LMS100 Gas Turbine System -...
Transcript of LMS100 Gas Turbine System -...
GE Energy
LMS100® Gas Turbine System”A flexible growth platform to meet changing energy needs.”
2 /LMS100 Gas Turbine System /
11/5/2009
LMS100
LM6000
LMS100
LM6000
LM6000
Sprint® Intercooling
CFM TECH56
CAPPs Combustor
Advanced Controls
MK VIe, Smart Sensors
Synthetic Logic
The LMS100 … game changing technology from frame and aero gas turbines
• 100MW
• 44-50% efficiency
• High part power efficiency
• Cyclic capability
• 10 minute starts
• Load following abilityGE90
High Pressure Ratio (42:1)
F/H Technology
CompressorHeat Exchanger
Packaging
3 /LMS100 Gas Turbine System /
11/5/2009
MS6001FALow Pressure Compressor (LPC)
Intermediate Pressure Turbine (IPT)
Exhaust Diffuser
Power Turbine (PT)
Power Turbine Shaft
Intercooler System
CF6-80C2High Pressure Compressor (HPC)
CF6-80EHigh Pressure Turbine (HPT)
Single AnnularCombustor (SAC)(DLE not shown)
Combining the best of both worlds
4 /LMS100 Gas Turbine System /
11/5/2009
Modular gen-sets
Scene 4 cont:
• The intercooler system reduces the workload of the
high-pressure compressor. Less workload equals
increased power outputs and better overall efficiency.
The end result is outputs above 100MW with simple
cycle thermal efficiencies in excess of 46% -- an
astounding 10% increase over our most efficient
competitors.
• CALLOUT : 10% efficiency increase over the
compeition.
• Comments: showing constant airflow cycle as camera
pans around entire plant13
14 15
Simple Cycle ExhaustGT Driver Package
Cooling Tower
MS6001FA Inlet System
Variable BleedValve (VBV) System
Air to WaterIntercooler
Dual RatedGenerator
5 /LMS100 Gas Turbine System /
11/5/2009
Typical plant arrangement
Cooling Tower
Power Control Module
Gas Fuel Heater
50 m
50 m
6 /LMS100 Gas Turbine System /
11/5/2009
50Hz Configurations / Applications*
SAC-Water DLE SAC-STIG DLE-CC***
Gen Terminal Plant, MW 102.8 99 110.8 116
Gen Terminal Heat Rate, KJ/KWH LHV 8,173 7,921 7,263 6,700
NOX Emissions, mg/Nm3** 50 50 50 50
• Hot day power
• 10 minute starts
• Fast load response
Flexible power with high efficiency
AssumptionsAltitude sea level * 50 Hz, Rated Power, Average Engine HR, Methane Fuel, Rounded Values, Temperature / Rel. Humidity 15oC/60% Excludes Intercooler Fan LossNo Inlet / Exhaust Losses ** 15% O2, Without SCR, Natural gas
*** Inlet / Exhaust losses = 101.6mm / 381mm H2O
• Part power efficiency
• Lower mass emissions
• Modular maintenance
WITH
7 /LMS100 Gas Turbine System /
11/5/2009
“Game changing” power and efficiency in cycling duty segment
30%
32%
34%
36%
38%
40%
42%
44%
46%
48%
50%
60,000 80,000 100,000 120,000 140,000 160,000 180,000 200,000
GT Output (kW)
Sim
ple
Cy
cle
Eff
icie
ncy
7EA
GT11NM
M501
GT11N29E
M701V64.3A
6FA
7FA
GT13E2
M501F
W501D5A
V94.2
SAC w/water
DLE
SAC w/steam
STIG
10% Improvement over best available
8 /LMS100 Gas Turbine System /
11/5/2009
Great hot day performance
9 /LMS100 Gas Turbine System /
11/5/2009
10 Minute starts to full power
XN25
0
2000
4000
6000
8000
10000
0 200 400 600 800 1000 1200 1400 1600 1800 2000
Time (sec)
XN
25 (
RP
M)
XN25
Dry
mo
tor
/ p
urg
e
Ign
itio
n
Accel
to S
I
Syn
c id
le
Decel to
min
id
le
Sh
ut
do
wn
Accel
to m
ax
Wate
r o
n a
t ~
30M
W
Min
id
le
Co
old
ow
n
47 /LMS100 Gas Turbine System /
5/3/2005
Aero gas turbines are designed to cycle
120 sec accel & decels
<8 sec to
max power
Thrust
Reverse
Cruise
climb
Typical Aircraft Engine Transient
Typical Aeroderivative
Industrial Engine Transient
High strength alloys, lighter sections
Designed for cyclic life
No start cycle penalty for
maintenance intervals
10 /LMS100 Gas Turbine System /
11/5/2009
50MW in less than a minute
11 /LMS100 Gas Turbine System /
11/5/2009
