Paper 4 - FlexEfficiency 50 _GE Energy

* Trademark of the General Electric Company.

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.


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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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


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

34

35

36

37

38

39

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


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


Paper 4 - FlexEfficiency 50 _GE Energy

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