+_

Sensors

Effectors

Control

Control Schedules

+_+_

Sensors

Effectors

Control

Control Schedules

+_+_

+_+_

+_+_

+_+_

+_+_

+_+_

+_+_

+_+_

+_+_

Lo

op

S

ele

cti

on

S

tru

ctu

re

ARES - ParameterEstimation

Engine Model

Virtual Sensors

Sensors

Effectors

Physics-Based Boundary Models

Lim

it S

ch

ed

uli

ng

CDM

Good: Schedule-Based• Indirect boundary control• No explicit deterioration accommodation

• Coupled effectors

Better: Model-Based• Direct boundary control

• Accommodates deterioration

• De-coupled effectors

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Profitable MWh’s 1

Fuel Consumption 2FlexEfficiency =

1 Excludes MWh’s during min turndown2 Includes fuel consumption during start-up

FlexEfficiency - evaluating the mission

109FA.03

109FB.03FE50

Cyclic mission impacts material selection and life-cycle cost

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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 productof



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350

330

310

290

270

250

230

210

50 Hz F- technology milestones

‘88 ‘90 ‘92 ’94 ’96 ’98 ’00 ’02 ‘04 ‘06 ’08 ’10 ‘12 ‘14

GT output (M

W)

Year

9FB.01

9F

9FA.01

9FA.03

DLN Combustion Single Crystal & DLN2

Material & Coating

Turbine

9H

9FB.03

> 2 decades adv. gas turbine

9FB.05

7FA.05

Compressor

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• 3D Aero, 14 stages

• Hybrid radial diffuser

• Non-integral bearing

• Oversized for grid code

Performance

Compressor Design Heritage

Maintainability• Field replaceable blades • Improved borescope access

• Blade health monitoring

• Automated water wash

3D aerodynamic airfoil

• GE90 & GEnx

• 7FA.05 compressor

validated in August 2011

Heritage

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DLN 2.6+ combustion system• Combines attributes of DLN 2+ and DLN 2.6 combustion systems

• Six fuel nozzles instead of five - increases

control

• Advanced coatings and materials - provides

increased durability

• Asymmetric fuel flow control – provides

operational flexibility

• Emissions < 25ppm NOx & CO

• Dual fuel capable

DLN2.6+ combustion system experience:

� 61 Operating 9FA/FB gas turbine units

� >800,000 Fired hours

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Power turbine technologyPerformance and improvements

• Hot gas path evolution • 3D aerodynamic design• Improved clearance management• 3 and 4 stages experience• Lessons learned

Hot gas path materials

• Single crystal (SX) technology• Aero technology transfer 2002• Largest operating fleet, FB & H

Super-alloy wheels

• Proven Ni-Fe Alloys• Aero-engine cyclic duty design• Applied to FA, FB & H gas turbine fleets

EA DS SX

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Turbine technology … Aero

Building on field rig and shared GE Aviation experience

Aero efficiency … GEnxEnhanced stage loading

and advanced aero

Advanced

shapes

Buckets and

diffuser

3D Aero

Advanced aero features

Validated CFD GE aircraft rig testing

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 1060mm and 850mm 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 tower and air condenser


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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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Key features

� 3-pressure drum design with reheat

� Cycle enhancement with gas turbine & steam turbine equipment

� Improved fast start capability

� Modularized construction

� Internals designed for easier maintenance access

� Low pressure circuit minimizes flow accelerated corrosion

� Advanced monitoring & control

HRSG Improvements

Customer benefits

� Increased performance

� Improved operational flexibility

� Increased reliability

� Faster erection

� Better maintenance access

Designed for cyclic operation

World-class test facilities


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1. Component & Systems tests• Inlet and VSV rig – blade durability

• Diffuser rig – performance improvements

• Combustion test module – engine replica

• Exhaust rig

2. Advanced compressor test• Completed August 2011

• Arrive at complete compressor map

3. Gas Turbine full load test

• Fully assembled & instrumented engine

• Test all possible operating conditions

- Not only one site location!

Diffuser rig … performance

Validation & testing – the Concept:Variable Stator

Vane rig

Exhaust rig … performance

Combustion rig … dynamics, emissions

Component, system and unit validation

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2. Advanced Compressor Test

� Test completed in August 2011

• Compressor Test Vehicle (CTV) driven by .03 gas turbine for testing without grid connection (allows variable speed testing)

• Full compressor map,… operated to surge limit !

• Met/exceeded all test objectives

• 14-stage compressor is robust.

$170M investment to deliver proven operability and performance

Drive train

* Trademark of General Electric Company.

Startermotor

Drivemotor

Torque converter

Gearbox

Compressortest vehicle (CTV)

Gas turbineDriver (.03)

Compressor

validated!

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Greenville, SC

3. Gas turbine Full Load testAn industry leading test facility

• Validation prior to customer delivery

• Full speed, full load, not-grid connected

• Testing beyond real world conditions

• Reduces onsite commissioning time

7FA.05 Test in 2012 ongoing• Fully Instrumented rotor

• Performance, Aeromechanics

• Combustion dynamics

• Operability on NG/liquid fuel

• Combustion and HGP thermal validation

• Grid code response

Drive trainTest conditions are more rigorous than during

8000 hours on a typical site !

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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.

First commercial projects with COD 2015

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GE Energy FlexEfficiency*50 Advanced high efficient CCGT...

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