Replaceable“Supercore”(24 Hr change out)
(All maintenance interval same as LM6000)
Maintenance Intervals:Hot Section - 25,000 HrsOverhaul - 50,000 Hrs
Rotable Modules:- Combustor- HPT- IPT- PT
Total down time < 4 days with rotables
“LM” modular maintenance philosophy
12 /LMS100 Gas Turbine System /
11/5/2009
Rotable modules for onsite overhauls …
Combustor HPT IPT
Typical HPT Rotable Workscope
Tear down rotor & stator
Repair / replace S1 blades, S1N, S2
blades & S2N
Balance / repair stator
Replace stator shrouds
High speed grind HPT rotor to match
fit with stator
HPC TMF
13 /LMS100 Gas Turbine System /
11/5/2009
Typical Aero Service Intervals
Interval Scheduled Maintenance Action Outage Duration
4,000 hours (every 4K h) Borescope Inspection (includes cool-down time) 12 hours
25,000 hours Hot Section Interval*
1) On-Site Hot Section Replacement (Combustor, HPT, IPT)
4 days(a)
50,000 hours Depot Maintenance(b)
1) Major Hot Section Overhaul (Combustor, HPT, IPT)
2) Inspect Booster, Intercooler, Scroll Frames, HPC, Aft Shaft & Bearings
(c)
3) Power Turbine Overhaul
4 days(a)
75,000 hours Hot Section Interval(b)
1) On-Site Hot Section Replacement (Combustor, HPT, IPT)
4 days(a)
100,000 hours Depot Maintenance(b)
1) Major Hot Section Overhaul (Combustor, HPT, IPT)
2) Inspect Intercooler, Scroll Frames, HPC, Aft Shaft & Bearings(c)
3) Power Turbine Overhaul
4) Booster & Shaft Inspection/Maintenance
4 days(a)
(a) Rotable module installed during maintenance period
(b) Lease/spare “supercore” and Power Turbine modules are installed during maintenance period. For depot maintenance, outage duration is 60 days if no spare/lease module(s) are used.
(c) Roller and ball bearings are replaced at 50,000 hours; hydrodynamic bearings are inspected.
14 /LMS100 Gas Turbine System /
11/5/2009
Potential for >90% CHP efficiency utilizing intercooler and exhaust energy
Intercooler
200
300
400
0 20 40 60 80 100 120
Inlet Temperature (F)
I/C
Te
mp
era
ture
, (F
)
-10 0 10 20 30 40
Degrees C
Deg
C
100
150
20050 Hz
60 Hz
700
720
740
760
780
800
820
0 20 40 60 80 100 120
Inlet Temperature (F)
Ex
ha
us
t T
em
pe
ratu
re, (F
) -10 0 10 20 30 40
Degrees C
Deg
C
380
400
420
50 Hz
60 Hz
HRSG
~25-30 MWT ~70-80 MWT
15 /LMS100 Gas Turbine System /
11/5/2009
Value in all applications
Application Capability / Benefits
• Simple Cycle peaking Cyclic ability with low maintenance and installed cost
• Simple Cycle Mid-range dispatch High efficiency/low installed cost
• Combined Cycle Small steam plant @ 54%
• CHP – steam to process High power/steam ratio Flexibility – power or process steam
• CHP – District Heating >90% efficiency – max energy use
• Coal Plant Feed Water Heating 57-60% gas to electric conversion
16 /LMS100 Gas Turbine System /
11/5/2009
LMS100 makes feed water heating applications extremely attractive
• High gas energy to electricity conversion > 47-54% for sub-critical repowering
applications
> 57-60% for new super-critical applications
• Project costs lower than combined cycle GT
• Integrated plant part power flexibility
• Lower plant emissions
17 /LMS100 Gas Turbine System /
11/5/2009
Low pressure compressor
MS6001FA17 Stage Compressor >8 Million hours of operation
LMS100 LPC- 1st 6 Stages of 6FA Compressor - Same operating speed - Same flow, pressure and temperature - Variable speed operation
LMS100 LPC
18 /LMS100 Gas Turbine System /
11/5/2009
Core – high pressure rotor
Introduced - 1985Operating hours >100 million
CF6-80C2/E
Introduced - 1991Operating hours > 9,000,000
LM6000
LMS100 Core- HPC derived from CF6-80C2
- HPT derived from CF6-80E
- Lower shaft speed
- Lower T3
- Increased firing temperature
19 /LMS100 Gas Turbine System /
11/5/2009
LM6000
LMS100
LMS100 Design
• Design basis … LM6000• Same CRF Volume & Diffuser• Areas Redesigned for Operability &
Performance:- Fuel Nozzle
- Swirler
- Liners
• Areas Redesigned for Reliability Improvements:
- Fuel Nozzle
- Swirler / Ferrule
- Splashplate
- Domeplate Cooling pattern
- Venturi
Standard Annular Combustor (SAC)
20 /LMS100 Gas Turbine System /
11/5/2009
2-stage turbine
Same hot flowpath and materials as LM6000
Based on CF6-80C2/E “boltless rotor” design with over 500,000 EOH
Increased flow capability
Operating Conditions (vs LM6000)- Pressure ratio 30% lower…………………...lower stress - Cooling temperatures 250F colder- Cooling flow higher …Same metal temperature - T41 8% higher- Rotor speed 7% lower ………………….…..lower stress
High Pressure Turbine (HPT)
21 /LMS100 Gas Turbine System /
11/5/2009
New design 2-stage turbine
Same materials as HPT
Based on successful HPT designs- Same design practices
IPT frame based on successful GE90 design
Drives the LPC through a mid-shaft and coupling:- Mid-shaft material and design same as LM6000 - Modified LM2500+ US Navy main drive coupling- Both operating at higher speeds and lower torque
Intermediate Pressure Turbine (IPT)
22 /LMS100 Gas Turbine System /
11/5/2009
Power Turbine
PT Sub-base Assembly (ALF)PT Shaft (ALF)
PT Case(Now fully Assembled))
Aft (Hot End Drive)
New design 5-stage turbine
Same materials as LM6000
Based on successful LPT designs for all GEAE LPT’s
Same pressure ratio, speed and inlet temp as LM6000
23 /LMS100 Gas Turbine System /
11/5/2009
P/N Girth Length9941 110' - 6" 44' - 8"9942 105' - 9" 43' - 2"0014 107' - 8" 44' - 4"0156 117' - 0" 47' - 4"0212 111' - 8" 48' - 2"0238 110' - 8" 44' - 0"
TEI Examples of manufacturing capability
Operating Experience:- Widely used for 40+ years in air industry
- Equivalent flows
- Higher pressures
- Higher temperatures
- Air and multiple gases
- Supplier validated heat exchanger code
Design and Test:- GEAE and GEPS Chief Engineers reviews
- GEPS H machine experience applied
(heat exchangers)
- Component test at GE-Global Research Center
Intercooler – heat exchanger experience
24 /LMS100 Gas Turbine System /
11/5/2009
Redundancy … a key reliability feature
• All reliability key sensors typically include 3 sensors or 2 dual element sensors
• Each signal routed to independent I/O block, eliminating single point failure modes
• Each I/O block communicates to multiple control processors through 2 independent networks
• Each I/O pack is power by two independent power supplies
• Power supply for the control includes a UPS system for backup in loss of AC power
• Mineral lube oil system includes redundant AC pumps and a backup DC pump
• Intercooler system includes dual 100% circulation pumps.
• Turbine hydraulic systems include redundant AC pumps and a backup DC pump
• Turbine enclosure ventilation includes redundant fans
• Generator ventilation includes redundant fans
• Power turbine load cage cooling includes a redundant blower.
25 /LMS100 Gas Turbine System /
11/5/2009
GE committed to providing the best product at the lowest risk
Robust NPI process
Operating conditions within current experience levels
Design based on existing gas turbine components and modules
Full scale validation testing
Fleet leader program
Reliability roadmap
26 /LMS100 Gas Turbine System /
11/5/2009
Comprehensive full scale validation tests
Combustor rig
Instrumented core engine
Production core engine
Instrumented power plant (FETT)
Production gas turbine generator set
27 /LMS100 Gas Turbine System /
11/5/2009
GE’s altitude test facility … ideal for matching LMS100 operating conditions
Provided required flow rate, at depressed inlet temperatures and elevated inlet pressures to simulate the LMS100 intercooler discharge conditions.
460 lbs/sec airflow
35-38 psia inlet pressure
~110°F inlet temperature
28 /LMS100 Gas Turbine System /
11/5/2009
Core engine test vehicle heavily instrumented…
• Dual fuel combustion system … liquid (Jet A / Diesel) or natural gas with water injection capability
• Configured with both forward and aft instrumentation slip rings.
Core Engine Cross-Section
• Slave front frame and aft frame
from flight engines
• Over 1500 pieces of instrumentation … system or component pressures, temperatures, and mechanical strains (stresses).
29 /LMS100 Gas Turbine System /
11/5/2009
Successful core engine test
• Great results …66+ hours / 74 starts
• 2 engine cell installations and test … June & November 2004
• Collected significant data:
– 500 transient data recordings
– 800 steady-state recordings
• Achieved 100% start reliability
• Rotor thrust balance verified
• Cleared all rotating hardware for aeromechanics
• Demonstrated core engine mechanical integrity
30 /LMS100 Gas Turbine System /
11/5/2009
LMS100 full load test stand
Evap cooling towers
Test facility capacity
120MW load banks
First-Engine-to-Test (FETT)
instrumentation data trailer
Modified 6FA inlet system Intercooler/
Heat exchangerAuxiliary
skid
Intercooler water
pump skid
VBV silencer stack
Variable bleed valves (VBV)
31 /LMS100 Gas Turbine System /
11/5/2009
Full load test objective … validate simple cycle power plant design
Full load test of the gas turbine generator set
Fully operational intercooler system
Complete package validation
Mark VI control system validation
Auxiliary skid “ring-out”
Full sensor suite across GT and package
Over 2500 sensors installed
Full range of operation covered
32 /LMS100 Gas Turbine System /
11/5/2009
Significant accomplishments
• Operated at max power conditions …110MW’s meeting requirements
• Demonstrated ability to meet heat rate
requirements
• Demonstrated 10 minute start ability
• Demonstrated load following ability
• Demonstrate ability to meet emissions requirements
• Conducted aeromechanic evaluations
• Evaluated rotor system vibration
• Conducted operability studies
• Conducted transient studies
• Validated all subsystems; MLO, start, fuel,water injection, gas and liquid fuel
• Demonstrated intercooler loop Variable Bleed Valve (VBV) system
• Demonstrated start capability on gas and liquid fuel
• Demonstrated gas fuel operation with water injection
Total test time: 121 hrs
Gas 110 hrs
Liq 11 hrs
Total # starts: 69
33 /LMS100 Gas Turbine System /
11/5/2009
10-minute starts validated
10:48 min to 100 MW
Power
HP rotor speed
PT rotor speed
IP rotor speed
Load bank adjustments caused delays
Not typical for grid operation
Adjusted time < 10 minutes10:48 min to 100 MW
Power
HP rotor speed
PT rotor speed
IP rotor speed
Load bank adjustments caused delays
Not typical for grid operation
Adjusted time < 10 minutes
34 /LMS100 Gas Turbine System /
11/5/2009
0
500
1000
1500
2000
2500
3000
0 200 400 600 800 1000 1200 1400 1600 1800 2000
Time (sec)
Em
iss
ion
s a
t 1
5%
O2
(p
pm
)
0
5000
10000
15000
20000
25000
30000
35000
40000
CO15_M
10XNOx_15_M
WF36corr
Ignition
Warm
Up
Sync
Accel to
power
NOx Water
on
NOx water off
Cool down
Fuel off
Fu
el fl
ow
(p
ph
)
LMS100 PA Startup / Shutdown Emissions Profile
* NOx values shown are the actual values multiplied by 10, for purposes of plotting.
35 /LMS100 Gas Turbine System /
11/5/2009
• Common 50/60 Hz generator………………….…………..+ fleet reliability
• Common GT and Package – both intercooler system…..+ fleet reliability
• No gearbox required for 50 or 60 Hz applications…….…+ performance and cost
• Intercooler options…………………………………………..+ site conditions flexibility
STIG – Steam Injection for power augmentation
Product Type Model
(Fuel Sys) 50Hz 60Hz Dry Wet
LMS100 PA Gas
Dual
Steam
STIG
LMS100 PB DLE
ApplicationIntercooler/
Cooling Tower
Reliability thru commonality – while maintaining flexibility